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Diesel Genset Monitoring
Monitor diesel consumption, minimise opportunities for theft and measure actual electricity generated per litre of diesel consumed. This helps customers to form rules regarding which systems to keep running and which systems to stop when mains supply fails. Optional advanced sensors can be used to monitor health and compare performance of multiple gensets used within the organisation.
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Real time energy monitoring
Energy consumed by machines can be monitored and managed regularly by our smart energy monitoring solutions. Embedded sensors, meters, and other IoT devices can monitor the energy utilized by each equipment. The energy utilization parameters can also be collected for a chain of assets to determine the overall consumption of an entire facility. Hence, strategic actions and decisions can be taken to subdue the consumption of electricity and boost up the overall efficiency.
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Advanced alerts and warnings with remote monitoring
The real-time alert system will enable you to gain alerts about inefficiencies in your facility. The derived parameters can be calculated, and alarms can be triggered in real-time that enables you to detect errors instantly when they occur.
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Compatible with most devices- no need to upgrade existing infrastructure.
We pick the right wireless and battery-powered sensors, meter, and gateways to transform data from endpoints into valuable information and make it available on the TruMonitor energy monitoring dashboard which is tailored according to your requirements.
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Mobile app and web portal for the same application
TruMonitor provides all the information related to the installed devices on machines on a single screen. Our centralized dashboard encompasses several cards and panels that project useful data in an intuitive and easy to understand manner.
Analysis using TraceWiz- customised as per customer need
- Consumption patterns and Control visualisations
- Real time equipment efficiency and status
How TruMonitor Works
TruMonitor collects energy usage data from the energy meters installed on site. IoT enabled energy meters can be installed which send data directly to the TruMonitor cloud. Else if industrial panel mounted meters are already present, then we can provide an RS485 converter which can gather data from compatible meters and uploads it to the cloud.
Ability to use existing industrial meters which have a digital RS-485 or Ethernet type output saves the cost of replacing the meters which are otherwise working properly.
Data can be transmitted to TruMonitor cloud using several ways, proper way can be selected depending upon the situations at the installation site. Most reliable way is via a WiFi network. If the installation location already has a WiFi network, our transmitters can be configured to take advantage of that network and transmit data directly to the TruMonitor cloud. Data can also be transmitted using standard off the shelf 2G, 3G or 4G transmitters over mobile network.
TruMonitor receives this data and stores it in the cloud database. By default, customers are given 5-year data retention. However, customers can request additional data retention for extra cost.
On the user’s side, the TruMonitor interface is divided into five levels, the organisation being the top level and Asset being the lowest level.
Asset (L1)
This is the lowest entity within an organisation. Asset can be something like a CNC machine for a manufacturer, an automatic fryer for food processing plant, robotic arm etc. Multiple sensors can be assigned to an asset. For example, a manufacturer may wish to have an Energy meter, an ON-OFF sensor, spindle speed sensor etc. for a CNC machine, food processing plant may have temperature sensor and oil flow meter along with an energy meter for an automatic frying machine. All of these sensors are considered L0 and can be mixed and matched with the assets.
L2
Multiple assets are grouped into a L2 system with additional sensors common for all the assets within that system, such as ambient temperature and humidity. For example, two CNC machines and one Robotic Arm operating together form a single unit. Similarly, an automatic frying machine with a drying machine can form a single unit with individual sensors for each asset, and a common ambient temperature, humidity and energy meter for the entire level.
L3
Multiple L2 level systems can be grouped into an L3 level system. This can represent a manufacturing line within a plant.
L4
L4 is usually the entire plant or site. Each organisation can have multiple L4 level entities.
All these entities and hierarchies are configurable as per the actual setup of the customer.
Parameters for Energy Monitoring
Standard parameters such as Energy consumption, active and reactive energy along with power factor are recorded depending upon the customer need. Readings can be taken as fast as one reading every one minute to once every hour or more.
Almost every industry relies on Diesel Generator Sets to provide power when the main grid fails. A diesel level monitoring device along with an energy meter to monitor electricity generated by the diesel genset can be installed. Customers can now easily monitor the actual cost of energy and keep tab on the diesel consumption and minimise possibility of theft. Insights can also be gained into the proper functioning of the gensets.
Additional parameters
Apart from energy, TruMonitor can collect any type of sensor data either from existing PLCs, controllers, and sensor modules if they have a standard digital output port or separate IoT sensors can be installed as per the need. Some other common sensors are
- Spindle speed, On-Off etc. for CNC machines
- Temperature
- Pressure
- Humidity
- pH and Turbidity
- Water/liquid levels
- Flow meters
Output
Each customer is given a dashboard of the organisation which gives a top-level view of the entire organisation. Through this dashboard, the customer can see the consumption pattern from Asset to L4 or organisation level.
Through data analytics, this pattern can be corelated with actual machine outputs, which can be done through another product TraceWiz.
For example, customers can see the CNC machine running time, energy consumed, downtime and corelate that with the production data to gain insights into the functioning. For a frying line, relationship between ambient temperature, oil temperature and energy consumption can be established and solutions to improve efficiency and reduce energy consumption can be implemented.
Monitoring of reactive energy and power factor in near real time gives the ability to time the operations of the machinery to improve the power factor and reduce the costs and avoid fines.