IndustriesSmart Diesel Generator Monitoring Solution
Facility operators managing diesel generators across multiple sites had no real-time view of fuel levels, runtime hours, or fault conditions. Manual inspections were too infrequent to catch problems early leading to unexpected generator failures, undetected fuel theft, and missed maintenance windows. With no centralized platform, keeping track of every DG unit across sites was slow, reactive, and unreliable.
We built a compact IoT monitoring device that connects directly to the DG controller via RS485 and reads live data fuel levels, runtime hours, voltage, current, and fault states using Modbus RTU. A fuel level sensor on the tank adds independent consumption tracking. The device transmits all data over 4G LTE to a cloud platform, with local buffering to handle connectivity gaps. The multi-site dashboard gives operators a live view of every generator from one place, with automated alerts for low fuel, faults, and maintenance due dates sent via email and SMS. The hardware is IP65-rated, making it suitable for outdoor generator enclosures in all weather conditions.
Real-time fuel visibility across all sites made consumption anomalies and theft detectable instantly replacing unreliable manual inspections. RS485 integration pulled live voltage, current, runtime, and fault data directly from the DG controller with no extra sensors. Runtime-based maintenance reminders automated service scheduling, and 4G LTE with local buffering ensured no data gaps at remote locations. A centralized multi-site dashboard replaced fragmented site-by-site checks with full fleet visibility from a single screen.
Live Fuel
Real-time fuel level monitoring across every generator site, consumption anomalies and theft flagged automatically, no manual checks needed.
Zero Gaps
4G LTE with local data buffering keeps monitoring continuous even at remote sites with intermittent connectivity.
Multi-Site
Every generator across all locations visible from one centralized dashboard with automated alerts for fuel, faults, and maintenance due dates.
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