Modular Sensor Box
The Challenge
Many machines on the factory floor have no way to share their data. Older machines were not built with digital communication in mind, while newer ones are often locked by software licenses or proprietary systems. When a facility runs machines of different brands or types, each tends to use a different protocol, making it difficult to bring all data together in one place. This lack of visibility makes it hard to monitor performance, catch problems early, or base decisions on actual machine data.
What This Demonstrator Does
The Modular Sensor Box is a compact, portable unit that can be connected to almost any type of sensor. Including current clamps, vibration sensors, cameras, colour detectors, and microphones. All collected data is displayed live on a dashboard that can be viewed from any device on the same network. Multiple boxes can be linked together, so each machine can have its own unit while all data is brought together on one central platform. A 4G option is available, meaning no existing factory network is required as the box creates its own Wi-Fi connection. Through Node-RED, a visual tool for building data flows, notifications, alerts, and automatic data analysis can be set up without any programming knowledge. Supported connection types include IO-Link, MQTT, ethernet, and analogue and digital inputs.
The integrated AI assistant makes the live data platform easier to use by allowing users to interact with their sensor data through natural conversation. Instead of manually reading graphs or applying filters, they can simply type or speak questions such as current power consumption, unusual machine behaviour, or changes during the last shift. The assistant uses both live and historical sensor data to provide clear, plain-language answers, making insights accessible without technical expertise.
What You Gain
- Live insight into machine performance, status, and energy use. All viewable from any device on the network
- Data from older machines that were never built to communicate digitally
- One central platform for data from multiple machines, regardless of brand or protocol
- Real-time notifications and alerts, for example when a machine changes state or crosses a set threshold
- Custom workflows built through visual programming, with no coding required
- No dependence on the factory’s existing network infrastructure, thanks to the built-in 4G option
- Ask questions about machine data in plain language, by typing or speaking, without needing to navigate dashboards or run technical queries
- Get faster access to relevant insights for operators, maintenance staff, and management, with answers tailored to each user’s needs
Who Is This For?
This demonstrator is suited for manufacturing companies, particularly small and medium-sized ones, that work with machines of different brands, ages, or types. It is especially relevant when machine data is unavailable, scattered, or impossible to combine due to incompatible systems. No technical background is required to operate the system once it has been set up. The AI assistant makes the data accessible to an even broader audience: operators, supervisors, and management can ask questions in their own words rather than reading technical dashboards.
Estimated Cost to Implement
Total estimated budget: around €1,000 for a basic setup. Adding the AI assistant introduces a small additional cost depending on the chosen solution: cloud-based language models typically involve a modest monthly subscription, while a locally hosted model involves a one-time setup cost with no ongoing fees.
Pilot Program
What does a pilot look like for this demonstrator?
During the pilot, the Modular Sensor Box is installed at the company’s facility and connected to one or more machines of choice. Sensors are selected and configured based on what needs to be monitored, and a live dashboard is set up for viewing the collected data. The AI assistant is configured alongside the sensor platform, connected to the live data, and demonstrated to the relevant staff. The project team remains available throughout the pilot period to provide guidance and support.
Services provided during the pilot:
- On-site installation and configuration of the sensor box and sensors
- A practical guide to using the system and reading the data
- Technical support during the pilot period
- Help setting up custom data flows, such as notifications, alerts, or data conversions
- Integration and configuration of the AI assistant, enabling users to interact with sensor data through chat or voice.
What you need to have / provide:
- A machine to connect the sensors to
- A power outlet near the machine
- Optionally, an Ethernet port — not required when the 4G option is used
- A contact person available during installation and for follow-up questions
- An internet connection at the machine location, when using a cloud-based language model. Not needed for a locally hosted model.