Factory Energy & Machine Telemetry Monitoring (Industrial IoT)
Field Challenge: DeviceLab phát triển hệ thống giám sát năng lượng và dữ liệu vận hành nhà máy, kết nối công tơ điện, cảm…
Smart Manufacturing · Industry 4.0
Digitalize Legacy Machines Without Replacing Equipment
Acquire Run/Stop telemetry, production output, energy consumption and OEE directly from existing machines — zero PLC changes, zero production downtime.
Legacy Machine Telemetry & Energy Monitoring: Non-invasive external clamp-on sensors; 100% zero PLC code changes, zero machine downtime.
Industrial Gateways & White-Label OEM: Multi-protocol hardware (Modbus, MQTT, 4G LTE), industrial Din-rail aluminum enclosure.
LIVE INDUSTRIAL TELEMETRY CONSOLE
RUNNING
Shift 1 · Molding Shop
Plastic Injection Molding Machine A01 (250T)
OEE:
89.2%
OUTPUT
1,420
pcs
POWER
42.8 kW
ENERGY
184.6 kWh
CYCLE TIME
28.4 s
- Zero PLC Modifications
- Installed While Running (2–4h/machine)
- Modbus RTU / MQTT / 4G LTE
- PoC on 1–3 Machines in 2–4 Weeks
Solution Orientation
Which Engineering Challenge Are You Looking to Solve?
Whether managing factory floor operations or engineering integrated systems for industrial clients, DeviceLab provides proven hardware solutions:
For Manufacturing Plants & Factories
Legacy Machine Telemetry & Operational Energy Monitoring
- Legacy machinery without digital communication ports.
- Accurate electricity (kWh) and peak power measurement per machine/sub-panel.
- Automated Run / Stop / Idle operational state detection.
- Real-time production output, cycle time logging and OEE calculation.
- Early warning for motor overheating, cabinet temperature, and air compressor pressure.
Safety Guarantee: Non-invasive external clamp-on sensors. Absolutely no PLC code changes, no main power cable cutting, zero production stoppage.
For System Integrators (SI) & OEMs
Multi-Protocol Industrial Gateways & Custom OEM Devices
- Multi-protocol Industrial Gateways: Modbus RTU/TCP, RS485, CAN, 4G LTE, MQTT.
- Edge computing firmware, structured JSON payloads matching software specifications.
- Custom laser-engraved partner logo on Din-rail aluminum enclosures (OEM/White-label).
- Complete tender dossier: Bilingual English/Vietnamese datasheets, 2D/3D CAD models, API documentation.
- Flexible batch production starting from dozens of units.
Partner Commitment: 100% in-house R&D in Vietnam. 1-on-1 technical support, strict confidentiality, and zero direct sales to SI clients.
Solutions for Manufacturing Plants
Transform Existing Machinery into Actionable Intelligence
No machine replacement. No PLC reprogramming. DeviceLab applies a non-invasive retrofit approach: adding an external data acquisition layer that feeds real-time production dashboards.
Actual Output
Know exactly how many units each machine, shift, or process stage completes in real time.
Operational OEE
Track actual % of design capacity; measure real cycle time variations against standard benchmarks.
Run / Stop / Idle
Automatically record how long machines run, stop, wait, or idle — instantly uncover hidden waste.
Detailed Energy Telemetry
Measure electricity (kWh, peak demand) per machine to accurately assign energy cost per production batch.
Raw Materials
Monitor feed rates and actual material consumption of machines per cycle and per batch.
Loss & Waste Rate
Automatically cross-reference raw material inputs against output yields to catch abnormal scrap.
Quality Rate (OK / NG)
Log qualified products (OK) and defective scrap (NG) per machine, shift, or production run.
Machine Health
Monitor motor temperature, bearing heat, cabinet climate, and pneumatic pressure to prevent sudden breakdown.
4 Non-Invasive Steps to Safe, Zero-Downtime Data Acquisition:
1
Existing machines running on shop floor
Mechanical or older machines operating standalone with zero digital connectivity.
2
Non-invasive external clamp-on sensors
Zero PLC touch, zero machine downtime — utilizing split-core CTs and independent optical/relay sensors.
3
Digitalization via 4G / Ethernet Gateway
Automatically aggregates telemetry: Output, Run/Stop/Idle, Energy and Cycle Times.
4
Actionable Dashboards & Waste Elimination
Live charts on shop floor TVs, management PCs and mobile devices.
