Case study

Case Study: Wireless Solutions for Bus Bar Temperature Monitoring

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Client

Requirement

Asian Paints is a leading paint manufacturer and supplier with a strong presence in the Indian market. The company is known for its high-quality paints and coatings and commitment to innovation and sustainability.

As part of its ongoing efforts to improve efficiency and safety in its operations, Asian Paints was looking for a solution to monitor the temperature of bus bars. The company was looking for a wireless, non-intrusive solution that could easily integrate into its existing systems.

Challenge

Several challenges are associated with manually monitoring the temperature of bus bars:

  1. Time-consuming: Manual readings of bus bar temperatures would have required engineers to physically go to each bus bar, take a reading, and then record the data. This process can be time-consuming and would have made monitoring temperatures in real-time challenging.
  2. Manual readings are subject to human error, which can lead to inaccurate data. Engineers may need help reading the temperature accurately or accidentally recording incorrect data.
  3. Engineers would have to be near the bus bars to take manual readings, which can pose a safety hazard if the bus bars operate at high temperatures.
  4. With Limited data collection, it would be challenging to identify trends or patterns in the bus bar temperatures.
  5. With manual readings, monitoring bus bar temperatures at remote locations or in different facilities would be challenging.

solution

To address this challenge, Asian Paints partnered with Bridge things to implement a wireless temperature monitoring solution. The solution was designed to address the challenge of manual reading of bus bar temperatures, which was time-consuming and error-prone. 

With the implementation of temperature monitoring solutions consisting of wireless contact temperature beacons (with a coin cell battery life of up to five years), BLE LoRaWan bridge, LoRaWan GateWay, along with IoT platform

Wireless contact temperature beacon: The wireless contact temperature beacons were attached to the bus bars and could measure the temperature in real-time. It uses Bluetooth technology to wirelessly transmit the temperature data to a nearby Bluetooth to LoRaWAN converter.

Bluetooth to LoRaWAN converter: This device receives temperature data from the sensor via Bluetooth and transmits it to a LoRaWAN gateway using the LoRaWAN protocol. It is designed to receive temperature data from up to 10 sensor beacons and transfer it to LoRaWAN gateways. 

The LoRaWan converter is essential in a temperature monitoring system, as it allows users to access and track temperature data from multiple sensor beacons remotely. Its Bluetooth and LoRaWAN capabilities enable it to connect to a wide range of sensors and gateways, making it a flexible and scalable solution for various applications.

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LoRaWAN gateway: This device receives temperature data from the converter and transmits it to the cloud system using a cellular connection.

LoRaWAN gateway is a device that enables communication between end devices and a network server, allowing data to be transmitted over long distances with low power consumption. It can then be processed and made available to end-users through an IoT Platform.

IoT platform

Our IoT platform provided real-time monitoring, allowing the company to quickly detect and address any issues with the bus bars. It also allowed for remote access, enabling engineers and managers to monitor the bus bars from anywhere at any time. Additionally, the platform provided advanced data analysis and visualization, which helped Asian Paints to identify patterns and trends in the temperature data and optimize its operations. It also included the ability to set alarms for specific temperature thresholds and generate reports for analysis, which helped to minimize the risk of damage to equipment or other safety hazards.

Electrical Panel Temp Map
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Benefits

  • Improved efficiency: By monitoring the temperature of bus bars in real-time, Asian Paints was able to quickly detect and address any issues, which helped to improve the efficiency of its operations.
  • Increased safety: The solution included setting alarms for specific temperature thresholds, which helped minimize the risk of damage to equipment or other safety hazards.
  • Remote access: The IoT platform allowed engineers and managers to access temperature data remotely, which provided greater flexibility and allowed them to monitor the bus bars from anywhere at any time.
  • Scalability: The dashboard was able to accommodate a large number of devices and sensors, making it possible to monitor multiple bus bars at once.
  • Data analysis and visualization: The platform provided advanced tools for data analysis and visualization, which helped Asian Paints to identify patterns and trends in the temperature data and optimize its operations.

Case study: Monitoring real-time water flow & consumption in an IT commercial facility via wireless technology.

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Commercial building

Company profile

A global technology company with a long history of innovation in the field of information technology. It has a diverse portfolio of products and services, including cloud computing, artificial intelligence, and data analytics. The company is committed to sustainability and has implemented numerous initiatives to reduce its environmental impact.

Project Requirement

Our Client manages a leading technology company with numerous office buildings across the country. To reduce water usage and improve efficiency, They decided to implement a water flow and consumption monitoring system in all its facilities. The project’s goal was to accurately measure and track water usage in real-time, identify waste areas, and implement corrective measures to reduce overall consumption

Challenge

One of the main challenges faced in implementing a water flow and consumption monitoring system was the sheer size and scale of the project. With numerous buildings located all over the country, finding a solution that could quickly implement and seamlessly integrated into existing infrastructure was critical. In addition, they needed a system that was accurate, reliable, easy to use, and capable of handling large amounts of data.

