DEV Community: Bin Johnson

How Ultrasonic Leak Detection Works in Industrial Systems

Bin Johnson — Fri, 04 Sep 2026 16:35:23 +0000

Industrial leaks can be difficult to identify through visual inspection alone.

When pressurized gas or air escapes through a small opening, turbulence can generate high-frequency acoustic energy.

Ultrasonic leak detection uses sensors designed to detect these signals.

Acoustic Generation

A leak creates turbulence as the pressurized medium escapes through an opening.

Ultrasonic Detection

A specialized ultrasonic sensor detects the resulting high-frequency acoustic activity.

Signal Analysis

The detected signal can be analyzed to distinguish potential leak activity from surrounding industrial noise.

Localization

The technician moves the sensor around the suspected area to narrow down the source.

Verification

The suspected leak point can then be inspected and confirmed using the appropriate maintenance or testing procedure.

Documentation

Inspection results can be recorded for maintenance planning, follow-up inspections, and condition-monitoring programs.

Basic Workflow

Leak → Turbulence → Ultrasonic Signal → Sensor → Analysis → Localization → Maintenance

Ultrasonic leak detection is particularly useful because inspections can often be performed while industrial systems remain in operation.

🌐 acoustictestingpro.com

UltrasonicTesting #LeakDetection #NDT #ConditionMonitoring #IndustrialIoT

Building an AIoT Architecture for Industrial Asset Tracking

Bin Johnson — Fri, 04 Sep 2026 16:20:08 +0000

Building an AIoT Architecture for Industrial Asset Tracking

Industrial facilities contain thousands of physical assets, from production equipment and tools to inventory and critical components.

The challenge is creating reliable visibility across these assets.

An AIoT architecture can connect physical assets with digital intelligence.

Asset Identification

RFID tags, BLE beacons, barcodes, or other identification technologies can associate digital identities with physical assets.

Location Tracking

Depending on the environment, technologies such as UWB, BLE, GPS, or RFID can provide location information.

IoT Infrastructure

Gateways collect signals from connected devices and transfer relevant data into an asset-management platform.

Edge Processing

Edge computing can process selected events close to the physical environment before forwarding information to centralized systems.

Data & Analytics

Analytics can identify:

Asset movement
Utilization patterns
Location changes
Inventory conditions
Potential anomalies

Operational Intelligence

AI can help transform raw tracking data into insights that support maintenance, logistics, production, and resource planning.

Simplified Architecture

Asset → Tag/Sensor → IoT Gateway → Data Platform → Analytics → Asset Intelligence

The objective is to move from periodic asset checks toward connected, data-driven asset visibility.

🌐 apertureventurestudio.com

AIoT #IndustrialIoT #AssetTracking #IoT #IndustrialTechnology

Building a Construction Workforce Intelligence System With AIoT

Bin Johnson — Wed, 02 Sep 2026 14:43:12 +0000

Building a Construction Workforce Intelligence System With AIoT

Commercial construction creates a difficult workforce-data problem.

Multiple subcontractors and specialty trades may operate simultaneously across floors, workfaces, mechanical rooms, staging areas, and restricted zones.

A modern workforce intelligence architecture can connect physical workforce activity with digital analytics.

Worker Identification

RFID badges, BLE tags, smart wearables, or other identification technologies can associate telemetry with individual workers or workforce groups.

Positioning

UWB, BLE, GPS/GNSS, and geofencing technologies can provide location information depending on site requirements.

Data Collection

IoT gateways collect workforce telemetry from active construction areas.

Edge Processing

Edge infrastructure can process and normalize field events before forwarding relevant information to centralized platforms.

Workforce Analytics

Analytics can identify:

Workforce density
Trade distribution
Movement patterns
Idle-time trends
Congestion events
Restricted-zone activity

Operational Intelligence

The resulting information can support workforce coordination, emergency accountability, safety oversight, and labor-to-schedule analysis.

Simplified Architecture

Worker → IoT Device → Gateway → Data Platform → AI/Analytics → Workforce Intelligence

The key shift is from simply recording attendance to understanding how workforce activity interacts with the construction environment.

🌐 commconai.com

ConstructionIoT #AIoT #WorkforceIntelligence #UWB #ConstructionTechnology

Building an AIoT Architecture for Workforce Safety

Bin Johnson — Wed, 02 Sep 2026 14:19:46 +0000

Building an AIoT Architecture for Workforce Safety

Workforce safety in industrial environments can benefit from connecting information from people, equipment, sensors, and operational systems.

An AIoT architecture can provide the foundation for this connected approach.

Workforce Identity

Digital credentials can associate workers with physical activities and access events.

Location

BLE, UWB, RFID, GPS, or other technologies can provide location information depending on the environment.

IoT Sensors

Sensors can monitor environmental and operational conditions.

Connectivity

IoT gateways and networks can transfer physical-world data to digital platforms.

Edge Processing

Relevant information can be processed closer to the source when fast responses are required.

AI & Analytics

Analytics can help identify patterns, anomalies, and conditions that may require attention.

