BeamTracker Overview

What is BeamTracker?

BeamTracker is a precision laser/LiDAR sensor designed for real-time production counting, utilization tracking, and downtime monitoring across automated or semi-automated production lines. Using non-contact laser detection, it accurately counts parts, monitors throughput, and provides actionable insights through the IoTFlows platform.

Key Capabilities

BeamTracker provides comprehensive production monitoring:

• Accurate part counting and throughput rates
• Real-time utilization and performance visibility
• Automated alerts for slow production or unexpected downtime
• Downtime classification and root-cause analysis
• Historical production trends and efficiency reports
• Notifications to operators and managers for rapid issue resolution
• Encrypted data transmission (in-transit and at-rest)

What Makes BeamTracker Different?

Laser-Based Detection

• Non-contact measurement — No physical contact with parts required
• Precision laser/LiDAR sensor — Accurate detection of passing objects
• Configurable detection range — Adapt to various part sizes and speeds
• Works with any part type — Packages, bottles, components, or products

Built-in Display

• Touchscreen interface — Configure directly on device
• Real-time feedback — See detection status immediately
• On-screen calibration — Set sensor range without dashboard
• Status monitoring — Check connection and operation at a glance

Plug-and-Play Deployment

• No PLC integration needed — Works independently
• Pre-configured — Arrives ready to deploy
• Quick setup — 5-15 minutes typical installation
• Cloud-based — No on-site servers required

Flexible Installation

• Mounting bracket included — Stable positioning for accurate detection
• Multiple connectivity options — WiFi or 4G/LTE
• Industrial power — M12 connector (12-24V DC)
• Compact form factor — Fits various production environments

What's in the Box

Your BeamTracker package includes:

• 1× BeamTracker device with built-in touchscreen
• 1× External antenna
• 1× M12 Power adapter OR 1× M12 power cable + 1× M12 T-Splitter (Sold Separately)
• 1× Mounting bracket (Sold Separately)

Setup Requirements

Before getting started, ensure you have:

• IoTFlows account (sign up here)
• Internet connectivity via one of:
  • WiFi network (2.4 GHz)
  • IoTFlows 4G/LTE router
• Mobile device (iOS/Android) for WiFi setup
• Power outlet or industrial power supply (12-24V DC)
• Clear line of sight for laser beam across part flow
• Stable mounting location perpendicular to part flow

Ideal Applications

BeamTracker works with any industrial process where parts move through a detection zone:

Production Lines

• Packaging lines
• Assembly lines
• Bottling and filling operations
• Food processing
• Pharmaceutical manufacturing

Material Handling

• Conveyor systems
• Sorting operations
• Palletizing lines
• Distribution centers

Manufacturing

• Component production
• Part fabrication
• Quality inspection lines
• Product testing stations

Requirements

• Parts must pass through a defined path
• Clear line of sight for laser beam
• Consistent part flow direction
• Stable mounting position available

How It Works

1. Laser Detection

BeamTracker uses a single-point, invisible laser to detect objects passing through its beam. Think of it as a precision tripwire.

2. Part Counting

Each time a part breaks the laser beam, BeamTracker registers a count and timestamps the event.

3. State Detection

Based on time between parts (configurable), BeamTracker determines if production is:

• Running — Parts passing within expected timing
• Stopped — No parts detected for configured duration

4. Cloud Analytics

All data is transmitted to IoTFlows Cloud for:

• Real-time dashboard visibility
• Historical trend analysis
• Downtime classification
• Production reporting
• Alert generation

Key Metrics Tracked

Part Counts:

• Total parts counted
• Parts per minute/hour/shift
• Production rate trends
• Target vs. actual comparison

Utilization:

• Running vs. stopped time
• Percentage of available time productive
• Efficiency trends over time

Downtime:

• Duration and frequency
• Categorized by reason (manual or auto)
• Time-of-day patterns
• Root cause analysis

Alerts:

• Slow production warnings
• Extended downtime notifications
• Target shortfall alerts
• Custom thresholds

Next Steps

Ready to set up your BeamTracker?

Follow the setup guide in order:

1. Installation — Mount and power up your device
2. Network Setup — Connect to WiFi or 4G/LTE
3. Dashboard Access — Verify device is working
4. Calibration — Configure detection settings (required)

Need help? Contact Support