Industrial Edge-AI Condition Monitoring & 3D Digital Twin

1. About the Team

We are a team of engineering students currently in our 4th semester at COMSATS University Islamabad, Abbottabad Campus in Pakistan. This project is our Complex Engineering Problem (CEP) for this semester. Our team consists of hardware designers, firmware developers, and web dashboard engineers. We are highly passionate about industrial automation, IIoT (Industrial Internet of Things), and Edge Computing.

2. About the Project

Industrial 3-phase motors often fail unexpectedly due to worn bearings, unbalanced phases, or bent shafts, causing massive factory downtime.

Our project solves this by using Edge-AI to predict motor failures before they happen. We have designed a custom hardware motherboard that clamps onto the motor. It continuously measures microscopic vibrations, RPM, and high-voltage current draw. The onboard AI analyzes this data in real-time. If it detects an anomaly (like a grinding bearing), it wirelessly sends an alert to a 3D Digital Twin web dashboard. If a catastrophic failure is imminent, our board triggers an industrial contactor to instantly cut the 480V power to the motor, saving the factory floor from a dangerous breakdown.

3. Technical Details & Why We Need a 4-Layer Board

Because of the extreme high-speed and industrial requirements of our design, our PCB is highly complex. We could not use a simple 2-layer board. Our architecture features:

Stackup: A 4-Layer impedance-controlled stackup.

Processing: An STM32H7 (480MHz) Core for real-time Edge-AI math processing.

Telemetry: An ESP32 Co-processor for Wi-Fi telemetry and rendering the 3D Digital Twin.

Connectivity: A WIZnet W5500 hardware TCP/IP Ethernet MAC with 100-Ohm differential pair routing.

Sensors: An STMicroelectronics IIS3DWB ultra-wide bandwidth vibration sensor using high-speed SPI.

Safety: A 5V mechanical pilot relay with physical isolation slots to drive a heavy-duty industrial contactor.

4. Why We Need PCBWay's Support

As university students, the cost of manufacturing and assembling (PCBA) this dense 4-layer board with fine-pitch components (like the STM32H7) exceeds our student budget. We chose PCBWay because of your reputation for flawless 4-layer impedance control and excellent PCBA placement accuracy for fine-pitch QFP components.

5. Media & Attachments

To demonstrate the seriousness and quality of our design, we have attached:

High-resolution 3D renderings of our Altium Designer layout.

Screenshots of our 3D Digital Twin web dashboard in action.

In exchange for your sponsorship, we have proudly placed the PCBWay logo on our Top Silkscreen. We will highlight PCBWay as our official manufacturer in our final university defense, and we will post photos and videos of the working system on LinkedIn, tagging the official PCBWay page to showcase your excellent manufacturing quality.

Thank you for reviewing our application. We look forward to partnering with you!