Safety Intelligence

The resulting information can support monitoring, alerts, and operational decision-making.

Simplified Architecture

People + Sensors → IoT → Data → AI → Situational Awareness → Action

The objective is not simply to collect more safety data.

It is to create a connected intelligence layer that helps organizations better understand their physical working environments.

🌐 https://apertureventurestudio.com/

AIoT #WorkforceSafety #IndustrialIoT #IoT #SafetyTechnology

Building an IoT Architecture for Acoustic Condition Monitoring

Bin Johnson — Thu, 27 Aug 2026 05:26:45 +0000

Building an IoT Architecture for Acoustic Condition Monitoring

Acoustic condition monitoring combines sensing, signal processing, connectivity, and analytics.

A basic architecture can include several layers.

Acoustic Sensors

Sensors capture acoustic or ultrasonic signals from equipment and physical environments.

Signal Conditioning

Signal-conditioning hardware prepares sensor signals for reliable acquisition and analysis.

Data Acquisition

DAQ systems convert incoming signals into usable digital data.

Edge Processing

Edge processors can analyze data close to the equipment and reduce the need to send every raw signal to the cloud.

IoT Connectivity

Gateways can connect field devices with cloud platforms, SCADA systems, or other enterprise applications.

Analytics

Signal-processing and analytics tools can identify patterns and potential anomalies.

Maintenance Workflow

Relevant findings can support inspection, troubleshooting, and maintenance decisions.

Architecture

Acoustic Sensor → Conditioning → DAQ → Edge → IoT → Analytics → Maintenance

The important part is designing the system around the actual monitoring objective—not simply collecting as much acoustic data as possible.

🌐 https://acoustictestingpro.com/

AcousticTesting #IoT #UltrasonicTesting #ConditionMonitoring #PredictiveMaintenance

Building an AIoT Architecture for Predictive Maintenance

Bin Johnson — Thu, 27 Aug 2026 04:48:53 +0000

Building an AIoT Architecture for Predictive Maintenance

Predictive maintenance requires a connection between physical equipment and intelligent software.

A typical AIoT architecture can contain several layers.

Sensors

Industrial sensors collect information about equipment condition and operating behavior.

Connectivity

IoT gateways and networks transfer data from physical equipment into digital systems.

Data Pipeline

Machine, production, and maintenance data can be collected and organized for analysis.

Edge Processing

Edge systems can process relevant information close to the equipment when low-latency analysis is required.

AI & Analytics

Models can identify abnormal patterns, equipment degradation, and other signals associated with potential maintenance requirements.

Maintenance Intelligence

Insights can be connected to maintenance planning and operational workflows.

The architecture can be summarized as:

Equipment → Sensors → IoT → Data → AI → Prediction → Maintenance Decision

The real value comes from connecting equipment condition with broader operational context.

🌐 https://apertureventurestudio.com/

AIoT #PredictiveMaintenance #IoT #IndustrialAI #DevOps

Building a Digital Access-Governance Architecture for Construction

Bin Johnson — Wed, 26 Aug 2026 13:46:45 +0000

Building a Digital Access-Governance Architecture for Construction

Construction sites are dynamic environments.

Access points, work zones, contractors, and workforce permissions can change throughout the project lifecycle.

A digital access-governance architecture can connect these moving parts.

Workforce Identity

Workers can be associated with digital credentials through technologies such as RFID, BLE, NFC, QR, or biometric verification.

Credential Management

The system can maintain contractor credentials, temporary passes, and authorization information.

Access Control

Smart gates, turnstiles, readers, and other access infrastructure can enforce entry policies.

Restricted Zones

Access rules can be applied to specific work areas based on authorization and project requirements.

Visitor & Delivery Management

Visitors and material-delivery personnel can be incorporated into controlled access workflows.

Analytics

Access events can be analyzed to provide broader workforce and site visibility.

The architecture becomes:

Identity → Credentials → Authorization → Access Point → Event Data → Analytics

For complex construction environments, the objective is to create governed access rather than simply recorded access.

🌐 https://commconai.com/

ConstructionTech #AccessGovernance #IoT #RFID #ConstructionAI

Building an AIoT Architecture for Access Control

Bin Johnson — Wed, 26 Aug 2026 13:28:47 +0000

Building an AIoT Architecture for Access Control

Modern physical-security systems can generate information from multiple sources.

The challenge is connecting these sources into a useful operational picture.

Identity

RFID, BLE credentials, biometrics, or other technologies can associate an individual with an access event.

Access Control

Connected doors, gates, and other access points generate digital events.

Location

Location technologies can provide additional context about where people or assets are operating.

IoT Sensors

Environmental and operational sensors can add physical-world context.

Connectivity

Gateways and networks transfer information from field devices to digital platforms.

Data Platform

The system can bring together:

Identity + Access + Location + Sensor Data + Time

Analytics

AI and analytics can help identify patterns within the connected information.