Products

Ultrasonic water flow meter

Ultrasonic Water Meter

Ultrasonic water meters are flow meters that use high-frequency sound waves to measure the water flow rate in a pipe. As the sound wave travels through the water, it is affected by the velocity and direction of the flow. Can calculate the flow rate of the water by measuring the time it takes for the sound wave to travel through the water and the change in frequency of the wave. The flow rate calculates the total volume of water that has passed through the meter. Can use this information to monitor water flow and consumption in various applications, including residential, commercial, and industrial settings.

modem rs485 transceiver

4G Rs485 Telemetry

4G RS485 telemetry is a type of remote communication system wireless technology and the RS485 serial communication protocol to transmit data over long distances. It is commonly used for remote monitoring and control of devices and systems, such as water and gas meters, environmental sensors, and industrial equipment. 4G RS485 telemetry systems typically consist of a transmitter and receiver, which connect to a device or system that needs to be monitored or controlled. The transmitter sends data from the device or system over a 4G wireless network to the receiver, typically located at a remote location. The receiver then converts the data into a form that can be interpreted and used by a computer or other device.

Solution

We implemented a wireless water flow and consumption monitoring system using advanced sensors and software(IoT Platform) to meet these challenges. The sensors were installed throughout the buildings, including restrooms and other high-use areas. The data collected by the sensors was then transmitted wirelessly to a central server, where it was analyzed and used to generate reports and alerts. The system is designed to accurately measure and track water usage in real-time, allowing it to identify waste areas and implement corrective measures to reduce overall consumption.

Installation pics

Real time water consumption monitoring
IBM3
IBM1
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IoT Platform

Day wise Water consumption
3

Outcomes

Implementing the wireless water flow and consumption monitoring system successfully achieved significant water usage reductions across all of its buildings. The system helped identify areas of waste and inefficiency, allowing corrective measures such as fixing leaky pipes, installing low-flow fixtures, and implementing water-saving policies. In addition, the system provided valuable data and insights that allowed us to make informed decisions about water management and conservation. Overall, the project was a win-win for both company and the environment. The company reduced its water usage and environmental impact while improving efficiency and saving money on water costs.

Case study: Advanced temperature monitoring and control in a radiant cooling system for a wide floor surface area.

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About client

Our client is a leading solutions provider in the Radiant cooling and heating industry. They are awarded the prestigious WWF Climate Solver for their radiant cooling solutions. Over a decade, they have provided innovative, sustainable, and scalable energy efficiency solutions in various sectors ranging from Pharma, Food, Construction, IT, Manufacturing, Warehousing, Defense, Power, etc.

Challenge 

Radiant cooling systems are an efficient and effective way to regulate the temperature in a building or space. These systems work by circulating cool water through pipes or tubes beneath a structure’s floor, walls, or ceiling. This cool water absorbs heat from the surrounding air, helping keep the space comfortable. The challenge with radiant cooling systems is accurately monitoring and controlling the temperature of the floor surface. If the floor is too cold, it can be uncomfortable for occupants and may result in decreased energy efficiency. On the other hand, if the floor is too warm, it may not effectively cool the space. Another one is to monitor the temperature for a wide floor surface area.

Products

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Thermostat
7 Channel Actuator controller (Gateway)

Solution

To address the challenge of accurately monitoring and controlling the temperature of a radiant cooling system, a custom solution has been designed using Bluetooth Low Energy (BLE) surface temperature beacons, a wireless thermostat, and a 7-channel actuator controller (gateway).

  1. Install BLE surface temperature beacons on the floor in a representative location. These beacons continuously measure the temperature and transmit the readings at a fixed interval (1 minute by default).
  2. Data received from wireless surface temperature beacons are sent to the thermostat, and the thermostat will transfer the data to the 7-channel actuator controller (gateway)
  3. Program the wireless thermostat to control the temperature of the space based on the temperature readings from the wireless surface temperature beacon and to measure the space’s humidity to prevent floor condensation.
  4. Program the 7-channel actuator controller (gateway) to receive temperature readings from the thermostat and to control the flow of cool water through the radiant cooling system based on these readings.
  5. Monitor the system’s performance using the thermostat and the 7-channel actuator controller (gateway). Adjust the settings as needed to ensure that the floor’s temperature is maintained within a comfortable range.

This solution offers precise temperature control, energy efficiency, comfort for occupants, and easy maintenance and calibration. By accurately controlling the floor’s temperature, the radiant cooling system can operate at maximum efficiency, reducing energy consumption and costs while ensuring the comfort of the space’s occupants. Wireless technologies also simplify the installation and maintenance of the system, as it eliminates the need for wiring between the various components.

Outcome

  • Precise temperature control: The wireless surface temperature beacon allows for real-time temperature monitoring of the floor surface, ensuring that the radiant cooling system operates optimally.
  • Energy efficiency: By accurately controlling the floor’s temperature, the radiant cooling system can operate at maximum efficiency, reducing energy consumption and costs.
  • Comfort: By maintaining a comfortable temperature range, the radiant cooling system helps ensure the convenience of the space’s occupants.
  • Easy maintenance and calibration: The BLE surface temperature beacon, thermostat, and 7-channel actuator controller (gateway) are easy to access for maintenance and calibration, ensuring the system operates at its best.
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