Case Study
Colibri
High-Speed Spindle Solutions
Colibri partnered with Iottive to develop a connected spindle monitoring solution with Bluetooth and IoT. The goal was to enhance precision machining. this was achieved through real-time RPM monitoring, vibration analysis and efficient data communication by resulting in faster and smarter reliable performance.
Colibri
Tech Partnership
Industrial / Manufacturing Technology
6 Months
- Real-Time Machine Health Monitoring
- Automated Stock & Refill Alerts
- Remote Diagnostics & Control
- Usage & Consumption Analytics
Key Outcomes
Enabled real-time RPM monitoring for coolant-based spindles.
Delivered a stable Bluetooth and iBeacon-based connection. It was for continuous data flow.
Achieved up to 25% increase in machining efficiency through live performance insights.
The Challenge
Before partnering with Iottive, Colibri was facing several issues:
Connectivity Limitations
Establishing stable and low-latency Bluetooth communication within industrial environments was complex.
Data Visibility
Ap Operators lacked real-time spindle performance feedback. This was during machining.
System Integration
Integrating IoT-based monitoring with existing industrial setups and machinery controls was challenging.
Scalability
The need to make the solution adaptable across different spindle configurations and accessories.
Our Solution
Iottive delivered a complete AIoT based smart monitoring system under a full-cycle product development model.
Bluetooth Expertise
We built a stable Bluetooth and iBeacon framework. It enabled seamless communication between the spindle and monitoring systems. This ensured precise and real-time RPM tracking. Even in noisy industrial environments.
Design Thinking Approach
We collaborated closely with Colibri’s R&D team to create an intuitive user interface for real-time visualization and analysis. We simplified the data presentation. It was by helping operators make quicker and smarter decisions.
Project Planning & Execution
We followed an agile development process with clear milestones from prototype validation to industrial deployment. This ensured reliable performance without interrupting ongoing production.
Real-Time Data & Insights
We developed live data visualization for RPM, vibration and temperature parameters. This gave operators clear and actionable insights. It was to optimize spindle performance, reduce wear and extend tool life.
Implementation Highlights
Sensors & Device Tracking
Enabled real-time RPM tracking using integrated sensors within the Jet Spindle system.
Edge & Connectivity
Bluetooth and iBeacon technology ensure fast and interference-resistant communication between the spindle and the operator interface.
Firmware & Performance Optimization
Designed low-power firmware for continuous operation and accurate data transmission without affecting spindle balance or efficiency.
Data Analytics & Visualization
Delivered live dashboards for spindle speed, performance trends and alerts for anomalies.
Dashboard & UX
User-friendly visualization interface with clear metrics to guide operators in real-time decision-making.
Security & Compliance
Ensured data integrity through encrypted Bluetooth communication and secure device pairing protocols.
Results & Impact
- Improved machining accuracy and speed through live spindle performance feedback.
- Enabled predictive monitoring for reducing tool wear and downtime.
- Achieved up to 25% higher machining efficiency with real-time data analysis.
- Enhanced operator confidence with clear visual performance tracking and alerts.
- Optimized production flow with smarter spindle control and reduced maintenance interruptions.
“Iottive Pvt. Ltd. was pivotal in transforming Colibri’s advanced spindle monitoring systems into a truly smart industrial solution. Their IoT expertise, especially in Bluetooth connectivity and real-time data synchronization, helped us bring precision and intelligence to CNC spindle operations. The team’s ability to merge hardware, firmware, and mobile technology delivered a flawless monitoring experience for our users. With Iottive’s innovative approach and attention to detail, Colibri now leads the evolution of connected manufacturing, delivering efficiency, insight, and performance across industries.”
— George Gurtovoy , Colibri
Lessons & Best Practices
Stable communication is key
Reliable Bluetooth and iBeacon integration ensure accurate and continuous data capture.
Actionable data drives efficiency
Simplified insights and clear visualization help operators make faster yet smarter decisions.
Scalability ensures sustainability
Designing adaptable solutions support multiple spindle models and future innovations.
Collaboration accelerates innovation
Continuous co-development with Colibri’s team enabled faster iteration and fine-tuning.
Technology
Comprehensive IoT Technology Stack
From devices and connectivity to cloud, apps, and security — we leverage a full-stack IoT ecosystem to build scalable, secure, and future-ready solutions.
Nordic
Bluetooth
Firebase
iOS Swift
Android Kotlin
Why Iottive’s the Right Partner
- 7+ years of industrial IoT and Bluetooth communication systems
- Proven record in building connected solutions for precision machinery.
- Strong design-to-deployment expertise by ensuring both performance and usability.
Next Steps for Colibri
Expansion of the smart spindle system across more product lines.
Integration with centralized factory monitoring platforms for unified visibility.
Advanced AI based insights for predictive maintenance and efficiency analytics.
Continuous refinement of real-time monitoring algorithms for higher precision.