Challenge
A leading automotive manufacturer in Bangalore was experiencing overheating on the output power cables connected to a Switch Mode Power Supply, or SMPS, used within its shop floor electrical system.
The SMPS was converting AC power to regulated DC power, with the output side operating at 24 volts and 10 amperes. These DC output cables distributed power from the SMPS to downstream assets in the facility.
The issue was not caused by loose electrical connections. Instead, the customer identified overloading as the source of abnormal heat buildup in the power cables. However, the installation did not have existing sensors, temperature monitoring devices, or continuous monitoring tools in place to provide early warning of cable overheating.
As a result, the facility had limited visibility into the condition of these SMPS output cables between scheduled inspections. In many similar environments, cable heating may only be detected during periodic thermography inspections, after a circuit protection device trips, or once the issue has already started affecting equipment reliability.
The customer needed a simple, visible, and practical way to identify overheating earlier, without relying solely on quarterly thermography inspections or waiting for circuit protection to interrupt power.
Solution
The customer purchased 50 Safe-Connect thermal clips for a trial installation on the SMPS output power cables.
Safe-Connect thermal clips were installed on the DC output side of the SMPS to provide a direct visual indication of overheating. Unlike traditional thermography inspections, which require an infrared camera and a scheduled inspection route, the thermal clips provided a passive, always-visible indicator at the point of concern.
When abnormal heat was present, the clips changed color. This color change gave maintenance personnel a clear visual warning that the cable had exceeded the clip’s response threshold and required attention.
Once a clip changed color, it would be replaced with a fresh clip. This allowed the customer to continue monitoring the location after the initial overheating event was identified and investigated.
The thermal clips also complemented the customer’s broader inspection strategy. While infrared windows and thermography are valuable for deeper inspection and temperature verification, the thermal clips offered a simple frontline visual cue for cable overheating in an area where no monitoring was previously available.
Outcome
During the trial, the Safe-Connect thermal clips changed color on the SMPS output cables, confirming the presence of overheating caused by overloading.
This gave the customer a clear early warning before the issue escalated to a circuit protection trip or an unplanned interruption. Instead of discovering the problem only during a periodic inspection or after a power event, the facility gained a visible indication that maintenance action was needed.
The installation helped the customer:
- Identify cable overheating caused by overloading
- Add visual temperature monitoring where no sensors were previously installed
- Support preventive maintenance actions before circuit protection devices tripped
- Improve visibility between scheduled thermography inspections
- Validate thermal clips as a practical monitoring solution for similar applications
For the customer, the trial demonstrated how Safe-Connect thermal clips can provide simple, continuous visual monitoring for electrical components that may otherwise go unchecked between inspections.
Summary
The Bangalore installation showed how Safe-Connect thermal clips can help industrial facilities identify overheating conditions in SMPS power cables before they lead to equipment trips, downtime, or further electrical stress.
By providing a visible color-change indication, the clips gave maintenance teams a straightforward way to detect abnormal heating caused by overloading. The result was a practical, low-complexity monitoring solution that supported earlier intervention and improved electrical reliability.
Safe-Connect thermal clips can be especially useful in applications where continuous sensors are not installed, inspection frequency is limited, or teams need a quick visual indicator to support condition-based maintenance.
