★ Sterling in-house AI product

AI-based Wireless Busbar Temperature Monitoring

Real-time temperature monitoring for HT/LT panels & switchgear with predictive maintenance — loose joints and overloaded feeders are caught long before they become arc-flash incidents or plant shutdowns.

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How it works

Clamp-on sensors. Zero wiring. Live alarms.

Sensors clamp directly onto busbars, cable joints and electrical contact points inside energised panels. Powered by the conductor's own electromagnetic field, they transmit temperature wirelessly to a gateway that feeds SCADA and your browser dashboard.

  • Wireless sensors — measure busbar & joint temperatures without signal wiring per point
  • Self-powered options — energy-harvesting sensors fed by the field around live conductors
  • Real-time monitoring — continuous or periodic acquisition per sensor specifications
  • Early-warning alarms — configurable high-temperature and temperature-rise (ΔT) alarms
  • SCADA integration — Modbus RTU/TCP via supported gateways
  • Central dashboard — monitor multiple panels and sensing points from one workstation
  • Predictive maintenance — temperature trending & abnormal-heating pattern detection
  • Retrofit friendly — for existing LT & HT switchgear, subject to clearance & safety assessment

🔥 Where failures start — and where we watch

Busbar joints, cable lugs, breaker contacts and incomer terminals run hottest when connections loosen. A 30% rise above baseline often precedes failure. Our AI flags exactly this trend.

Applications

  • LT distribution panels, PCC & MCC
  • HT switchgear and electrical substations
  • Power-plant auxiliary electrical systems
  • Transformer and bus-duct connections
  • Industrial plants & manufacturing facilities
  • Water treatment plants and pumping stations
  • Data centres and critical power distribution

System architecture

From busbar joint to dashboard — wireless end to end

Battery-powered and self-powered CT sensors clamp onto the busbar, report over a 100 m local wireless link, and the gateway sends data to SCADA and the STERLING BusbarGuard dashboard over RS485 or 4G.

STERLING BusbarGuard wireless busbar temperature monitoring system: clip-on wireless sensors, STERLING wireless gateway, 4G DTU and the STERLING BusbarGuard dashboard
STERLING BusbarGuard system architecture — clip-on sensors, gateway, 4G DTU and dashboard. Every sensor and gateway carries the STERLING nameplate.
STERLING BusbarGuard monitoring dashboard with live busbar temperature trends, hot-joint counts and predictive alerts
The STERLING BusbarGuard dashboard — live sensor count, hot joints, peak temperature, 24-hour trend and predictive alerts in one screen.
−60%

Unplanned thermal faults (typical pilot result)

0 wires

Per sensing point — clamp-on installation

<4 hrs

Typical installation across a PCC room

24×7

SCADA-integrated surveillance

Start with one PCC room. Prove it. Expand.

Our standard pilot covers one PCC/MCC room with dashboard, alarms and a 30-day trend report.

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