Sensors on the equipment
Temperature, pressure, level, vibration, current and water quality are read at the machine, not walked round with a clipboard.
Industrial IoT
Know the moment a machine or a room leaves its range.
Karuturi Dynamics designs, builds and runs monitoring systems for machinery and plant: sensors on the equipment, readings every minute on a live dashboard, and an alert on the phone of the person who can act.
A machine checked on a walk round can fail between two walks. A sensor reads it every minute, and the person responsible hears about a problem before the next round would have found it.
What the system does
From the sensor to the person who can act.
Readings every minute
Every reading reaches a live dashboard within the minute, on the desk and on the phone.
Alerts to the right person
When a reading leaves its range, the person responsible for that machine gets a call or a message, and the next person if nobody responds.
History beside every alert
Each alert opens with the hours of readings before it, so the cause is visible before anyone reaches the site.
Works through power and network cuts
The site gateway stores readings locally during an outage and sends them when the connection returns, so no gap appears in the record.
Maintenance from trends
Rising vibration, longer run hours and slow drift show which machine needs service before it fails.
What it watches
Every machine and room on one dashboard.
The sensors are chosen for each site from ready-made industrial parts, and every one reports to the same dashboard.
01
Motors and pumps
Dry running and overload are flagged.
Reads
- Body temperature
- Vibration
- Current
- Run hours
02
Compressors
Stops and short cycling are flagged.
Reads
- Discharge pressure
- Temperature
- Power draw
03
Tanks
Low and high levels are flagged before a pump runs dry or a tank overflows.
Reads
- Level
- Temperature
- Pressure
04
Cold rooms
Recorded minute by minute for each room.
Reads
- Temperature
- Humidity
- Door state
- Power
05
Sheds
Reads
- Temperature
- Humidity
- Ammonia
- Fans running
- Power
06
Ponds
Reads
- Dissolved oxygen
- pH
- Water temperature
- Aerator power
07
Power supply
A cut is known as it happens.
Reads
- Mains
- Generator
- Inverter state
08
Water quality
For treatment plants and pool plant rooms.
Reads
- pH
- ORP
- Conductivity
- Pressure across filters
01 / 01
Where it is used
One system, set up for each operation.
Manufacturing
Motors, compressors and process lines watched for faults and wear between shifts.
Cold chain
Every cold room and chiller with a continuous temperature record for each batch.
Water treatment
Pumps, filters, tank levels and water quality across a plant or a set of sites.
Warehousing
Temperature, humidity and power across storage halls and the equipment in them.
Agriculture and aquaculture
Ponds, poultry sheds and pump sets watched day and night.
How it is set up
Designed, fitted and run afterwards.
- 01
Site survey
Each machine and room is listed with what to measure, its normal range and who is responsible for it.
- 02
Sensors and gateway
Ready-made industrial sensors are wired to a gateway on site, which buffers readings and sends them to the cloud.
- 03
Dashboard and alerts
The dashboard is built around the site, and each alert goes to a named person with a fallback.
- 04
Running it
Karuturi Dynamics watches the system's own health, adjusts ranges as the site learns its normal, and adds sensors when needed.
Example, in progress
Aqvastar
Pool, fountain and irrigation equipment distributor, Bengaluru.
- The work
- Monitoring for pool plant rooms: pumps, filters, water chemistry and heating, read by ready-made RS-485 sensors.
- Gateway
- A modular RS-485 (Modbus RTU) gateway, configured per site for whichever sensors that installation has.
- Dashboard
- A monitoring dashboard for Aqvastar's team. Karuturi Dynamics is also building Aqvastar's website and its company operations dashboard.
- Stage
- Sensor selection is under way; the gateway and dashboard follow once the sensor set is confirmed.
Questions
Asked before a site goes live.
Does Karuturi Dynamics sell sensors or kits?
No. Karuturi Dynamics designs, builds and runs the monitoring system as a service. Ready-made industrial sensors are specified for each site and fitted as part of that system.
What happens when the power or the internet goes down?
The gateway on site keeps recording during the cut and sends the stored readings when the connection returns. A loss of power or network is itself an alert.
Who receives the alerts?
Each machine or room has a named person for its alerts, by call or message, with a second person if the first does not respond within a set time.
Can it work with equipment already on site?
Often, yes. Many machines and meters already give a Modbus or analogue output, which the gateway can read alongside new sensors.
Who can see the data?
The business owns its readings. Access to the dashboard is set per person.
Start with one site.
A 30-minute meeting to list the machines and rooms worth watching.
Book a meeting