⚡Industrial IoT

Predictive Maintenance & Energy Management

Reduce downtime, increase asset utilization, and cut energy waste. Real-time monitoring of motors, flow, pressure, temperature, and power - with predictive analytics to forecast failures before they happen.

System Overview

TIBS Predictive Maintenance

Sensors → Edge Gateway → Analytics → Alerts → Action

TIBS predictive maintenance architecture - sensors on motors, flow, energy meters connected to wireless gateway
Continuous monitoring of motor vitals, process parameters, and energy consumption - with predictive analytics
Motor + Process
Sensors
Energy Meters
Wireless
Edge Gateway
Local Analytics
Alerts
SMS / Dashboard
Predictive
Forecast
Wireless Retrofit Anomaly Detection Bottleneck Analysis PLC Integration
Why TIBS Predictive Maintenance

Key Benefits of IoT Predictive Maintenance

From reactive to proactive - maximise uptime and efficiency

Reduce Unplanned Downtime

Predictive alerts allow maintenance teams to intervene before a breakdown, cutting unplanned stops by up to 60%.

Increase Asset Utilization

Real-time bottleneck detection and performance optimisation improve OEE (Overall Equipment Effectiveness).

Lower Energy Costs

Identify machines with abnormally high consumption - replace or repair before they waste energy.

Extend Equipment Life

Proactive maintenance reduces wear and tear, prolonging the life of motors, pumps, and furnaces.

Data-Driven Decisions

Replace manual logbooks with streaming sensor data - precise, timely, and actionable.

Fast ROI

Retrofit existing machines with wireless sensors - no rip-and-replace. Typical payback <12 months.

Capabilities

What Predictive Maintenance Delivers

Complete sensor suite + analytics platform

Core Monitoring Features

  • Real-time machine health monitoring (motor fin temp, RPM, vibration, pressure, oil temp)
  • Flow sensors - invasive & non-invasive for liquids/gases
  • High temperature measurement (furnace interior / crucible exterior)
  • Liquid temperature & level monitoring (multiple grades)
  • Motor Control Units for automated shutdown/slowdown
  • Wireless split-core smart meters - single & three phase
  • Smart Meter Adaptor - converts existing meters into wireless smart meters
  • Anomaly detection & predictive alerts - reduce unplanned downtime

Wireless & Integration

Connectivity Options
  • Zigbee / LoRaWAN / Wi-Fi / 4G
  • Split-core CTs - no electrical shutdown for installation
  • Smart Meter Adaptor - clip onto existing meters
  • Modbus / OPC UA to existing PLC/SCADA
Predictive Analytics

Machine learning models trained on historical data to forecast failures days or weeks in advance.

Sensor Portfolio

Predictive Maintenance Sensors

Retrofit any machine - from motors to furnaces

Motors

Motor & Rotating Equipment

Comprehensive health monitoring for motors, pumps, compressors, and fans.

  • Motor fin temperature sensor (prevents overheating)
  • Motor RPM sensor - speed deviation alerts
  • Vibration sensor (accelerometer) - bearing wear detection
  • Oil temperature & pressure sensors for lubrication systems
  • Motor Control Unit - automatic shutdown on critical anomalies
Process

Flow, Pressure & Level

Monitor process parameters that affect efficiency and safety.

  • Invasive flow meters (inline) & non-invasive ultrasonic clamp-on
  • Pressure sensors (0-10 bar, 0-100 bar, custom ranges)
  • Level sensors - ultrasonic, radar, capacitive for liquids & solids
  • High temp measurement up to 1200°C (furnace/crucible)
  • Liquid temperature monitoring (-40°C to +150°C)
Energy

Energy Monitoring

Wireless energy meters to track consumption and identify waste.

  • Wireless split-core smart meters (single & three phase)
  • Smart Meter Adaptor - retrofits existing meters with wireless
  • Real-time kW, kVA, power factor, harmonic distortion
  • Identify malfunctioning machines via abnormal energy signatures
  • Energy dashboards & carbon footprint reporting
Analytics

Predictive Analytics Platform

Edge gateway + cloud analytics to forecast failures before they happen.

  • Local edge processing - alerts without internet
  • Machine learning models for failure prediction
  • Real-time dashboard & mobile notifications
  • Integration with existing SCADA / PLC / MES
  • Historical trend analysis & maintenance scheduling

Stop Unplanned Downtime Today

Retrofit wireless sensors on your critical assets - get real-time health data, energy insights, and predictive alerts. Increase OEE and reduce maintenance costs.

Request a Live Demo

Free plant walkthrough - we'll identify your top 5 failure risks.