TELOGIX

What it does

TELOGIX is a low-cost real-time energy and machine monitoring system for SMEs, offering a free dashboard, Excel logging, and Telegram alerts, solving the cost and complexity of IoT platforms like Thingsboard and HiveMQ with no subscriptions.

Your inspiration

The idea for TELOGIX was inspired by the challenges faced by small manufacturers, many of whom have shut down due to high energy bills and limited access to modern technology. As industries rapidly adopt IoT and smart automation, SMEs are left behind due to costs, complexity, and complexity. TELOGIX bridges this gap by providing a low-cost IoT system that enables real-time monitoring of both industrial energy usage and machine behavior. With a free dashboard, Excel data logging, and automated Telegram alerts, TELOGIX offers SMEs a powerful yet simple way to manage operations efficiently, without relying on expensive cloud services.

How it works

TELOGIX is a compact IoT-based device for real-time monitoring of industrial energy use and machine behaviour. It uses an ESP32 microcontroller with Wi-Fi to collect data from three PZEM-004T sensors measuring voltage, current, power, energy, frequency, and power factor, and a DHT22 sensor for temperature and humidity. A 2.4" TFT screen displays live readings, and a cooling fan auto-activates above 40 °C. Data is sent via Wi-Fi to a local Python server, logged into Excel, and visualised on a web dashboard and through Telegram every 5 minutes. Alerts are triggered and a voice note is sent when thresholds are exceeded. Unlike costly IoT SCADA systems like ThingsBoard or HiveMQ, TELOGIX provides a free, Excel-based monitoring solution ideal for SMEs facing high platform costs and limited access to advanced smart systems.

Design process

The concept for TELOGIX emerged from witnessing small-scale manufacturers struggle with high energy bills and unplanned machine downtimes due to the lack of affordable smart monitoring tools. Most industrial IoT platforms like HiveMQ and ThingsBoard require costly subscriptions and complex setups, making them inaccessible for many SMEs. My goal was to build a cost-effective, offline-capable system that enables real-time monitoring, Excel-based data logging, and intelligent alerts through Telegram. I began by identifying essential metrics: voltage, current, power, energy, temperature, and humidity. The ESP32 was selected for its strong connectivity and GPIO support, paired with PZEM-004T sensors capable of measuring up to 100 A, ideal for industrial loads. A DHT22 sensor added environmental sensing. The prototype was built on a breadboard and connected to a Python Flask server that handled logging, plotting, and alerts in text and voice formats via Telegram. After testing, I transferred the circuit to a Vero board for reliability. I then housed it in a custom 3D-printed enclosure designed in SolidWorks and Tinkercad, with precise cutouts for the TFT display, terminals, cooling fan, and vents, completing a robust and accessible solution for industrial monitoring.

How it is different

TELOGIX redefines industrial monitoring with an offline, Telegram-integrated IoT solution that eliminates the need for costly cloud platforms like HiveMQ or ThingsBoard. Tailored for SMEs, it delivers real-time energy and machine monitoring without subscriptions or third-party databases. Supporting up to five unique Telegram users, TELOGIX ensures multi-user accessibility. It uses PZEM-004T sensors capable of measuring up to 100 A, making it ideal for industrial environments. Unlike conventional systems, it sends graphs, summaries, and voice alerts via Telegram, while logging all data locally in Excel. Smart cooling is triggered when ambient temperatures exceed 40 °C. With its compact, low-cost, and ready-to-deploy design, TELOGIX brings powerful Industry 4.0 monitoring capabilities to small-scale manufacturers, simplifying adoption through a user-friendly, plug-and-play approach.

Future plans

I plan to upgrade TELOGIX into a full industrial-grade solution with cloud support and bi-directional Telegram control, enabling users to both monitor and remotely control operations. Excel logs and Telegram data will support AI/ML for smart scheduling, fault detection, and energy prediction. TELOGIX will be positioned as a low-cost, subscription-free alternative to SCADA platforms like Thingsboard or HiveMQ. Targeting SMEs, I aim to bridge the digital divide, with future steps including pilot testing, enclosure refinement, and scaling through partnerships or grants.

Awards