Strainlabs System

Uncontrolled bolted joint conditions threaten asset lifespan, uptime and safety Problem description

In railway infrastructure, bolted joint integrity is critical. Vibrations, thermal expansion, and relaxation can cause loosening, often missed by manual, time-consuming inspections. This raises the risk of failures, downtime, and accidents.

Without real-time insight, maintenance is often inefficient and reactive. Predictive, condition-based maintenance is key to improving reliability and reducing costs. Continuous remote preload monitoring enables early fault detection, data-driven decisions, and compliance – with a patented solution ready for global deployment.

Condition monitoring of bolted joints Our Solution

Strainlabs introduces e-Bolts equipped with embedded sensors to monitor preload in real time. Each e-Bolt includes a miniaturized optoelectronic system that captures mechanical strain and transmits data wirelessly. The system provides alerts on preload loss, supporting Predictive Maintenance and reducing the need for manual inspections. Data is visualized on a dashboard, highlighting critical joints and maintenance needs.

They are built for Harsh Environments, with long battery life and robust wireless communication.

A globally patented system ensures unique technological value, enabling early risk detection, repair verification, and optimized maintenance – especially in Industrial and Railway applications.

How it works

Wireless e-Bolts with embedded strain and temperature sensors

Preload loss detection with real-time alerts for maintenance

Visual dashboards highlighting critical risks and interventions

Predictive maintenance alerts from continuous monitoring data

Long battery life with configurable measurement frequency

Proprietary protocol ensuring secured, compliant, and certified communication

Product description

Strainlabs’ solution embeds a miniaturized optoelectronic sensor that continuously measures mechanical strain to determine preload. The system integrates an LED-sensor, microcontroller, and wireless transmitter, with data sent periodically to an internet gateway for cloud analysis. The optoelectronic design offers superior mechanical and thermal resistance, minimal EMI sensitivity, and stable measurements without recalibration. The design is mechanically passive, ensuring that the bolt retains its full structural function without interference from the sensor.

The system operates on a battery that lasts over 5 years at default settings which can be extended by adjusting the measurement frequency. They are CE-marked, demonstrating compliance with industrial standards for electromagnetic compatibility, electrical safety, and controlled wireless transmission power, while guaranteeing robustness and endurance in Industrial and Railway environments.

Whitepaper Overview and data sheet

Strainlabs System Data Sheet