Energy monitoring systems and power electronics development

What need does a custom energy monitoring board solve?

Machine manufacturers may need a special board in cases where the standard device does not fit mechanically or integrate with the product interface. A business may want to associate existing meter data with its own production software. We first evaluate whether it is appropriate to work with the interface of a ready-made measuring device or to develop customer-owned measuring electronics. Production quantity, maintenance access and total system cost are included in this decision.

Apart from current and voltage, it is determined which outputs such as active power, energy, operating time or load status are required. The time resolution of the values, the storage period, and how they will be used in the software are clarified. If the same board will be used in different machine models, input ranges, connectors and parameter sets are planned. The project is shaped not only by the component list but also by the customer's operating and service process.

• Measurement and operating status monitoring embedded in the machine
• Gateway to collect data from existing analyzer or meter
• Board and interface design suitable for customer product

How to choose current sensor and measuring chain?

Shunts, current transformers and Hall-effect sensors are compared against AC/DC requirements, measurement range, heating, isolation and cost. No single approach suits every application. The voltage measurement stage, analogue filters, ADC or metering IC, reference and clock are considered together. Where calculations combine current and voltage, the timing relationship between channels is also a design input.

ADC resolution alone does not define device accuracy. An error budget is prepared for sensor tolerance, offset, gain, temperature variation and coupling effects. It is decided at which points the correction will be made, where the calibration coefficients will be stored and how they will be associated with the device serial number. Comparison conditions with the reference device are shown in the prototype; It is not considered a product feature until it is verified with targeted performance measurement results.

• Comparison of shunt, current transformer and Hall sensor
• Analog front end, ADC and evaluation of temperature effects
• Error budget and device-based correction data

Technical scope of energy measurement electronics and monitoring software →

Integration of power electronics circuit design and measurement stage

In custom devices, there may be a need for more than one supply line, switching power supply or DC-DC converter, load switching and status monitoring. The architecture is selected based on input range, sudden load change, efficiency target, temperature and board space requirements. In projects requiring SMPS design, switching structure, magnetic components, feedback, loss distribution and thermal management are evaluated within the defined operating range of the project.

PCB layout addresses separation of the measurement stage from supply noise and high-current paths. We define reverse-polarity, overcurrent, undervoltage and controlled-startup requirements. Isolation boundaries, cable and connector ratings, enclosure and cooling are assessed with the design. Electrical safety and electromagnetic compatibility tests follow the product's intended use; a prototype alone is not a certified product.

• Scope of power distribution boards, DC-DC converters and project-specific SMPS
• Protection, thermal design and controlled load management
• Co-location of power paths with measurement signals

Custom SMPS and DC power supply design →

How is energy data transferred to the electrical control panel and management software?

Data exchange with existing systems can be developed through RS485/Modbus RTU, Modbus TCP, CAN or another suitable interface. Selecting Modbus alone is insufficient: addresses, data types, units, scaling, signedness and fault states must be documented. Where a gateway reads existing devices, the manufacturer's register map and supported functions are reviewed. Polling frequency follows the total data load and operational requirements.

For Wi-Fi or cellular transmission to a server, we define device identity, user permissions, local logging and behaviour during connection loss. Energy consumption is correlated with production counts or machine status using the customer's process information. The dashboard shows historical data, gaps and measurement status together. Data access and control authority are designed separately, with the existing cabinet's protection and control responsibilities kept clear.

• Modbus data map and existing device integration
• Local recording, API and server-based dashboard
• Defining read and control permissions separately

How to test a sample machine measurement board?

For an energy monitoring board to be installed inside a machine manufacturer's product, for example, the supply and load ranges, data interface and mechanical dimensions are defined first. The prototype runs under representative load conditions. Startup, steady operation, standby and shutdown behaviour are recorded. The comparison plan against reference measurements covers low and high measurement points, temperature conditions and repeatability expectations.

Situations such as communication breakage, restarting, wrong parameters and sensor failure are also tried. If there is a power stage, load transitions, heating and defined protection behaviors are verified separately. The required electrical safety, scope of EMC or other product testing, and external testing services are planned with the customer.

• Comparison with reference and defined load points
• Thermal, outage, error and restart scenarios
• External testing and conformity preparation according to the product

How are project confidentiality and source file delivery handled?

At your request, we sign an NDA before you share machine operating information, a product idea or a custom power architecture. We develop the design and software for your project and do not offer customer work as our own product. Required measurement performance, load conditions, test methods and deliverable files are defined at the outset. Component availability, production and maintenance expectations also inform technical decisions.

At the end of the project, source codes, electronic schematics, PCB files, mechanical CAD data and technical documents within the scope are delivered. The material list, programming method, calibration parameters, communication map and test records are included in the delivery plan. Third party licenses and component terms are stated separately. Sample PCB fabrication and electronic component assembly are offered only within the scope of prototyping and validation studies of customer projects developed by VOMRO.

• Before sharing technical details, NDA upon request.
• Electronics, software and in-scope CAD source files
• Testing, programming and integration documents