Challenge
A manufacturing equipment company needed vibration sensors for predictive maintenance across industrial facilities.
The solution required a rugged design, reliable wireless mesh networking, and battery-powered operation with
peak power consumption under 100mA.
Solution
- High-Precision Sensing: 3-axis accelerometer (±16G range) for detailed vibration analysis.
- Edge AI Processing: STM32L476 MCU running anomaly detection algorithms locally.
- Mesh Networking: Thread-based wireless mesh network enabling self-healing communication across facilities.
- Optimized Power Design: Battery system designed for periodic high-current transmissions.
- Rugged Build: IP67-rated enclosure with resistance to mechanical shocks.
- Energy Efficiency: Device remains in deep sleep 90% of the time to extend battery life.
Outcome
- Wide Deployment: Installed 500+ sensors across 20+ industrial facilities.
- Early Fault Detection: Identified bearing failures up to 10 days in advance.
- Cost Efficiency: Achieved $45 per unit in volume production.
- Operational ROI: Reduced maintenance costs by 35%.
