Customer Cases

Customer Profile

• Industry: Industrial Automation & Manufacturing
• Country: Germany
• Company Type: Mid-sized automotive parts manufacturer (operating 20 production lines with PLC-controlled machinery)
• Core Need: A reliable Modbus temperature humidity sensor to enable real-time monitoring of control cabinet conditions, prevent overheating and condensation-related equipment failures, and ensure seamless integration with existing PLC and HMI systems.

Challenge

• Blind cabinet monitoring: Legacy temperature and humidity sensor units lacked standardized communication protocols, making it impossible to integrate with the factory’s PLC and HMI systems—leaving technicians blind to rising temperatures and humidity spikes until equipment failed.
• Complex installation: Old sensors required custom wiring and software configuration, taking 2+ hours per unit to install and delaying system upgrades by 3+ weeks.
• Inaccurate readings: Low-quality sensors drifted over time, leading to false alarms and missed critical conditions—resulting in 12 unplanned downtime incidents in 6 months, costing €180,000 in lost production.
• Limited compatibility: Existing sensors were incompatible with the factory’s Kingview and MCGS HMI software, requiring manual data entry and delaying response to anomalies by 15+ minutes.

Solution

• Seamless PLC/HMI integration: As a premium Modbus temperature humidity sensor, it uses the standard Modbus-RTU protocol (RS485 output) to connect directly to the factory’s PLCs and HMI systems (Kingview, 3D Force Control, MCGS), enabling real-time data visualization and automated control triggers.
• Simplified installation: Tool-free DIN rail mounting and pluggable terminals cut installation time per unit to 15 minutes, allowing the entire deployment to be completed in 2 days with zero production downtime.
• High-precision sensing: Swiss-imported measurement units deliver ±0.5°C temperature accuracy and ±3%RH humidity accuracy, with 1s data refresh and long-term stability (≤0.1°C/year for temperature, ≤1%RH/year for humidity) to ensure reliable condition monitoring.
• Flexible power supply: 5–30V DC wide voltage input ensures compatibility with the factory’s existing control cabinet power systems, eliminating the need for additional power supplies.
• Durable enclosure: Compact ABS plastic housing with integrated vents resists dust and minor moisture, making it a robust temperature and humidity monitor for industrial environments.

Results

• Downtime eliminated: 0 unplanned downtime incidents related to control cabinet overheating or condensation in 12 months post-deployment, saving €360,000 in lost production costs.
• Operational efficiency boosted: Seamless PLC/HMI integration cut response time to temperature/humidity anomalies from 15+ minutes to under 1 minute, reducing maintenance labor by 80%.
• System upgrade simplified: Tool-free installation and standardized communication allowed the entire 80-unit deployment to be completed in 2 days, with zero production downtime and no custom software development required.
• Data accuracy improved: High-precision sensors eliminated false alarms and missed critical conditions, ensuring 100% reliable condition monitoring and reducing unnecessary maintenance checks by 65%.