industrial current monitoring system

Optimizing Equipment Performance and Energy Management Using Current Monitoring System

Many businesses and organizations are always looking for new ways to improve their operations and cut costs. Current monitoring is one area that is sometimes overlooked yet is crucial to accomplishing these objectives. The process of measuring, processing, evaluating, storing, and exchanging energy usage and status information with facility management is known as current monitoring system. This data can be utilized to improve equipment performance, decrease downtime, and increase energy efficiency.

Current Monitoring System

Current monitoring systems sample different data of several parameters for energy monitors, power monitors, electricity monitors, and other types of current monitoring equipment. Energy monitors are used to measure the quantity of energy consumed by equipment or processes in different industrial settings such as power plants, manufacturing, automotive, and more. Current monitors are used to measure voltage, current, power factor, and other electrical parameters important for determining the health of a power system. Electricity monitors are devices that measure the quantity of electricity consumed by a building, facility, or process.

Current monitoring devices are linked to a central monitoring system that can process, analyze, and store data. Engineers, facility managers, and operators may now access data in real time through the wireless, over-the-air transmission of data samples, allowing them to make informed decisions about equipment performance and energy management.

Thermocouples are made of two different metals joined together at one end. When the temperature changes, a voltage is generated across the two junctions, which is proportional to the temperature difference. This voltage can be measured and used to calculate the temperature. 

RTDs are made of a length of wire or thin film that changes resistance in response to temperature. The resistance of the wire or film is measured and used to calculate the temperature. 

Thermistors are made of a semiconductor material that changes resistance in response to temperature. The resistance of the thermistor is measured and used to calculate the temperature.

Once the temperature is measured by the sensor, it is transmitted wirelessly to a central hub or cloud-based system. This data can then be analyzed and used to make decisions, such as adjusting the temperature of a room or detecting changes in a manufacturing process.

Benefits of Current Monitoring

Implementing a current monitoring system in facilities or structures has many advantages. One of the most significant advantages is the ability to optimize equipment performance. Engineers and operators can spot potential concerns before they become major issues by monitoring the health and status of equipment in real-time. This enables predictive maintenance, which can increase equipment life and save downtime.

By having a current monitoring system in place, organizations can make sound decisions about how to reduce energy use by monitoring energy consumption. Identifying locations where energy is wasted, helps improve energy efficiency, gain significant financial savings, and lower carbon footprint over time.

For example, current sensors can accurately track the operating hours of HVAC systems and generators. By collecting data on equipment usage, monitors can provide real-time information on how long these systems are running, which directly correlates to greenhouse gas emissions. 

Current monitoring also delivers complete energy usage and reliability statistics to organizations. This data can be utilized to discover trends, track performance, and provide thorough reports that can be used to make informed energy management decisions.

In industries such as manufacturing, food processing, and pharmaceuticals, maintaining precise temperature levels is critical for various reasons:

  1. Quality Assurance – temperature control is essential for ensuring consistent product quality. Inaccurate temperature measurements can lead to product defects, compromised quality, or even product recalls.
  2. Process Efficiency – accurate temperature control helps maintain optimal operating conditions for machinery and equipment, reducing energy consumption and extending the service life of the equipment.
  3. Safety – temperature regulation is crucial in industries where high heat or extreme cold is part of the process. Proper temperature management can prevent accidents, fires, equipment damage, or downtime.

Implementing a Current Monitoring System

Choosing the right current monitoring sensors and devices is crucial to gathering relevant data to monitor and analyze the equipment, facility, or process. These sensors should be compatible with the current power system and capable of measuring the necessary KPIs. It is also critical to have a scalable system that can be expanded as the company develops and expands.

Once the sensor is selected, it must be installed and configured. This may require the assistance of a qualified electrician or power systems engineer. The system must be properly calibrated and tested to ensure that it is measuring the KPIs accurately and reliably.

Industrial IoT Wireless Sensors for Current Monitoring

Leveraging the Internet of Things (IoT) has resulted in the development of wireless, long-distance current monitoring equipment that integrates with any cloud service. These sensors are compact, low-power devices that may be easily mounted on equipment or power lines to monitor certain parameters such as current, voltage, and power usage.

The Industrial IoT Wireless AC Current Monitor Sensor is one example of an IoT sensor used for current monitoring and power calculation. This sensor transmitter works together with three split-core current sensors (included). It samples current at a high data rate and calculates the RMS Current value and sends a wireless transmission.

Industrial IoT Wireless AC Current Monitor Sensor
IoT sensor used for current monitoring and power calculation

Similarly, IoT Long Range Wireless AC Voltage Monitor Sensor is employed in power systems to monitor voltage. This product has an additional feature of detecting changes in voltage at user-defined detection time intervals and sending out data if the voltage change is greater than the user-defined detection change percentage. 

These sensors can be installed on power lines or on specific pieces of equipment to offer real-time data on the health and functioning of such devices. These sensors, with over-the-air configuration, may be readily adjusted or updated without requiring a physical connection, making them suitable for remote or difficult-to-reach areas.

Current monitoring is an important part of modern business operations. It enables organizations to improve equipment performance, decrease downtime, and increase energy efficiency. Industrial facilities can obtain useful insights into their energy usage and establish plans for cost reduction and sustainability by deploying a power monitoring system. Whether you’re a system integrator or an IoT engineer, understanding the benefits of power monitoring and how to implement a system can help you deliver value to your clients and customers.

How Can We Help You?

Do you need assistance selecting and creating a current,  energy monitoring, and power calculation system? Take advantage of our services. 

  • Wide range of sensors and devices for current monitoring
  • We custom-design products based on your requirements
  • Our industrial sensors and devices are highly accurate,  long-range, and wireless with over-the-air configuration capabilities
  • Long battery life of up to 10 years.
  • Our white labeling service allows you to rebrand our sensors and devices with your logos and branding, giving you a fully customized solution to offer to your clients.
  • Our products are made in the US


To inquire about our products and services, email us here.