Unit Economics: Old PLC Reprogramming vs DeviceLab Retrofit Solution
Why non-invasive sensor retrofit is always the safest and most cost-effective choice for factory management:
| Comparison Criteria | Reprogramming Old Machine PLC | DeviceLab Retrofit Solution |
|---|---|---|
| System Intervention | ✕ Deep intervention: Risk of losing original logic if PLC is password-locked or source code is lost. | ✓ Zero PLC touch: Operates with 100% independent external clamp-on sensors. |
| Implementation Time | ✕ 2 to 6 weeks: Requires control circuit tracing, ladder logic rewrites, and complex acceptance tests. | ✓ Only 2 to 4 hours / machine: Installed in parallel during normal production shifts. |
| Downtime Risk | ✕ High risk: Requires full machine shutdown; logic bugs can halt entire manufacturing lines. | ✓ Zero risk: Galvanically isolated sensing circuits; absolutely no impact on machine control. |
| Initial Investment | ✕ High capital expenditure: Expensive new PLC hardware, specialist engineering fees, and lost production time. | ✓ Highly cost-effective: Start with a 1–3 machine trial at minimal cost; scale only upon proven ROI. |
Hardware Devices & Solutions for SIs & OEMs
Need an Industrial Gateway Tailored to Your Project Specifications?
DeviceLab engineers custom industrial gateways and IoT devices: from hardware design, firmware, and industrial protocols to OEM white-labeling and tender documentation.
Modbus / RS485 / 4G / MQTT
Modbus RTU/ASCII/TCP, 2.5kV isolated surge-protected RS485, Ethernet, MQTT, 4G LTE connecting seamlessly to SCADA, Cloud MES, ThingsBoard.
Project-Tailored Firmware
Edge computing, noise filtering, customized JSON formatting. Integrated onboard flash memory buffers data during network dropouts.
OEM / White-Label Branding
Laser-engraved partner logo on Din-rail aluminum enclosure; custom web GUI branded under your company identity. Batches from dozens of units.
Comprehensive Bidding Dossier
Complete bilingual English/Vietnamese datasheets, 2D/3D cabinet CAD drawings, wiring schematics, Modbus register maps and API docs.
R&D & Hardware Manufacturing Capabilities
Mastering Hardware Technology from Circuit Schematics to Turnkey Products
Every device reliably operating in harsh industrial environments is the result of rigorous hardware research, firmware engineering, and laboratory verification at DeviceLab:
Layer 01
Field Devices
Sensors · I/O · CTs · Modbus RS485
Layer 02
Industrial Gateway
2.5kV Isolation · 9–36V · Din-rail Aluminum
Layer 03
Edge Computing
Edge Processing · Noise Filter · Flash Buffer
Layer 04
Communication Protocols
MQTT JSON · REST API · Ethernet · 4G LTE
Layer 05
Enterprise Systems
OEE Dashboard · SCADA · Cloud MES · ERP
R&D & Industrial Circuit Design
Multi-layer PCBs with EMC/EMI pre-compliance, reverse polarity protection, overvoltage surge suppression, and optoisolated RS485.
Testing Lab & Specialized Instruments
Waveform and transient spike analysis using high-bandwidth oscilloscopes, communication integrity validation, and power consumption testing.
Thermal Stress & 72h Burn-in Testing
Continuous 72-hour burn-in under industrial ambient conditions (-20°C to 70°C) prior to delivery, ensuring defect rates < 0.1%.
Technical Dossiers & Acceptance Testing
Pin-by-pin detailed datasheets, 2D/3D CAD enclosure drawings, Modbus register maps, and formal factory acceptance test (FAT) reports.
Hardware Engineering
Schematic, 4-6 Layer PCB
Firmware / RTOS
ESP32, STM32, FreeRTOS
Embedded Linux
Yocto, Buildroot, Edge Box
Industrial IoT
Modbus, MQTT, Cloud API
Edge AI Computing
Edge Vision & Anomaly Detection
OEM & Pilot Batches
From Prototype to Pilot Production
Risk-Minimizing Trial Process
No Need for Widespread Upfront Investment — Start with 1–3 Test Machines
Measure real operational data over 2–4 weeks, accurately determine waste and calculate exact ROI before scaling:
01
Select 1–3 Machines
Prioritize injection, CNC, stamping
02
Install Clamp-on Sensors
2–4h, zero PLC intervention
03
Collect Data 2–4 Weeks
Track Run/Stop/Idle & energy
04
Report & ROI Analysis
Identify exact idle & loss hours
05
Scale Plant-Wide
Systematic roll-out across lines
Field-Proven Results
Real Engineering Deployments Measured in Numbers
Performance proven not by promises, but by verified data collected on factory floors:
Factory Deployment Case
Energy Monitoring & OEE for Legacy Injection Molding Cluster
Field Challenge: Cluster of 8 legacy injection molding machines without digital ports; suspected excessive idle power during mold pre-heating and waiting for material drying.
Delivered Solution: Installed non-invasive clamp-on sensors and 4G Gateway on 2 key machines in half a day without stoppage.
Quantitative Results:
Identified 25% idle run time; eliminated 12% monthly electricity bill waste; full payback on monitoring hardware achieved in just 2.5 months.
System Integrator / Contractor Case
120 OEM Industrial Gateways for Water Pumping & Treatment Stations
Field Challenge: System integrator winning municipal water infrastructure tender required Modbus-to-MQTT 4G Gateways under custom private brand with full CAD/Datasheets.
