Challenge
A factory automation OEM wanted to add vibration-based predictive maintenance to their motor-driven conveyor lines without replacing existing 400V motor infrastructure — requiring isolated sensing from a hostile electrical environment.
Solution
ST STM32H7 microcontroller with TDK InvenSense IAM-20685 6-axis automotive IMU mounted on a wireless sensor node powered by energy harvesting. Hardware isolated RS-485 link to existing PLC.
Key Outcomes
Bearing fault detected 6 weeks in advance
Unplanned downtime reduced by 73%
Node battery life: 4 years (energy harvesting supplement)
Sensor node BOM cost: <$45 per motor