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BoltSense – Innovative fasteners for load measurement

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square with tentacles  Project title

BoltSense – Innovative fasteners for load measurement

outline of the upper man silhouette  Name of Beneficiary/Beneficiaries

Transmission Dynamics Poland Sp. z o.o.

briefcase icon  Name of programme

Innovative SMEs

newspaper icon  Competition

Eurostars-3 Call 1

two heaps of coins icon  Project value

PLN 798,870.56

hand icon with two circles above it  Funding value

PLN 479,322.34

clock icon  Project delivery period

from 1 July 2022 to 4 January 2024

See the results of our work

1

BoltSense measuring bolt

 

2

Implementation of measuring bolts in a ball mill

What problem does our project solve?

Our BoltSense project addresses the challenge of remote monitoring of fastener stresses in hard-to-reach and critical locations, such as wind turbines and ball mills. The BoltSense technology provides detailed information about the state of these components, enabling precise calibration, advanced analysis, and reporting. By integrating wireless communication technologies, including Bluetooth LE and LoRa, BoltSense dynamically switches between frequency bands, ensuring efficient communication over both short and long distances. Supported by funding from the Innovative SMEs competition (Eurostars-3) in 2021, the project involved developing communication concepts, advancing LoRa technology, and conducting functional and safety tests. The implementation of Bluetooth LE and LoRa technology, along with a 3-axis accelerometer, enables stress to be monitored under extreme conditions while optimising energy efficiency, ensuring the system runs for three years on battery power. Additionally, the project implements advanced security measures to prevent unauthorised access. Our engineering team developed an intuitive web interface and customer portal, integrating seamlessly with device monitoring databases, adapting to regional requirements, and eliminating data misinterpretation. Thanks to the Global Data Network server, data is provided in real time, enabling devices to be configured immediately without data loss. 

Who will benefit from the project's results?

The primary beneficiaries of the BoltSense project include key manufacturers and stakeholders across various heavy industries who can implement the technology in practice. The wind energy, mining, power generation, construction, and the rail sector are just some of the industries that will be able to use the new technology to monitor fasteners. Additionally, Copper State Bolt & Nut Company, which has already installed over 4,000 BoltSense bolts, will act as a principal distributor, facilitating global market commercialisation. Collaboration with JR Dynamics Ltd. ensures further development and sales of the technology, generating revenue through hardware sales and SaaS subscriptions. 

What was the biggest challenge for us in implementing the project?

The biggest challenge during the project was the commercialisation of the results. This required the team to independently execute numerous development tasks, identify suitable partners, and target markets for the BoltSense solution. Ensuring the technology's compliance with the requirements of various heavy industry sectors, such as wind energy, mining, power generation, construction, and railways, was critical. Launching the product also involved building trust with key manufacturers and stakeholders, securing strategic agreements, and navigating industry-specific demands. 

Our advice to other Applicants

Based on the experience gained during the BoltSense project, we offer the following advice to other applicants:

  • comprehensive planning – develop a detailed plan covering all stages of the project, from R&D to commercialisation. Be prepared for unexpected challenges and maintain flexibility in your strategies.
  • the importance of partnerships – collaborate with experienced international partners who can contribute unique competencies and resources.
  • commercialisation and trust – successfully implementing the technology in practice can significantly facilitate commercialisation.
  • scalability of solutions – ensure your solutions are scalable and adaptable to various industries. This expands market reach and maximises sales potential.