Retrofitting manufacturing efficiency: low-cost electrical current monitoring for industrial machinery

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Abstract

This research investigates the development of a low-cost electrical current monitoring system designed to augment manufacturing efficiency while addressing the sustainability challenges posed by legacy machinery. Recognising the substantial cost of equipment failure associated with maintaining industrial machinery, particularly legacy systems, this study focuses on developing a retrofittable low-cost monitoring system for existing industrial setups. The system utilises a Wi-Fi-enabled microcontroller-based sensor device that clips onto existing electrical connections, capturing the machinery’s current consumption with adjustable sampling rates. The sensor data are transmitted to an agnostic pipeline to improve adoption ergonomics; here, we propose the use of a simple, extensible open-source visualisation pipeline. Through continuous monitoring of electrical currents, the system can facilitate early fault detection and proactive maintenance planning, thereby mitigating downtime and extending the lifespan of legacy machinery. Furthermore, the monitoring device enables manufacturers to optimise energy usage, ensure regulatory compliance, and implement remote monitoring capabilities. Adopting this low-cost monitoring system empowers manufacturers to operate more efficiently, sustainably, and profitably.
Original languageEnglish
Title of host publicationIET Conference ProceedingsVolume 2024, Issue 11: Low-Cost Digital Solutions for Industrial Automation (LoDiSA 2024)
PublisherIET Digital Library
Pages33-38
Number of pages6
DOIs
Publication statusPublished online - 3 Oct 2024
EventLow-Cost Digital Solutions for Industrial Automation - Cambridge, United Kingdom
Duration: 1 Oct 20242 Oct 2024
Conference number: 2024

Publication series

NameIET Conference Proceedings
ISSN (Print)2732-4494

Conference

ConferenceLow-Cost Digital Solutions for Industrial Automation
Abbreviated titleLoDiSA
Country/TerritoryUnited Kingdom
CityCambridge
Period1/10/242/10/24

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