🏭Industrial IoT

Machine Retrofit Monitoring

Retrofit sensors onto existing machines - monitor motor coil temperature, oil levels, pressure switches, production counts, and more. Wireless controllers push real-time data, generate alerts, and can trigger automatic shutdowns. No machine replacement needed.

System Architecture

TIBS Machine Retrofit

Add wireless intelligence to existing machines - no rip-and-replace

TIBS machine retrofit - sensors on hydraulic pack, wireless controller, data to cloud/PLC
Example: Hydraulic pack monitoring with oil level, temp, pressure sensors and wireless controller (top right)
Coil / Oil
Temp Sensors
Level / Pressure
Switches
Multiport Controller
Wireless + Edge
Alerts
SMS / Dashboard
PLC / HMI
Existing
Video Analytics Conveyor Slippage Production Count Tank Level
Why Retrofit with TIBS

Key Benefits of Machine Retrofit Monitoring

Maximise uptime, safety, and efficiency without replacing machines

Predictive Maintenance

Alerts before breakdown - motor coil temperature rise, oil level drop, or pressure anomaly triggers early warning.

Reduced Downtime

Monitor KPIs that top management tracks. Real-time anomaly detection cuts unplanned stoppages by up to 60%.

Operator Safety

Eliminate manual oil level/pressure checks in hazardous areas. Automatic shutdown prevents catastrophes.

Fire Prevention

Conveyor slippage on drying machines detected instantly - avoids wood buildup and potential fires.

Energy & Resource Efficiency

Tank level monitoring with auto pump triggers prevents dry runs and overflow. Energy monitoring identifies waste.

Future-Ready Legacy

Extend life of existing machines by adding intelligence. Data can be fed into your existing PLC/HMI for unified view.

Capabilities

What Retrofit Monitoring Delivers

Comprehensive sensing, alerting, and control for existing assets

Core Monitoring Features

  • Motor coil temperature sensor - prevents burn-out related breakdowns
  • Oil level, temperature & pressure monitoring - eliminates manual inspection risks
  • 24V/240V switch output tapping - alerts from existing pressure/oil switches
  • Real-time production count from machines or entire production lines
  • End-to-end process automation using sensors + video analytics (plywood case study)
  • Wood log volume calculation via edge-based video analytics
  • Boiler monitoring & control - temperature, pressure, fuel levels
  • Wood peel drying machine monitoring - conveyor chain slippage detection (fire prevention)
  • Tank level monitoring (liquids & solids) - auto pump triggers
  • Conveyor belt & motor monitoring in warehouses - predictive maintenance alerts

Technical Specifications

Wireless Controller
  • 8-16 analog/digital inputs
  • 4 relay outputs for shutdown/slowdown
  • Zigbee / LoRa / Wi-Fi / 4G backhaul
  • Edge processing - alerts without cloud
Data Integration

Modbus TCP/RTU to existing PLC, MQTT to cloud, REST API. Visualise on existing HMI or new dashboard.

Solution Components

Retrofit Subsystems

Hardware and software modules for any industrial environment

Vitals

Motor & Mechanical Health

Real-time vitals of motors, pumps, and hydraulic systems.

  • Motor coil temperature sensor (prevents burnout)
  • Vibration analysis for bearing wear
  • Current monitoring for overload detection
  • Hydraulic pack monitoring: oil level, temp, pressure
  • Coolant-in / coolant-out temperature differential
Controller

Wireless Retrofit Controller

Multiport controller that interfaces existing sensors and pushes data wirelessly.

  • Accepts 0-10V, 4-20mA, and digital inputs (24V/240V)
  • Taps into existing oil/pressure switch outputs
  • Wireless data push (Zigbee / LoRa / Wi-Fi / 4G)
  • Local edge processing for instant alerts
  • Can trigger actuators to slow/shut down machines
Automation

Production & Process Automation

Custom automation using sensors and video analytics.

  • Real-time production count from any machine or line
  • Wood log volume calculation (edge video analytics)
  • Plywood press automation (one-touch start, thickness control)
  • Boiler monitoring (steam pressure, fuel level, exhaust temp)
  • Wood peel drying machine: conveyor slippage detection
Integration

Legacy PLC / HMI Integration

Retrofit data can be fed back to existing control systems.

  • Push sensor data to existing PLC via Modbus
  • Visualise retrofit data on existing HMI screens
  • Reprogram PLC to act on new sensor inputs
  • No need to replace existing controllers
  • Seamless coexistence with factory automation network

Ready to Retrofit Your Machines?

Add wireless intelligence to existing assets - monitor motor health, oil levels, production counts, and more. Avoid breakdowns and improve OEE without replacing machinery.

Request a Live Demo

Free on-site assessment - we’ll identify the highest-value retrofit points.