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Wireless mold cycle counter

A small wireless counter that mounts on an injection mold and records every cycle. Counters on many machines report over LoRa to one system, so the client can track and analyze production across the whole plant.

Client
Industrial monitoring company
Scope
Hardware, firmware and dashboard integration
Timeline
6 months
Delivered
Board design, complete firmware and manufacturing documentation

The challenge

Every mold cycle, from every machine, in one place

Mold counters usually keep their count on the mold, where someone has to walk up and read it. The client wanted to measure each injection molding cycle and its parameters, and to collect the data from many machines in a central LoRa system that analyses it and shows it on a dashboard.

The counter sits on a hot, working mold, so it had to be small, contactless, sealed and resistant to high temperatures. It also had to run on a battery for a long time and be protected against tampering.

What we built

A sealed, low-power STM32U counter with LoRa networking

Hardware

Counter board

A small, battery-powered board built around a low-power STM32U microcontroller. It wakes up only when the press closes and sleeps the rest of the time.

  • Contactless detection with Hall and reed sensors and a mating magnet
  • Wake-up on press close detection
  • LCD for reading the count on site
  • Tamper protection
  • LoRa radio
  • Sealed, high-temperature enclosure

Firmware

Complete low-power firmware

Firmware that counts and measures each cycle, shows it on the display and reports it over LoRa while using as little power as possible.

  • Cycle detection and measurement
  • Low-power modes between cycles
  • Local readout on the LCD
  • LoRa communication
  • Integration with the client's dashboard

Delivery

Ready to manufacture

Everything needed to build the counters and connect them to the client's system.

  • Schematic and PCB layout
  • Complete firmware
  • Dashboard integration
  • Manufacturing documentation

Result

Plant-wide mold monitoring

  • Data from many machines collected over LoRa and shown on one dashboard.
  • Contactless and sealed, built to work on hot molds on a long battery life.
  • One hardware iteration, right first time.
  • Six months from the start of the project to a working system.

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