Delivered Solution: DeviceLab customized flash buffer firmware, laser-engraved partner logo, and delivered complete bilingual tender dossiers within 7 days.
Quantitative Results:
100% acceptance test pass rate; saved 35% hardware costs compared to foreign imports; delivery fulfilled 5 days ahead of schedule.
Production Hardware Delivered in the Field:
Edge AI Box — Industrial Edge Computing & On-Premise Computer Vision
Field Challenge: Các bài toán Computer Vision cần độ trễ thấp, hạn chế băng thông hoặc xử lý tại chỗ — cloud thuần túy…
Delivered Solution: Xây dựng Edge AI Device chạy inference tại biên, nhận luồng camera, phát hiện và đẩy kết quả vào hệ thống.
IoT Gateway Công Nghiệp — Thu thập dữ liệu máy móc và kết nối SCADA/Cloud
Field Challenge: Nhiều máy móc cơ khí, ép nhựa, CNC trong nhà máy là máy cũ, chỉ có cổng RS485 Modbus hoặc không có…
Delivered Solution: Thiết kế gateway công nghiệp nhiều cổng RS485 cách ly quang, tự động quét thanh ghi Modbus, chuyển đổi dữ liệu thành…
Technical & Commercial Inquiries
Frequently Asked Questions on Data Acquisition & IoT Hardware
Direct answers to the most common questions from factory directors, technical managers, and system integrators:
1. Can you acquire data from older machines without digital communication ports or with password-locked PLCs?
Absolutely yes. This is DeviceLab’s core engineering specialization. We implement a non-invasive retrofit architecture using external clamp-on current transformers (CTs) for electrical power and load profiling, paired with external optical sensors or auxiliary dry-contact relays to count output units and log cycle times.
This methodology completely bypasses the machine’s internal PLC, requires zero password cracking, modifies no source code, and eliminates 100% of machine software corruption risks.
2. Does the hardware installation require shutting down our factory production lines?
Never. All clamp-on sensors and data acquisition modules are purpose-engineered for hot installation while machines run under regular production shifts. Engineers do not need to cut primary supply cables or de-energize control panels.
Survey and physical installation take an average of only 2 to 4 hours per machine, allowing plant production to proceed uninterrupted.
3. What communication protocols do DeviceLab Gateways support, and where is data transmitted?
Industrial Gateways engineered by DeviceLab support all key industrial protocols: Modbus RTU / ASCII (2.5kV surge-isolated RS485), Modbus TCP, Industrial Ethernet, and high-speed 4G LTE.
Data is standardized and transmitted via secure TLS-encrypted MQTT JSON or HTTP REST APIs, integrating seamlessly with existing SCADA software (Siemens, Ignition, Wonderware), cloud platforms (AWS, Azure, ThingsBoard), or enterprise MES / ERP systems.
4. Can System Integrators (SI) and Machine Builders (OEM) private-label (White-label) the hardware?
Yes. DeviceLab offers flexible OEM and white-label partnerships: laser-engraving partner brand logos on Din-rail aluminum enclosures and skinning local web GUIs to match your brand identity.
Furthermore, we supply complete tender packages (bilingual English/Vietnamese datasheets, 2D/3D cabinet CAD drawings, wiring schematics, and Modbus register maps). DeviceLab commits to 100% project confidentiality and strictly never approaches or sells directly to SI clients.
5. How does the 1–3 machine PoC trial package work, and how soon are results available?
Enterprises do not need to commit to large capital outlays or plant-wide rollouts immediately. We provide a low-risk PoC trial package on 1–3 representative machines (e.g., injection molders, CNCs, stamping presses) over 2 to 4 weeks.
Following on-site verification, DeviceLab delivers a comprehensive report detailing Run / Stop / Idle time distributions, energy consumption curves, and a verified ROI model, providing leadership with solid empirical backing prior to plant-wide expansion.
6. What warranty and technical support policies apply to DeviceLab hardware?
All industrial hardware products engineered by DeviceLab include an official 12 to 24-month replacement warranty. Devices incorporate dual-bank Over-the-Air (OTA) firmware upgrade capability, enabling remote maintenance and feature additions without on-site hardware removal.
Our Vietnam-based engineering team provides direct 1-on-1 technical assistance, rapid hotline/WhatsApp support, and on-site field visits whenever necessary.
Technical Consultation & Solutions
Connect Directly with DeviceLab Engineering Team
No need for complex blueprints or tender specs to start. Simply share your machinery setup or project challenge, and DeviceLab engineers will consult on technical feasibility and provide a quotation within 24 hours.
Direct Engineering Support Channel
Standing on the factory floor or in front of an electrical cabinet?
Take a photo of machine nameplates or electrical panels and send via WhatsApp. DeviceLab engineers will evaluate signal connection feasibility and provide initial feedback within 15 minutes.
💬 Chat on WhatsApp with Field Engineer
Or call 24/7 Technical Hotline:
+84 982 503 355