Machine Health Monitoring
We design non-invasive current-transformer sensor nodes and motor temperature loggers that track machinery cycle times and flag operational anomalies.
Machine Diagnostics Challenges
Manual machine inspections lead to unexpected downtime and high maintenance costs:
- High Integration Risk: Wiring directly into machine control lines can void warranties.
- No Historical Data: Missing motor load records and temperature cycles.
- Delayed Failure Alerts: Machine failures are only noticed after they break down.
- Isolated Machines: Standalone machinery has no data connections.
Thinkfinity Non-invasive Nodes
We deploy clamp-on current sensors and magnetic thermal probes:
- Split-core Current Clamps: Installs on power cables without cutting copper lines.
- Isolated Data Acquisition: High-resolution ADC boards capture signal metrics.
- Local Edge Flags: Microcontrollers flag spikes or drops locally.
- Low-Power RF Link: Streams data to local gateways via Wi-Fi or LoRaWAN.
System Architecture
How the Diagnostic System Connects
Our machine health telemetry architecture enables fast, non-invasive installation:
- Clamp-on CT: Split-core current transformer clamps read current draw without cutting wires.
- Analog Front End: ADC converters digitize currents and temperature voltages.
- Edge Gateway: Summarizes cycle run-times and streams metrics to ThingsBoard or AWS IoT.
Hardware Specs
- - ESP32 or STM32 microcontroller board
- - 16-bit high-resolution ADS1115 ADC
- - Split-core Current Clamps (up to 100A AC)
- - Magnetic DS18B20 temperature probes
- - isolated RS485 communication line