Custom Software for Sensor Data Acquisition, Processing & Analytics

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Custom Software for Sensor Data Acquisition, Processing & Analytics
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Turn raw signals into decisions. Intelgic builds bespoke software that reads data from virtually any sensor—image sensors, IR and heat sensors, color sensors, temperature and humidity, proximity and photoelectric sensors, encoders, load cells, vibration and acoustic sensors, and more—then cleans, fuses, analyzes, and visualizes it for humans and machines. From shop‑floor telemetry to executive dashboards, we engineer the entire

Ingest

Process

Analyze

Act

From Sensors to Actionable Insights

Any Sensor, Any Protocol

Camera/vision, IR, thermocouples/RTDs, photodiodes, ToF/LiDAR, colorimeters, spectrometers, ultrasonic, pressure, flow, torque, RFID, barcode/QR, proximity/inductive, encoders, photoelectric, vibration (IEPE), microphones, and more.

Edge‑to‑Cloud Architecture

Deterministic edge collection with low latency, secure uplink to on‑prem or cloud analytics.

Actionable Analytics

KPIs, trends, alerts, and Digital Quality Certificates (DQC) for traceability.

Industrial‑Grade

Designed for harsh environments; integrates with PLCs, MES/ERP, SCADA, CMMS.

Turnkey Delivery

Hardware selection guidance, software engineering, dashboards, APIs, and support.

Building Sensor Analytics

1. Data Acquisition & Connectivity

  • Drivers for OPC UA/DA, Modbus TCP/RTU, EtherNet/IP, Profinet (via gateways), MQTT/AMQP, REST/gRPC, serial (RS‑232/485), and vendor SDKs.
  • High‑throughput camera ingestion (area/line‑scan), frame grabbers, hardware triggers, encoder‑synchronized capture.
  • Buffering, backpressure control, and store‑and‑forward for unreliable networks.

2. Signal & Image Processing

  • Calibration, unit normalization, filtering (IIR/FIR), denoising, baseline drift removal.
  • Feature extraction (statistics, FFT, STFT, wavelets), edge detection, segmentation, morphology.
  • Sensor fusion (e.g., vision + IR + encoder alignment) for richer context and precise localization.

3. Analytics, AI & Rules

  • Thresholds, SPC (X̄‑R, Cpk), anomaly detection, classical ML (RF, SVM), deep learning for images/time‑series.
  • Golden‑template and recipe‑based inspection, defect classification, severity scoring.
  • Predictive maintenance signals (vibration/thermal trends) and early‑warning alerts.

4. Dashboards, Reporting & DQC

  • Real‑time tiles, trend charts, Pareto/defect trees, OEE, shift/line/part views.
  • Report builder: PDF/Excel export, scheduled emails, APIs for data pull.
  • Image overlays with defect pins, IR heatmaps, and region‑wise color/CMYK deltas for printing QA

5. Actions & Integrations

  • PLC/robot feedback (accept/reject, diverters), stack‑lights/hooters, email/SMS/WhatsApp, webhook
  • MES/ERP connectors (SAP, Oracle, custom REST), CMMS tickets, warehouse WMS events.

Supported Sensors & Sources (Examples)

Image sensors & cameras

Area/line‑scan, industrial RGB/Mono, NIR/SWIR, thermal.

IR/Heat/Temperature

Thermocouples, RTD, IR pyrometers, thermal arrays.

Color & Spectral

Color sensors, spectrometers, printing CMYK validation.

Encoders

Rotary/linear for speed/position synchronization.

Vibration/Acoustic

IEPE accelerometers, MEMS mics for bearing/fan health.

Environmental

Humidity, pressure, flow, gas.

Typical Use Cases

Quality Inspection

Vision + sensors to detect defects, verify assembly, confirm labels/prints.

Process Monitoring

Temperature/pressure/flow profiles with SPC and alarms.

Predictive Maintenance

Vibration + thermal + current draws for early anomaly alerts.

Traceability & Compliance

Part‑wise records, Digital Quality Certificates with evidence.

Printing & Color QA

Compare region‑wise CMYK/ΔE against master references.

How It Works (Pipeline)

  • Connect to sensors/PLCs/cameras via drivers or gateways.
  • Ingest & Buffer data streams with lossless persistence.
  • Process signals and images (filters, calibration, alignment).
  • Analyze with rules, SPC, ML/AI; compute KPIs and events.
  • Visualize dashboards and generate reports (PDF/Excel/API).
  • Act via outputs, alerts, and system integrations.

Technical Highlights

  • High‑rate ingestion (kHz for time‑series, 100+ FPS for cameras depending on setup).
  • Deterministic triggering with encoder linkage and strobed lighting.
  • Recipe management and golden templates per product/variant.
  • APIs: REST/gRPC, WebSocket live feed, CSV/Excel export, database connectors (SQL/NoSQL).
  • Scalability: Multi‑line, multi‑site, tenant‑aware deployments.

Deliverables

  • Requirements & interface specs
  • Software (acquisition → analytics → dashboards)
  • Installation + configuration
  • User training & admin guide
  • Validation test reports and acceptance criteria

Support & SLA

  • Remote and on‑site support options
  • Preventive maintenance checks
  • Model re‑tuning (for AI use‑cases)
  • Versioned releases with rollback

Industries We Serve

Medical Devices

Pharmaceuticals & medical devices

Automotive

Automotive

Electronics

Electronics/PCB

Metal and Steel

Metal and Steel

Glass Surface

Glass & ceramics

Plastic and Films

Machinery & heavy industry.

Coating and Color Surfaces

Energy & utilities

Coating and Color Surfaces

Printing/packaging

Frequently Asked Questions

Yes—OPC UA/DA, Modbus, MQTT, REST, and vendor SDKs are supported.

Absolutely. We align vision data with encoders/IR/others for richer context.

Both. Many clients choose hybrid edge + on‑prem or edge + cloud.

We can compute region‑wise CMYK, ΔE/ΔE2000, and compare against your master references.

Thresholds, rules, AI anomalies; notifications via emails/SMS/WhatsApp and PLC/robot outputs.

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