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Mast & Boom Proximity Lock Sensors
— A Digital Approach
At IODE, innovation starts with listening. Captains, service centers, and technicians that told us the same thing: traditional mast and boom sensor systems were unreliable, heavy, and difficult to configure. We set out to change that.
Core Functions
CANbus reliability with marine-ready hardware
Minimum / maximum time on for outputs
Isolation of faulty sensors without network loss
Weight savings aloft
Designed for sailors, tested by sailors
From Prototype to Proof
Our first prototype used a Particle Boron MCU with GSM connectivity, enabling remote programming, a Nextion touchscreen, and global monitoring via web app.
24VDC sensor data ensured strong noise immunity.
Opto-coupled level shifting down to 3.3VDC provided robust triggers.
Over-the-air updates and app feedback gave technicians real-time visibility during installation.
The prototype proved the concept: short, rapid sensor triggers could be captured, latched, and output reliably — even for fast-moving events like hoisting past a sensor.
Key Learnings
Through real-world testing and client input, we built features that matter:
Minimum time on — even the briefest trigger delivers a meaningful output for example allowing suffiicent on time for buzzers to sound.
Maximum time on — lights and buzzers automatically deactivate after a defined period, improving safety and usability during night sailing.
Multiple outputs — separate mast and boom triggers for clearer, safer crew feedback.
Isolation of damaged sensors — faulty inputs can be removed from the network without taking down the whole system.
These features transformed reliability and gave crews confidence in their rigging systems.
Smarter System Architecture
Taking cues from the automotive industry, we partnered with MRS (Germany), MicroControl GmbH, Fluid and EPEC to bring marine-ready PLCs into our design.
The result: a CANbus backbone running from mast base to masthead — the same robust protocol Bosch developed in 1986 and still trusted in automotive today.
Benefits:
Reliable, time-based feedback with built-in fault detection
Easy onsite programming
Proven long term stability, 5 years and zero hardware warranty claims!
Major weight savings: 26.5kg reduced wiring on a 55m mast with 13 sensors
Designed for the Crew
Every IODE system is designed to give crews clarity and control:
Touchscreen interface — real-time visibility of sensor states
Custom naming — sensors labelled for exact mast/boom locations and functions
Assignable outputs — map any sensor to any output
Remote assistance — quick reprogramming via shipped cables
Rugged build — carbon fibre junction boxes, connectors, and waterproof PLCs ensure long service life at sea
Work in Progress
We’re not stopping here. Our next developments include:
Strain gauge amplifiers (with partners in motorsport)
High-frequency data logging (20+ sensors @ 50Hz)
CANbus-to-NMEA gateway integration
Advanced calibration rigs for proof testing
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