Retrofitting manufacturing efficiency: low-cost electrical current monitoring for industrial machinery

This research investigates the development of a low-cost electrical current monitoring system designed to augment manufacturing efficiency while addressing the sustainability challenges posed by legacy machinery. Recognising the substantial cost of equipment failure associated with maintaining industrial machinery, particularly legacy systems, this study focuses on developing a retrofittable low-cost monitoring system for existing industrial setups. The system utilises a Wi-Fi-enabled microcontroller-based sensor device that clips onto existing electrical connections, capturing the machinery’s current consumption with adjustable sampling rates. The sensor data are transmitted to an agnostic pipeline to improve adoption ergonomics; here, we propose the use of a simple, extensible open-source visualisation pipeline. Through continuous monitoring of electrical currents, the system can facilitate early fault detection and proactive maintenance planning, thereby mitigating downtime and extending the lifespan of legacy machinery. Furthermore, the monitoring device enables manufacturers to optimise energy usage, ensure regulatory compliance, and implement remote monitoring capabilities. Adopting this low-cost monitoring system empowers manufacturers to operate more efficiently, sustainably, and profitably.