Problem Statement
Diesel pumps deployed in remote and infrastructure-critical locations operate without real-time visibility.
This leads to undetected failures, fuel wastage, incorrect operation logs, and delayed maintenance actions.
Ground Reality (Field Observations)
During on-site PoC at Mumbai installations, the following issues were observed:
- Battery draining within 2 days, making continuous monitoring unreliable
- Temperature sensor stuck at constant reading (~57°C), indicating calibration or placement issue
- False ON/OFF detection due to lack of reliable sensing logic
- No visibility of actual pump runtime and usage patterns
Key Insight: Traditional monitoring approaches fail because they rely on assumptions rather than actual machine behavior.
Solution Approach
Hexitronics proposes a minimal yet highly effective 2-sensor IoT solution using:
- Vibration Sensor: Accurate detection of pump ON/OFF state based on mechanical activity
- Temperature Sensor: Monitoring thermal behavior to identify overheating and abnormal conditions
The system is powered by an optimized battery system with provision for solar charging and transmits data periodically over a 4G network.
Sensor Logic (Core Intelligence)
- Vibration present → Pump is ON
- No vibration → Pump is OFF
- Temperature rising abnormally → Potential failure or stress condition
System Architecture
[ Architecture Diagram Placeholder ]
IoT Device → Sensors → 4G Network → Cloud → Dashboard
Key Features
- Battery-powered system with extended backup using drone-grade battery
- Optional solar charging for long-term deployment
- Data capture at high frequency with transmission at optimized intervals (e.g., every 5 minutes)
- Accurate pump runtime calculation
- Cloud-based monitoring with alerts
Future Dashboard & Analytics
The system will provide a centralized dashboard with:
- Pump ON/OFF timeline
- Total runtime analysis
- Temperature trend graphs
- Alert notifications for abnormal conditions
- Predictive maintenance indicators (future upgrade)
Benefits
- Eliminates false operation reporting
- Reduces fuel wastage
- Improves maintenance planning
- Increases equipment reliability
- Enables remote monitoring of distributed assets
Deployment Strategy
Step 1: Pilot deployment (PoC at one site)
Step 2: Validation of sensor logic and power system
Step 3: Scale deployment across all pump locations