.png)
.png)
.png){kind=logo}
As part of the Danube DNA project, partners developed and validated two technological solutions designed to support the digital transformation of manufacturing SMEs. While these solutions are implemented directly within industrial environments and cannot be integrated into the B2GreenHub platform itself, they are presented (in the menu Resources - Improve - Monitoring and Optimization) here as examples of innovative technologies developed and promoted through the Danube DNA Network.
EM4 System Condition
Developed by FH CAMPUS 02 (Austria) within the Danube DNA project, EM4 System Condition is an innovative energy monitoring solution designed to help small and medium-sized enterprises improve energy efficiency and gain better insight into their production processes. The system provides flexible and wireless energy monitoring, enabling companies to collect and analyse energy consumption data without extensive modifications to existing infrastructure. One of its key advantages is the ability to transmit data wirelessly, even over longer distances, making it suitable for a wide range of industrial environments.
The solution has been specifically designed for quick and easy retrofitting of existing machines and power consumers. Sensors can be installed directly on equipment or mounted within electrical control cabinets, allowing companies to monitor multiple processes and energy flows with minimal installation effort. The user-friendly interface presents all relevant information through clear graphical dashboards, helping users quickly identify consumption patterns, inefficiencies, and opportunities for optimisation.
The sensor data sampling unit supports up to 18 measurement channels, allowing the monitoring of either six three-phase supply lines or eighteen single-phase circuits. Collected data is transmitted via LoRaWAN technology to a central gateway, which securely transfers the information to the cloud for further processing and analysis. The dashboard can be configured according to the specific needs of each company, while customised alarm settings enable users to receive notifications when predefined thresholds are exceeded or unusual consumption patterns occur.
A particularly valuable feature of EM4 System Condition is its flexibility and cost-effectiveness. Once energy consumption has been optimised in one production area, the sensor data sampling unit can easily be relocated and deployed elsewhere within the company. This allows SMEs to continuously improve energy performance across different operations while maximising the return on investment. By combining wireless connectivity, flexible deployment, and advanced energy analytics, EM4 System Condition supports SMEs in their digital and green transformation, helping them reduce energy costs, improve operational efficiency, and strengthen long-term competitiveness.
Tool is available under Resources - Improve - Monitoring and Optimization - EM4 System Condition or directly from link here: HERE.
WeldWise
Developed within the Danube DNA project, WeldWise is an Industrial IoT-based monitoring and analytics solution designed to support the digital transformation of manufacturing SMEs. The solution was developed through the collaboration of ICT Cluster Bulgaria, acting as the responsible project partner and beneficiary of the joint solution, and COMICON Ltd., Bulgaria, which carried out the technical development and system integration. Originally created to address a real industrial need in spot-welding production systems, WeldWise combines production monitoring, electrical energy measurement, KPI calculation, historical data archiving, and real-time visualisation within a robust on-premises edge-computing architecture.
The solution enables real-time monitoring of machine activity and automated counting of production events, providing manufacturers with immediate visibility into operational performance. In addition to tracking production processes, WeldWise measures electrical energy consumption at machine or process level, allowing companies to better understand resource usage and identify opportunities for optimisation. The system automatically calculates key performance indicators, including energy consumption per produced unit, helping manufacturers improve efficiency, reduce waste, and support sustainability objectives.
WeldWise also provides comprehensive historical data storage, reporting capabilities, and configurable real-time dashboards that present operational and energy-related information in an accessible and actionable format. Through its modular Industrial IoT architecture, the solution can detect abnormal operating conditions and support preventive maintenance activities, reducing downtime and improving overall process reliability.
The solution was initially tested and validated at EDE16 in a spot-welding production environment and was subsequently piloted at MDC in a broader industrial setting, including applications involving a powder coating oven, industrial compressor, and laser cutting process. These pilot activities demonstrated the flexibility and adaptability of WeldWise across different manufacturing environments and industrial processes.
With its combination of machine-level monitoring, energy visibility, process transparency, and advanced analytics, WeldWise offers significant application potential across a wide range of industries, including spot welding, metal processing, laser cutting, industrial ovens, compressors, and other production environments where operational efficiency, energy management, and data-driven decision-making are essential for competitiveness and sustainable growth.
Tool is avaible under Resources - Improve - Monitoring and Optimization or directly from link HERE.
