IOT Sensors for asset health in energy

client

ENERGY

role

IOT, BATTERY POWERED, LPWAN

year

2024

This project involved the development and deployment of IoT-based solutions to enhance asset health monitoring across electricity distribution networks. The system provided real-time fault detection and predictive maintenance, ensuring critical infrastructure was monitored efficiently and reliably, even in remote locations. The process included the following stages:

1. Requirements Analysis & Design

The project began with a thorough analysis of the operational needs of the electricity distribution network. Key assets to be monitored were identified, along with the environmental and operational parameters most critical to asset health. Power consumption, data transmission range, and environmental conditions were taken into account in the design to ensure long-term reliability.

2. Hardware Development

Suitable IoT sensors were selected to measure the necessary parameters. Custom PCBs were designed to integrate sensors and LPWAN transceivers, optimising them for low-power consumption and efficient communication. Robust enclosures, with an IP rating appropriate for outdoor use, were developed to protect the sensors from harsh environmental conditions.

3. Firmware Development

Firmware was developed to manage data acquisition and transmission. The sensors were programmed to operate in low-power modes and periodically wake to capture and transmit data. Real-time alerts were configured to trigger in response to abnormal conditions, such as overheating or excessive vibrations, using energy-efficient transmission protocols to maximise battery life.

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4. Cloud Integration & Data Management

The collected data was transmitted via LPWAN networks to a central cloud-based platform. Real-time data processing algorithms were implemented to detect anomalies and send alerts when predefined thresholds were exceeded. The system was integrated with existing maintenance workflows to enable immediate action when faults or issues were detected.

5. Prototyping & Testing

Prototypes were developed and tested under real-world conditions to ensure reliability and performance. Testing focused on hardware durability, power efficiency, and the robustness of communication over LPWAN. Feedback from these tests informed iterative improvements to both the hardware and firmware.

6. Deployment & Maintenance

The solution was deployed across a wide geographic area, with sensors installed on poles throughout the distribution network. Remote management systems were implemented to handle firmware updates and monitor the health of the sensor network. Over-the-Air (OTA) updates were integrated to allow seamless updates without the need for physical access to the devices.

7. Long-Term Support & Continuous Improvement

Following deployment, ongoing support was provided to analyse the sensor data and refine the predictive maintenance algorithms. Regular updates to the firmware and hardware allowed for continuous improvement, and the solution was further optimised over time to increase accuracy and extend battery life. Data trends informed long-term maintenance strategies, reducing equipment failure rates and operational costs.