Industrial & Factory Setup Guide

Overview

Industrial monitoring doesn't have to cost tens of thousands of dollars. Giantronic gives you fleet-scale device management, per-machine energy tracking, and predictive maintenance alerts — all built on affordable ESP32 hardware.

Deploy ESP32 sensor nodes on each machine or production line to monitor current draw, vibration, temperature, and operational status. Group machines into fleets by production line or floor zone. Track energy consumption per machine to identify inefficiencies. Set up maintenance alerts based on vibration patterns or current anomalies. And manage everything from a single dashboard with real-time updates.

Fleet Management

Group machines by production line, floor, or type. Monitor fleet health at a glance.

Energy Per Machine

Track current and power consumption per machine. Identify waste and optimize usage.

Maintenance Alerts

Predictive maintenance based on vibration patterns and current anomalies. Fix before it breaks.

Bulk OTA Updates

Push firmware updates to all machines simultaneously. Roll back if issues are detected.

Hardware You Need

Industrial-grade components for reliable 24/7 monitoring.

ESP32 (Industrial)

One per machine or production line. Use DIN-rail mounts for easy installation in electrical cabinets.

Current Sensor (ACS712)

Hall-effect current sensor for non-invasive machine power monitoring. 5A, 20A, or 30A variants depending on load.

Vibration Sensor (SW-420)

Vibration detection for predictive maintenance. Anomalous vibration patterns indicate bearing wear or misalignment.

Temperature Sensor (DS18B20)

Industrial-grade temperature probe. Monitor motor temperature, bearing temperature, or ambient conditions.

Relay Module

For emergency stop or remote power cycling. Optional but recommended for critical equipment.

Ethernet Module (W5500)

For factories with unreliable WiFi. ESP32 + W5500 Ethernet shield for stable wired connectivity.

Fleet Setup

Organize machines into fleets for grouped monitoring and bulk operations.

Fleet Organization

Create fleets based on your factory's natural groupings:

Fleet Name	Devices	Description
`Line A — Assembly`	4-8 machines	Primary assembly line with robotic arms, conveyors, and press machines
`Line B — Packaging`	3-5 machines	Packaging line with fillers, sealers, and labelers
`HVAC & Utilities`	2-4 nodes	HVAC units, compressors, and utility monitoring
`Warehouse`	3-6 nodes	Lighting, door sensors, and environmental monitoring

Creating a Fleet

Go to Fleet Management
Navigate to the Fleets section in the dashboard and click "Create Fleet".
Name and Describe
Give the fleet a descriptive name (e.g., "Line A — Assembly"). Add a description for documentation.
Add Devices
Select the ESP32 devices that belong to this fleet. Each device can only belong to one fleet.
Configure Health Thresholds
Set fleet-wide health thresholds for temperature, current draw, and vibration levels.

Fleet health dashboard: Once configured, the fleet view shows aggregated health metrics — total devices online, average energy consumption, active alerts, and per-device status cards.

Pin Configuration

Configure sensor and actuator pins for each machine monitoring node.

Pin Name	GPIO	Type	Mode	Description
`Current Monitor`	34	ACS712	Input	Machine current draw (Amps via ADC)
`Vibration Sensor`	35	SW-420	Input	Vibration detection (HIGH = vibration detected)
`Temperature`	4	DS18B20	Input	Motor/bearing temperature probe
`Run Indicator`	2	LED	Input	Machine run status (reads control panel LED)
`Emergency Stop`	15	Relay	Output	Remote emergency stop relay (optional)
`Status LED`	16	LED	Output	Node status indicator (green=OK, red=fault)

Energy Per Machine

Track power consumption per machine to identify waste and optimize production schedules.

Current Monitoring

The ACS712 current sensor provides a voltage output proportional to the current flowing through it. The ESP32 reads this via its ADC and converts it to Amps.

Current Reading Calculation

// ACS712-20A: 100mV per Amp, centered at VCC/2
adc_value = analogRead(GPIO34)
voltage = (adc_value / 4095.0) * 3.3
current_amps = (voltage - 1.65) / 0.1  // 100mV/A sensitivity
power_watts = current_amps * 220  // multiply by mains voltage

Energy Dashboard

The Giantronic fleet dashboard displays per-machine energy metrics:

Real-Time Wattage

Live current draw displayed on each device card in the fleet view.

Daily Consumption

Accumulated kWh per machine per day. Compare machines of similar type to identify outliers.

Cost Reports

Automatic cost calculations based on your electricity rate. Monthly summaries for accounting.

Predictive Maintenance

Detect equipment problems before they cause downtime using sensor data patterns.

Vibration Monitoring

The SW-420 vibration sensor detects abnormal vibration patterns that indicate bearing wear, misalignment, or looseness. Giantronic tracks vibration frequency and duration to predict maintenance needs.

Pattern	Likely Cause	Recommended Action
Intermittent vibration	Loose mounting bolt	Schedule tightening within 48 hours
Continuous vibration	Bearing failure imminent	Schedule immediate maintenance
Vibration + high current	Mechanical jam	Emergency stop, inspect machine
Vibration + high temperature	Overheating bearing	Reduce load, schedule lubrication

Current Anomaly Detection

Sudden current spikes or gradual increases indicate problems:

Sudden current spike (>20% above baseline)
May indicate a jam, short circuit, or mechanical failure. Trigger emergency alert.
Gradual current increase over days/weeks
Indicates increasing friction or wear. Schedule preventive maintenance during next planned shutdown.
Current draw with no vibration
Electrical issue — possible motor winding degradation or capacitor failure. Electrical inspection needed.

Alert thresholds: Start with conservative thresholds and tune over 2-4 weeks of baseline data. Every machine has different normal operating parameters.

Bulk OTA Updates

Push firmware updates to your entire fleet simultaneously with rollback support.

Upload Firmware
Upload your compiled .bin file to the Giantronic firmware section, or link a GitHub release for automatic fetching.
Select Target Fleet
Choose which fleet(s) to update. You can update one production line at a time for staged rollouts.
Deploy
Giantronic pushes the update to all devices in the fleet. Each device downloads the firmware and reboots automatically.
Monitor & Rollback
Watch the fleet health dashboard during deployment. If devices report errors, rollback to the previous firmware version with one click.

Staged rollouts: Update 10% of devices first, monitor for 24 hours, then push to the remaining 90%. This minimizes risk of production disruption.

24/7 Monitoring

Keep your factory floor under constant surveillance with automated monitoring and alerts.

Device Heartbeats

Each ESP32 sends periodic heartbeats. If a heartbeat is missed, the device is marked offline and an alert fires.

Trend Analysis

Historical data for all sensors. Spot trends over days, weeks, and months. Correlate energy use with production output.

Multi-Channel Alerts

Email, push notifications, and in-dashboard alerts. Escalation rules for critical alerts that aren't acknowledged.

Audit Logs

Complete audit trail of all device changes, configuration updates, and user actions. Essential for compliance.

Next Steps

Deploy your industrial monitoring system today.

Full Documentation

Complete platform docs — device pairing, fleet management, API reference.

Mobile App

Android app setup — monitor your factory floor from anywhere.

API Reference

REST API docs — integrate with SCADA systems and ERP software.