Contents

Pumplogger

Monitor your motors from the field to the cloud on one platform.

An SMB Teknoloji projectDevelopment complete · verified on real hardware and an energy analyser

Monitors electric motors at pump stations, industrial plants and remote sites: the field gateway collects temperature, vibration, speed and energy-analyser data and sends it to the cloud over Ethernet, Wi-Fi or a cellular network; the platform turns it into live screens, alarms, reports and continuous monitoring by SMB Teknoloji's predictive-maintenance AI.

  • 10× PT100
  • 2× 4-20 mA
  • RPM
  • Modbus RTU/TCP
  • Ethernet · Wi-Fi · Cellular
  • TLS MQTT
  • SMS commands
  • OEE
  • Time-series database
  • Cloud or on-premise
  • AI
01 Story

From idea to today

Why

Submersible and horizontal pumps at remote sites and critical motors in plants are usually noticed only when they stop. Bearing and winding temperature, vibration and speed stay on site; running hours and maintenance counters are kept by hand. The energy analyser's data lives on a separate screen, in a separate world. And these are not cheap machines: each is an expensive motor representing a serious investment; an unplanned failure means repair cost and downtime at once.

What we built

Three layers, one product. The industrial field gateway reads 10 PT100 channels, 2 × 4-20 mA (pressure transmitter or front/rear motor vibration) and speed, bridges the energy analyser to the platform over RS485, and sends the data to the cloud over Ethernet, Wi-Fi or a cellular network with priority-based automatic failover and TLS-protected MQTT. The platform runs in the cloud or, on request, on-premise within your organisation; with a company → location → station → motor hierarchy it writes the data to a time-series database, runs it through a threshold-based alarm engine and pushes it to live screens instantly; it sends e-mail, SMS and in-app notifications and produces CSV/Excel/PDF and scheduled reports. A public API and signed webhooks connect it to ERP and SCADA systems; a Modbus TCP server feeds local SCADA directly. Even at a site with no internet at all, the device takes commands and is managed over SMS. All of this data is continuously monitored by the predictive-maintenance AI model developed by SMB Teknoloji.

Today

Development is complete; the field gateway and the platform are up and running. The automatic rollback on remote network changes has been verified on real hardware in four scenarios, and RS485 reading with a real energy analyser. The web panel, licence management, public API and webhooks are ready for use.

02 Highlights

What sets it apart

Sensor inputs

10 PT100 channels (2/3/4-wire auto-detect, per-channel setup), 2 × 4-20 mA (pressure transmitter or front/rear vibration), speed reading up to 180,000 rpm from a 24 V pulse input, and up to 120 Modbus channels over the RS485 bridge.

Three paths, uninterrupted connectivity

Ethernet, Wi-Fi and cellular; priority-based automatic failover, a health check every 30 seconds, configuration without reboot, 5 APN profiles.

Automatic rollback on remote network changes

A network change made from the cloud cannot strand the device: if it cannot reconnect within 90 seconds it reverts to the previous settings by itself; failing that, it falls back to a safe uplink mode and reports the outcome to the cloud.

Encrypted on every interface

TLS-protected MQTT, pinned certificate, per-device derived credentials. No telemetry is sent before the clock is synchronised.

Local management: web UI, serial console, SMS

The built-in web UI opens from every interface and from the cloud panel; the serial console has tab completion and a setup wizard; the same command set works over SMS at sites with no internet at all.

Remote commands over SMS

Even at a site with no internet at all, the device is managed over SMS: the command set and replies are the same as on the serial console, network settings apply instantly over SMS, and a 20-entry SMS log is kept. Alarm SMS messages are also sent through the device's own SIM with delivery confirmation.

OEE calculation

Overall equipment effectiveness (OEE) is calculated per motor: Availability from the running time derived from the speed signal against the planned time in the shift calendar; Performance from the nominal speed and the production count read from the PLC over the RS485 bridge; Quality from good/reject counts taken from the PLC or the production system. Planned and unplanned stops are classified with the alarm records; the result goes into shift and daily reports. At pump stations the same data yields pump-efficiency and specific-energy trends.

SCADA and ERP integration

Modbus TCP server on the device (port 502, TCP→RTU gateway); read-only public REST API and HMAC-signed webhooks in the cloud.

