Background

An Electrical Appliance Manufacturing Company was looking for ways to save losses by controlling some temperature based process parameters.

As a Solution Demo, I built a system with a non-contact Temperature Monitoring Device that wirelessly connected to a Computer running a script for plotting and logging the data in realtime. I demonstrated this on the machine at their Manufacturing Plant in Pune.

The Problem:

  • The process needed a strict operating temperature range
  • In case of a deviations, there were downstream losses
  • The temperature was not being monitored

Ranjit_Bhinge

The Demonstration

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My task was to develop a retrofit solution to stream the temperature data of their process, find the points in this data set that corresponded to the temperature at the moment of the closing of the machine doors (critical temperature points) and report whether that temperature value was within limits.


My Solution:

I set up a 3 part Demonstration in a week:

  1. A device to pick up realtime temperature of the intended part of the Machine
  2. Some Javascript (on a Laptop) to compile the data and plot it in realtime
  3. A report based on the analysis of this plotted data

The Temperature Monitoring Device:

This was a non-contact device that would be mounted near the machine. It's functionality:

  • Since the Machine had a lot of moving parts, this device was a long range Temperature Monitor measuring from a distance (1m)
  • It used an IR based temperature sensor on board
  • It connected to a Laptop over WiFi and streamed the realtime temperature data

From the first run, we plotted the data and found clear patterns. This helped us quickly identify the critical temperature points on the plot.

Plotting, analyzing and presenting:

We monitored the process for an hour before compiling the results and presenting them to the top management of the Company.

We were able to reliably point out the critical temperature values in the process over 1 hour, and highlight the standard deviation on them. These were the expected insights.

Our proposal was to then set up the Monitoring System and use a Cloud Analytics platform to process the data, plot the critical temperatures and provide a Dashboard.

My Role:

I teamed up with a CAD Engineer and worked closely with the Infinite Uptime Team on this project. I defined the system, developed the Software (NodeJS with MQTT), built the Electronics on a proto-board, wrote the Firmware (ESP8266) and got the enclosure designed and 3d-printed with the help of the CAD Engineer.

For the Demonstration, I was accompanied by an Engineer from Infinite Uptime, who used my CSV results to generate a presentable graph and diagram which I used to present to the Management.



I was very keen on this project, since our solution had the potential to add immense value every week by saving Lakhs of Rupees for the Customer. It gave me the opportunity to work with the extremely fast and lean Infinite Uptime team and learn the value of rapid prototyping in a young startup.

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Readout from the Laptop Script Ranjit_Bhinge

The temperature plot Ranjit_Bhinge

The Temperature Monitor specs Ranjit_Bhinge

Get In Touch

  • Pune (MH), India
  • ranjitbhinge@gmail.com