Case Study: Factory Air Filter Panel Condition Monitoring

Aug 18

2 min read

Objective

Monitor the life and condition of panel air filters in industrial air handling systems, transitioning from time-based to service-based replacements with fault monitoring.

Solution

Innovisory developed a back-end dashboard system to monitor each system and panel filter condition. We began with a prototype system, capturing Filtrex’s requirements and creating a basic, low-cost platform for trialling. Feedback from the successful trial allowed us to refine the requirements and system architecture before full development.

Development

Custom Hardware: Schematic, PCB, and mechanical design of remote devices, using differential pressure sensors and low power radio technology. Utilised LoRa (Long Range IoT radio platform) for local comms.
Custom Firmware: Developed firmware for the remote devices to schedule wake periods and prolong battery life.
Cloud-Based Dashboard: Developed a feature-rich, web-based dashboard to display data received from each remote sensor with limited customer-facing access levels and reporting. Remote configuration of every device on the network.
Production: The remote monitoring units were designed for ease of manufacture with simple assembly processes offering a low-cost solution.

Test Results

Achieved very long ranges for a low-power radio solution in complex industrial environments, with battery life of several years.
Reliable radio communications, accurate data measuring and low data running costs.

Enhancements Over Three Years

Improved hardware, firmware, and dashboard functionality.
Added equipment fault monitor alerts and event logging.
Continuous development to stay ahead of the competition.

Current Status

400+ remote-sensing devices deployed across UK factories.
International launch planned.

Summary

Innovisory successfully developed and implemented a comprehensive monitoring system for Filtrex, transitioning from time-based to service-based filter replacements. The system’s long-range, low-power radio solution and cloud-based dashboard have proven effective in complex industrial environments. With ongoing enhancements and international expansion plans, the solution continues to deliver reliable performance and cost efficiency.