AI Electrical Panel & Gauge Reading Solution
Automated AI system for reading electrical control panels, analog gauges, and digital meters with real-time monitoring and SCADA integration.
Real-time Electrical Parameter Reading
- Analog Gauge Reading (Pressure, Temperature, Voltage)
- 7-Segment Digital Meter Reading (Current, Power, Frequency)
- Indicator Lamp Status Detection
- Circuit Breaker Position Monitoring
Architecture Overview
The Manual Reading Problem
- • Human transcription errors & inconsistent timing
- • Delayed anomaly detection (shift-based rounds)
- • Safety exposure in hazardous areas
- • Labor intensive & difficult to audit
- • No real-time integration to MES / SCADA / CMMS
Our Approach
GaugeSnap deploys vision sensors or leverages existing CCTV. Edge AI reads dials & digits, normalizes values to engineering units, and streams structured data for monitoring, analytics, and predictive maintenance.
Secure encryption at source + offline buffering ensures data integrity.
Supported Instruments
Pressure Gauges
Analog dial pressure (vacuum to 400 bar)
Temperature Gauges
Dial / bi-metal / gas filled thermometers
Differential Pressure
DP gauges & indicators across filters
Vacuum Gauges
Vacuum / compound dial indicators
Flow Indicators
Rotameters, variable area & sight flow
Tank & Level
Float, tape, sight glass & dial level
Steam / Gas Flow
Orifice, vortex & turbine dial indicators
Ultrasonic Flow
Clamp-on display modules
Water Meters
Mechanical / turbine / multi-jet registers
Electric Energy Meters
kWh, multi-tariff & demand LCD / 7‑seg
Gas Meters
Diaphragm, rotary & turbine index dials
Digital Panel Meters
V, A, Hz, °C, RPM, kWh multi-parameter
Mechanical Counters
Stroke, batch & production totalizers
Totalizers
Flow / batch cumulative count dials
pH / ORP / Conductivity
Panel analyzers & digital readouts
Turbidity / Water Quality
Bench / inline analyzer displays
Torque / Dial Indicators
Analog torque & test dial faces
Vibration Meters
Panel RMS / velocity / acceleration
Refrigeration Gauges
Compound pressure & temperature dials
Hydraulic Manifold Gauges
Multi-port pressure indication
Key Capabilities
99%+ Reading Accuracy
Robust AI models handle glare, vibration, partial occlusion, and lighting variance.
Fast Processing
Edge inference under 1.5s per gauge reading including normalization.
Historical Trends
Automatic time-series logging & anomaly detection.
Threshold Alerts
Multi-level warning & critical thresholds with escalation.
SCADA / IoT Integration
MQTT, Modbus TCP gateway & REST webhook connectivity.
Offline Edge Mode
Continues operating & buffers data if network drops.
Technical Architecture
A modular pipeline ensures reliable extraction of numeric value from diverse analog dial designs and digital segments.
- Image capture (scheduled / event / trigger)
- Pre-processing (distortion + contrast normalization)
- Gauge ROI detection & dial segmentation
- Pointer / digit extraction + scale mapping
- Value normalization & unit assignment
- Outlier filtering & confidence scoring
- Publish to dashboard / API / alert engine
Edge + Cloud Hybrid
Critical inference happens on the edge device for latency and resilience. Aggregated results sync to cloud analytics for fleet-wide visibility.
- • Supports ARM / x86 edge gateways
- • Hardware acceleration (GPU / NPU optional)
- • Encrypted payloads (TLS 1.2+)
- • Configurable read intervals & triggers
- • REST + MQTT publishing
Related Equipment & Solutions
Deployment Timeline (Typical 4 Weeks)
Industry Applications
Operational & Financial Impact
- • Eliminate manual rounds & transcription
- • Earlier anomaly detection reduces downtime
- • Improved safety in hazardous zones
- • Audit-ready digital history & compliance
- • Data foundation for predictive maintenance
- • Seamless integration to existing systems
Related Technologies & Solutions
Expand gauge reading capabilities with integrated technologies
Supported Equipment
Start Automated Reading System Today
Reduce manual reading errors and increase monitoring efficiency