Industrial IoT Device Development and AI Maintenance Platform for Compressor Manufacturer

The client needed temperature monitoring sensors that could also track vibration and magnetic fields, withstand extreme conditions from -40°C to +250°C, and remain safe in factories where even a single spark could cause an explosion.

However, off-the-shelf devices simply weren’t built for that kind of pressure. Most couldn’t monitor all parameters at once, weren’t certified for hazardous environments, or required frequent recharging.

What the client really needed was something far tougher: custom sensors capable of operating for years without a battery change while surviving extreme industrial conditions.

To meet these requirements, our engineers started by designing the complete electronic system architecture and detailed circuit schematics. From there, we translated those schematics into physical board layouts and built the first prototypes.

Each prototype then went through rigorous testing to ensure functionality, durability, and full compliance with ATEX Zone 2 and other regional certifications, including UKCA, NEC 500/505, CQST, KOSHA, and TIIS.

Once the prototype passed all tests, we supported the client’s transition to mass production by connecting them with a trusted manufacturing partner. In parallel, and thanks to our partnerships with Notified Bodies, official organizations that verify product safety worldwide, we ensured the device met all required certifications.

The investment paid off quickly: the custom-built device delivered exactly what the client needed, without unnecessary features or expensive components they would never use.

Once the sensors were ready, we connected them to AWS IoT Core. Data from factory-wide edge gateways, each covering a 1 km radius, is securely transmitted to the cloud.

In the cloud, our AI models analyze historical and real-time sensor data to generate customized maintenance schedules, predicting potential failures and enabling timely interventions before costly breakdowns happen.

To have all the data in one place and know when to check each machine, we built responsive dashboards for tablets and mobile devices, perfect for on-site operators. These dashboards display all essential machine data in real time and allow operators to monitor performance at a glance, including:

• Temperature and vibration levels
• Magnetic field readings
• Working hours for each machine
• Machine location
• Maintenance history and schedules

If a sensor shows signs of wear, the system sends alerts, giving the team time to react before a failure occurs and saving thousands of dollars on replacing machines.

Our client’s customers, factories running these systems, needed easy data access as well. So we developed a public API that lets them pull this information straight into their own monitoring systems.

With real-time machine monitoring, clients have more trust in the equipment. It also helped the manufacturer stand out in a market where most competitors still rely on manual processes.