Vendor-neutral energy-analyser support

The device works as an RS485 bridge; the platform does the polling. Up to 120 user-defined registers per motor; selectable data types and byte orders; maps are deployed from the cloud and loaded from a template library with one click.

Alarm engine

Runs on raw data; warning band, alarm only on sustained exceedance, symmetric clearing, reminders and acknowledgement flow. A value oscillating at the limit does not produce endless alarms; who was notified is logged for every event.

Notifications and reports

E-mail, delivery-confirmed SMS sent through the field device's own SIM, and in-app notifications. CSV, Excel and PDF export; scheduled daily, weekly, monthly and yearly e-mail reports with charts.

AI-assisted predictive maintenance

The predictive-maintenance model developed by SMB Teknoloji monitors every motor continuously: it scans hourly, assigns a state from 2-hour and 24-hour statistics (Normal, Watching, Attention, Alarm, Critical) and writes only on change. Questions can be asked in natural language; detected anomalies become a separate alarm source with their reasoning. Each company chooses its own AI provider.

Safe updates

A/B partitions: new firmware is written to the passive slot, a failed update never touches the running version. From the cloud panel, from a URL or from a local file; works over cellular too.

Motor running counters

A tamper-resistant running-hours counter kept in three-way sync between device, sensor board and cloud, never decreasing. A resettable second counter for the maintenance team with the last 10 resets on record.

03 Who it is for

Who benefits

Water and wastewater pump stations

Bearing/winding temperature, vibration and speed of submersible and horizontal pumps at remote sites; uninterrupted data over the cellular network.

Industrial plants

Running hours and maintenance counters of critical motors; power, current and energy from the energy analyser on the same panel.

Maintenance service providers

Multi-customer structure, per-customer user and licence management, scheduled reports.

SCADA / ERP integration

Local SCADA over Modbus TCP, enterprise systems over the public API and webhooks.

04 Technical specifications

In numbers

ProcessorDual-core Xtensa processor, 240 MHz, A/B update partitions
Sensor boardDual-processor design: second processor on the sensor board, 4 s hardware watchdog, EEPROM counter backup
PT100 inputs10 channels, 2/3/4-wire auto-detect, per-channel setup
4-20 mA inputs2 channels, 16-bit resolution; pressure transmitter or front/rear motor vibration sensors
Speed input24 V pulse input (reed switch), optocoupler-isolated reading, up to 180,000 rpm; finer resolution with a 2–4 magnet multiplier
RS485RS485 bridge (Modbus RTU), 1200–115200 baud, 120 channels, u16/s16/u32/s32/f32; the platform does the analyser polling
Modbus TCPPort 502, FC 03/04/06/16, 4 clients, TCP→RTU gateway
Ethernet / Wi-FiFast Ethernet, DHCP/static; 2.4 GHz Wi-Fi, access point + client simultaneously
CellularBuilt-in cellular modem, 5 APN profiles, SMS
FailoverPriority-based, 30 s health check, automatic rollback
Cloud protocolMQTT (TLS), HTTP POST fallback; telemetry interval 100 ms – 60 s
Local managementWeb UI, serial console, SMS commands
Battery protectionDeep sleep below 8.0 V, wake at 9.0 V
Platform stackTime-series database and MQTT broker; retention: raw 30 days, records 2 years, audit 3 years
Deployment optionsIn the cloud (multi-tenant) or on-premise within your organisation
RolesSystem admin, company admin, supervisor, field technician
NotificationsE-mail (SMTP / Microsoft Graph), SMS (device SIM), in-app
ReportsCSV, XLSX, PDF; daily / weekly / monthly / yearly schedules
IntegrationPublic REST API (120 req/min), HMAC-signed webhooks
OEEPer motor: availability × performance × quality; defined by shift calendar, nominal speed and PLC piece counter; shift and daily reports
AIPredictive-maintenance model developed by SMB Teknoloji; continuous monitoring, hourly state assessment, predictive alarms
LicensingHardware sales are independent of the platform; per-motor monitoring licence (developer, adaptation, annual). Data of an unlicensed motor keeps being collected.

Work order

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