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Machines that tell you before they fail.

Unplanned stops of pumps, motors, fans and conveyors cost far more than planned repairs. Vibration, thermal and power sensing on every critical machine, analysed at the edge to the international condition monitoring standards, tells maintenance teams which machine is wearing and what to fix.

Industry

Industry

Measurements

4

Sources cited

5

1. Industry · Machine condition monitoring

   Stops that cost the most

   An unplanned stop of a pump, motor, fan or conveyor costs far more than a planned repair: lost output, rushed parts and damage to the machines around it. Most failures give warning weeks ahead in vibration, heat and power, if someone is listening.

2. What is measured

   Vibration, heat and power

   Vibration sensors on the bearings of motors, pumps, fans, gearboxes and conveyors measure how each machine runs. Thermal cameras watch motors, drives and switchgear for heat, and power meters on motor circuits show load and current, so every machine has its own condition record.

   Instruments

   Vibration sensors · Thermal cameras · Power meters

3. The base node

   A diagnosis, not an alarm

   The node computes vibration spectra and the standard severity evaluation, recognises bearing wear, misalignment and imbalance, links them with temperatures and power, and sends a diagnosis with its evidence, so maintenance knows what to fix and not just that something changed.

4. Radio and links

   Private 5G across the floor

   A private 5G network connects machines across the plant without new cabling and with the reliability industrial control needs. Wi-Fi serves tablets on the floor, and the edge node reaches the plant network and enterprise systems over fibre. Each link is chosen for the place, not from a catalogue.

   Links

   Private 5G · Wi-Fi · Fibre

5. How it works

   From a bearing tone to a planned repair

   A conveyor drive bearing shows a rising tone in its spectrum. The node diagnoses early outer-race wear and opens a work order with the evidence. The bearing is replaced in the next planned stop, three weeks before it would have seized and stopped the line.

6. From order to operation · Order

   Scope the critical machines

   The scope reads the plant’s machines, their criticality, failure history and maintenance strategy. Nexus Observatory Inc. returns the machine list to monitor, sensor plan, private network design, diagnosis rules and a price per machine and per year. Every assumption in the scope is written down and priced.

   Plan a deployment

7. From order to operation · Survey

   Survey machines and coverage

   Crews survey each machine with maintenance engineers: sensor positions on bearings, camera views, drive interfaces, and coverage of the private network. Baseline vibration is taken with a portable instrument. Every finding is kept with the site record for the crews who follow.

8. From order to operation · Permits

   Plant rules and spectrum

   Work follows the plant’s safety and lockout rules, private network spectrum is licensed under local rules, and connecting to plant systems goes through change control. Every approval is kept with the plant record. Approvals are tracked site by site, so nothing waits unseen.

9. From order to operation · Build

   Build and configure

   Sensors, gateways, cameras, small cells, the core and node are configured, nodes enrolled with their identities and the machine model and severity limits loaded. Everything runs together before shipping. Test results travel with the kit to the site. Nothing ships until the whole kit has passed its tests together.

   Open the Station Builder

10. From order to operation · Install

    Install during stops

    Crews fix sensors on bearings and motor circuits during planned stops, mount cameras and small cells, install the node and connect to the plant network. Every sensor is labelled with its machine and position. The site record is updated before the crew leaves.

11. From order to operation · Commission

    Commission against the baseline

    Each node proves its identity. Readings are compared with the portable baseline, alarm levels are set from the standard and the machine’s own history, and diagnoses are reviewed with the maintenance team. Results are signed and kept with the site record.

12. From order to operation · Operate

    Fix before failure

    Maintenance teams see every machine’s condition and diagnosis. Work orders are opened with the evidence attached, repairs are planned into stops, and every failure avoided or found is kept for the reliability review. Reports for owners and funders come from the same record.

13. From order to operation · Maintain

    Learn from every repair

    Findings from each repair confirm or correct diagnoses, sensors are checked on routine rounds, software updates roll out in rings, and diagnosis rules improve with the plant’s history. Spares and procedures travel with the crews. Maintenance history stays with each site for its whole life.

    Book field services

14. Data products

    For maintenance, planners and managers

    Maintenance and reliability teams receive machine condition and diagnoses; planners receive work orders with evidence; plant managers receive availability and avoided failures; equipment suppliers receive condition data under service contracts, each tied to machine and time. Each product carries its site, time and quality flags.

