Condition Monitoring System for Manufacturing Unit
**Business Case:** [WheelsOn Technology Case Study](https://wheelsontech.com/case-studies/condition-monitoring-system)
**Client Profile:** [DotKeys](https://www.dotkeys.in/)
**The Challenge:**
Manufacturing facilities frequently face unexpected equipment failures, resulting in decreased productivity and higher maintenance expenses. To ensure operational efficiency, it is essential to monitor key factors such as pressure, temperature, vibration, and air quality.
**Solutions:**
WheelsOn created an advanced Condition Monitoring System that utilizes microcontroller units (MCUs) to gather real-time data from essential sensors located on the factory floor. This innovative solution facilitates continuous monitoring, employs edge computing for immediate decision-making, and integrates with the cloud for remote analysis.
**Sensor Integration and Data Collection:**
The system interfaces with various industrial sensors—measuring pressure, temperature, current, voltage, gas, liquid flow, air quality, and vibration—through I2C, UART, SPI, and ADC communication protocols.
**Edge Computing for Real-Time Control:**
The MCU serves as an edge computing unit, processing sensor information locally to make prompt decisions based on predetermined criteria.
**Cloud Data Transmission:**
Sensor data is relayed to a cloud platform via the MQTT protocol, allowing for the analysis of trends, historical data, and predictive maintenance insights.
**Actuator Control for Preventive Action:**
The system can automatically operate actuators or alert maintenance personnel when specific thresholds are exceeded, enabling real-time notifications and timely interventions.
**Outcome:**
- Improved Real-Time Monitoring
- Enhanced Decision-Making
- Decreased Downtime and Maintenance Costs
**Benefits:**
- Increased Equipment Reliability
- Reduced Downtime and Maintenance Costs
- Instantaneous Data Processing and Decision-Making
- Scalable, Cloud-Integrated Solution