Preventing energy waste and industrial equipment downtime with a circuit-level monitoring solution

R&D PROJECT

Smart Energy Monitor is a self-powered, wireless energy monitoring solution that tracks energy consumption at the circuit level across industrial machinery, distribution grids, and individual appliances. Through its non-invasive sensors and AI-driven analytics, it gives industrial plants, data centers, building complexes, and energy supply companies the visibility they need to optimize costs and prevent equipment failures.

CHALLENGE

Most organizations have a general picture of their energy consumption – total usage by building or by billing period – but no visibility at the load level. But without knowing which machines, circuits, or appliances are consuming energy, when, and how much, it’s impossible to identify the area of waste, detect unauthorized usage, or catch dangerous overloads.

Equipment maintenance compounds the problem: its cycles are typically based on estimated operating hours rather than actual usage data, which means maintenance happens either too early, wasting time and money, or too late, resulting in unexpected failures. The cost of that uncertainty accumulates across every asset in a facility.

SOLUTION

The designed Smart Energy Monitor solution comprises wireless current sensors, a hub, and a cloud-based monitoring platform.

The sensor clamps directly onto any circuit breaker wire, harvesting power from the electromagnetic field of the monitored circuit. It measures current across 1-phase, 2-phase, and 3-phase loads and transmits readings every 20 seconds to the wireless hub over ISM 915MHz or 434MHz bands, or Bluetooth. This sensor is fully customizable and can be installed below the circuit breaker without interfering with existing infrastructure.

The wireless hub aggregates sensor data on-site, processing readings locally to minimize latency and maintain reliable alerting even during network outages. It connects to the cloud platform over Wi-Fi, Ethernet, or cellular network (2G/3G/4G/NB-IoT).

The cloud monitoring center gives operators a live view of energy consumption across every monitored circuit. Key capabilities include:

Real-time tracking of current, voltage, and power consumption per circuit.
Anomaly detection, including dangerous overloads and unauthorized usage.
Predictive maintenance – algorithms calculate actual equipment operating time to flag service needs before failures occur.
Customizable dashboards and automated reports for consumption trends, cost analysis, and other operational insights.
API-based data export for integration with third-party platforms.

For organizations with data residency requirements the platform can be deployed to the local cloud.