A simplified architecture is:

Identity → Access → Location → IoT → Data → Analytics → Security Intelligence

The objective is not to replace established security procedures.

It's to create a more connected information layer for physical environments.

🌐 https://apertureventurestudio.com/

AIoT #AccessControl #PhysicalSecurity #IndustrialIoT #DataEngineering

Building a Workforce Intelligence Architecture for Construction Sites

Bin Johnson — Mon, 24 Aug 2026 16:14:02 +0000

Construction sites are complex physical environments where people, equipment, materials, and schedules interact every day.

A workforce intelligence platform can help connect these different operational layers.

Workforce Identification

Digital identification systems can provide information about workers entering and operating within a site.

Site Access Data

Access systems can provide visibility into site entry and movement events.

Location & Activity Data

Connected technologies can help create better understanding of workforce activity across different zones.

Data Integration

Information from multiple sources can be combined into a unified operational view.

Analytics Layer

Analytics can help identify patterns and provide useful insights.

Construction Applications

Dashboards and applications can support project teams with better operational visibility.

Architecture:

Worker → Access → Site Data → Integration → Analytics → Construction Intelligence

The objective is creating a connected information layer for modern construction operations.

🌐 https://commconai.com/

ConstructionTech #ConTech #WorkforceIntelligence #DigitalConstruction

Building an AIoT Architecture for Asset Tracking

Bin Johnson — Mon, 24 Aug 2026 15:53:33 +0000

Building an AIoT Architecture for Asset Tracking

Asset tracking becomes more useful when location data is connected with other operational information.

A basic system may answer:

“Where is the asset?”

An AIoT architecture can go further by connecting asset identity, location, IoT infrastructure, and operational data.

Asset Identification

RFID, BLE, sensors, or other technologies can provide a digital identity for physical assets.

Location

Location technologies can provide information about where an asset is within a defined environment.

IoT Infrastructure

Connected devices and gateways collect and transmit physical-world data.

Data Pipeline

Data from different sources can be collected and organized into a common platform.

AI & Analytics

Analytics can help turn asset data into operational insights.

Applications

Dashboards and applications can make the information useful to operations teams.

The architecture can be summarized as:

Asset → Identify → Locate → Connect → Analyze → Operational Insight

This approach can support the broader goal of asset visibility, rather than treating tracking as an isolated function.

🌐 https://apertureventurestudio.com/

AIoT #AssetTracking #IoT #IndustrialIoT #SoftwareArchitecture

Building an AIoT Architecture for Workforce Safety

Bin Johnson — Fri, 21 Aug 2026 06:33:26 +0000

Building an AIoT Architecture for Workforce Safety

Workforce safety in industrial environments can involve more than monitoring individual workers.

It can require understanding the relationship between people, locations, assets, equipment, and physical conditions.

AIoT can connect these different layers.

Workforce Identification

RFID, BLE, wearables, credentials, or other technologies can provide digital identification depending on the use case.

Location

Location technologies can provide information about where workers are operating within a defined environment.

Access Control

Access systems can provide information about movement through controlled areas.

Environmental Sensors

IoT sensors can monitor relevant environmental conditions.

Connectivity

Gateways and networks connect field devices with edge or cloud platforms.

Data Platform

The system can bring together:

Identity + Location + Access + Sensors + Time + Operational Context

Analytics

Analytics can help identify patterns and events that may require attention.

The simplified architecture becomes:

Worker → Identification → Location/Sensors → Connectivity → Data → Analytics → Safety Insight

The technology should support defined safety objectives and appropriate organizational policies.

The goal is to turn physical-world information into useful safety intelligence.

🌐 https://apertureventurestudio.com/

AIoT #IoT #WorkplaceSafety #IndustrialIoT #WorkerSafety

Understanding a Guided Wave Ultrasonic Testing Technology Stack

Bin Johnson — Fri, 21 Aug 2026 06:16:53 +0000

Understanding a Guided Wave Ultrasonic Testing Technology Stack

Guided Wave Ultrasonic Testing uses ultrasonic guided waves that travel along a structure.

A modern GWUT workflow involves several components.

Transducer System

A ring or array of transducers can be positioned around a suitable structure to generate and receive guided waves.

Guided Wave Generation

The system generates controlled ultrasonic waves that travel along the structure.

Signal Reception

Reflections from changes in the structure can be detected by the system.

Data Acquisition

The inspection equipment captures the returning signals for analysis.

Signal Analysis

The collected data can be analyzed to identify areas that may require further investigation.

Location Estimation

The system can help estimate the position of a detected indication relative to the inspection location.

Follow-Up Inspection

Potential indications can then be investigated using an appropriate detailed NDT method.

The workflow can be summarized as:

Transducers → Guided Waves → Signal Reception → Data Acquisition → Analysis → Screening → Follow-Up Inspection

The key idea is that GWUT can provide long-range screening, while detailed inspection methods can be used to characterize specific areas.

🌐 https://acoustictestingpro.com/

GWUT #UltrasonicTesting #NDT #PipelineInspection #IndustrialTechnology