Altosens enhances the availability, safety and cost-effectiveness of your wind turbines.
Altosens makes bolted connections smart
The altosens.system combines hardware and software into a comprehensive solution for the digital monitoring of safety-critical bolted connections. Easy to retrofit, innovative and patented.
At the heart of the system is the altosens.disc. It looks like a washer, it is a washer, but it is also much more: a force measuring component. It records forces and transfers this information to the digital data bus. This turns every screw connection into a reliable source of data.
What sets this product apart: The installation space for our sensor has been incorporated into the design as a washer. This means that any system can be digitized without design changes, specialist expertise, or training.
Digitization has never been easier!
Predictive maintenance
Less maintenance effort thanks to condition-based monitoring of bolt forces
Higher availability
No unplanned downtime, maximum efficiency
Cost savings
Lower operating costs through optimized use of personnel
Increased safety
Protecting both personnel and infrastructure
Future-proof
Innovative, patented technology ensuring maximum reliability
Why bolted connections are critical
Bolted connections hold the world together…
Large systems consist of many individual components and are usually assembled on site. Bolted connections are indispensable, as they make constructions detachable and enable repairs and maintenance.
However, these connections must remain secure during operation.
The challenge: Screws are exposed to wind, weather, vibrations, and changing loads. To ensure safety, they have been checked manually – a process that is time-consuming, costly, and ties up valuable skilled personnel.
Altosens automates this process. With our technology, bolted connections are continuously monitored – efficient, reliable, and without the high costs of traditional methods.
Products
Our solutions for smart bolted connections
The altosens.system is modular in design and combines hardware and software components into one comprehensive solution – from measurement directly at the bolt to evaluation in the cloud.
Hardware
- altosens.disc – a washer that measures preload forces in real time
- altosens.edge-ai – the communication and computing module for data transfer and on-site pre-processing
Software
- altosens.analytics – the platform for data visualization, analysis, and automated alerts. Together, they form a system that not only monitors screw connections but also makes data actionable and creates real added value.
Customized solutions
Not every application is the same. That’s why Altosens develops customer-specific solutions – from prototypes to series production. Whether it’s special sizes, demanding environmental conditions or customised interfaces – together we’ll find the right solution for your challenge.
Let’s talk about your project.
From demo kits and system solutions to fully customised developments – we support you on your path to smarter bolt monitoring.
The smart washer
altosens.disc
The altosens.disc is the core of our technology. It replaces a conventional washer and measures forces where they actually occur: directly at the bolted connection.
Features
- Force measuring washer. Measures preload and axial forces during operation
- Available from size M20
- Communication via CAN bus interface
- Robust design with high overload capacity
Advantages
With the altosens.disc, every screw becomes a data source. This enables continuous condition monitoring without additional effort. Deviations can be detected at an early stage, helping operators avoid downtime.
Application examples
- Wind turbines with thousands of bolted connections that previously had to be checked manually
- Mechanical engineering and industrial plants with critical connections under permanent load
- Infrastructure such as bridges and railways, where safety is paramount
Intelligent communication and computing module
altosens.edge-ai
While the altosens.disc measures forces directly at the bolt, the altosens.edge-ai takes care of data processing and transmission. It collects the values from several sensor washers, processes them locally, and reliably transfers the relevant information to existing systems or to the cloud.
Features
- Integration of multiple altosens.disc sensors
- Local pre-processing of data (edge computing)
- Communication via CAN bus and flexible interfaces for local networks and cloud connections
- Scalable from individual bolted joints to complex systems
Advantages
The altosens.edge-ai simplifies installation and operation. By intelligently pre-processing data, it reduces the volume of information to be transmitted, ensures reliable communication, and enables seamless integration into existing IT and OT infrastructures. This turns individual measuring points into a comprehensive, usable picture of the entire system.
Application examples
- Wind farms: Bundling data from thousands of bolts for comprehensive plant monitoring
- Infrastructure: Continuous monitoring of critical structures such as bridges or railways
- Industry & mechanical engineering: Flexible scalability for production plants with numerous bolted connections
Your data at a glance
altosens.analytics
The altosens.analytics platform is the control centre for your data. All information from the sensors and modules comes together here – clearly visualised, intuitive to use and available at any time.
Features
- Online platform for monitoring and analysis
- Real-time visualisation of preload, forces and temperature
- Customizable configuration of warning thresholds
- Automatic notifications in case of deviations
- Access from anywhere – on any device
Advantages
With altosens.analytics, you always have critical connections in view. Deviations become immediately visible, risks are identified early, and maintenance becomes predictable – making predictive maintenance a reality.
Application examples
- Wind power: Control centres monitor critical connections remotely and centrally
- Infrastructure: Operators configure alarms for defined limit values
- Industry: Use of data for quality assurance, verification and documentation
Applications
Our solutions for smart bolted connections
Our force-measuring washers combined with altosens’ modular system enable reliable and digital condition monitoring of bolted connections – across a wide range of industries.
We provide solutions that deliver exactly where they are needed:
- Wind turbines
- Infrastructure
- Agriculture & logistics
- Customised applications
Energy
Wind turbines
Wind turbines contain thousands of bolted connections – on rotor blades, towers and foundations. These are exposed to heavy loads from wind, vibrations and temperature fluctuations and must therefore be checked regularly.
With altosens, safety-critical bolts can be continuously monitored. This makes maintenance planning more effective and significantly reduces downtime.
Unique benefits for wind energy:
- Continuous monitoring of rotor blade, tower and foundation connections
- Fewer climbing operations and manual inspections
- Higher plant availability through pre-planned maintenance
Infrastructure
Bridges, railways and beyond
Bridges, railways and pipelines rely on stable bolted connections. Over time, these are exposed to varying loads, environmental conditions and vibrations – risks that are hardly visible to the naked eye.
Altosens provides safety through permanent data collection directly at the connection. This makes infrastructure operation more reliable and allows risks to be identified at an early stage.
Unique benefits for infrastructure:
- Continuous documentation of bolt condition
- Early detection of changes in critical structures
- Greater safety for transport, supply and the public
In the field & on the road
Agriculture & Logistics
In agricultural and logistics applications, bolted connections are exposed to heavy loads – for example on vehicles, loading areas, silos or containers. At the same time, there is a strong demand for weight measurement and efficient use of resources.
With altosens, forces and loads can be continuously recorded during operation. This makes processes more transparent and reliable.
Unique benefits for agriculture & logistics:
- Weight measurement directly on vehicles or silos
- Transparency in transport and storage processes
- Optimized utilisation and increased safety
Your application
Customized solutions
Not every application is the same. Some industries have specific requirements regarding size, environmental conditions or interfaces.
Altosens develops tailor-made solutions for these needs – from prototypes to series production. This enables our technology to be used flexibly wherever standard solutions are not sufficient.
Unique benefits for customized solutions:
- Adaptation to special sizes or operating environments
- Customised interface integration
- Development from prototypes to series production
Altosens GmbH
Sensorik made in Niedersachsen
Altosens is a young technology company based in the Osnabrück Innovation Centre. Founded in 2022 as a spin-off of Fraunhofer LBF, we develop sensor washers that make safety-critical bolted connections digitally measurable – directly during operation and without major modifications to existing systems.
In doing so, we help to increase the reliability and availability of machines, plants and infrastructure.
Cooperation
We are only strong as a team. Altosens cooperates with and is supported by ...