    See the data products

15. Evidence

    Condition monitoring to standard

    The programme follows the international condition monitoring guidelines, vibration is evaluated to the standard severity method, data are processed and presented to the data processing standard, thermography follows its standard and the private network meets the service requirements for industrial control.

    Drawn against

    ISO 17359 · ISO 20816-1 · ISO 13374 · ISO 18434-1 · 3GPP TS 22.104

16. What you get

    Mine, plant and port site monitoring

    Slope radar, tailings monitoring, dust and water, and site connectivity for operations and closure. Delivered as managed service and hardware + software, for mining, heavy industry, ports. Scale: Site portfolios. Service levels are written as numbers you can measure on your own dashboard.

    Talk to sales

17. Next step

    Plan machine condition monitoring with us

    Tell us the site, the measurements and the rules it answers to. We reply with a survey proposal, a design and a scope for machine condition monitoring. An engineer replies with a survey proposal and a scope, and the plan grows from one site to the network you need, at your pace.

    Plan a deploymentOpen the Station BuilderOpen the Studio

01The place and its hazards

Where it runs, and what can go wrong.

Operating contextCondition monitoring of machines follows international guidelines for the overall programme, standard evaluation of machine vibration, data processing and presentation, and thermography. Wireless connectivity for industrial control has service requirements defined for private cellular networks.

Hazards

• Bearing and gearbox failures that stop a line
• Misalignment and imbalance that wear machines early
• Overheating motors and electrical connections
• Machines nobody can reach to inspect safely
• Alarms without a diagnosis

02What must be measured

What, where, how often, and under which rules.

Each measurement names where it is taken, how often, and the public standard or regulation behind it. Numbers in the sources column open the cited source below.

03The observation stack

From one base unit to a network.

The same blocks at every scale: instruments and a base node, a site with its radio, a fleet run as one, and a network federated on the open protocol.

1. 01

   Base unit

   A machine point: vibration and power sensors on an industrial gateway, with a thermal camera covering a group of machines.

   Build a station →
2. 02

   Site

   A line or plant: every critical machine linked over a private cellular network to an edge node.

   Plan a site →
3. 03

   Fleet

   Every plant of a manufacturer on one condition view, with shared diagnoses.

   Managed offers →
4. 04

   Network

   Condition data reach maintenance systems and equipment suppliers through open standards.

   The open protocol →

• 01Vibration and condition monitor
• 02Energy and power-quality meter
• 03Thermal camera
• 04OT gateway (OPC UA, Modbus)
• 05Small cell (4G/5G)
• 065G core appliance (UPF/core)
• 07Edge node (Wedge)
• 08Fibre terminal

Radio and links

Private 5G

A private 5G network connects machines across the plant without new cabling, with the reliability industrial control needs.

Radio and links

Wi-Fi

Wi-Fi serves tablets for maintenance teams on the floor.

Radio and links

Fibre

The edge node reaches the plant network and enterprise systems over fibre.

Edge computeThe node computes vibration spectra and the standard severity evaluation, recognises bearing, misalignment and imbalance patterns, links them with temperatures and power, and sends a diagnosis with its evidence to maintenance.

PowerSensors run from the machines’ control power or on long-life batteries; the node runs from the plant’s supply with backup.

04How it works

From the instrument to the product.

One observation’s path, tier by tier, with the interface on every link and a bill of materials below; then how the one node grows to a site, a fleet and federated networks.

05From order to operation

Every step, from the first call to a running site.

The same crew and the same record carry the work from scope to maintenance.

1. 01 Order

   Scope the critical machines

   The scope reads the plant’s machines, their criticality, failure history and maintenance strategy. Nexus Observatory Inc. returns the machine list to monitor, sensor plan, private network design, diagnosis rules and a price per machine and per year. Every assumption in the scope is written down and priced. 2

2. 02 Survey

   Survey machines and coverage

   Crews survey each machine with maintenance engineers: sensor positions on bearings, camera views, drive interfaces, and coverage of the private network. Baseline vibration is taken with a portable instrument. Every finding is kept with the site record for the crews who follow. 1

3. 03 Permits

   Plant rules and spectrum

   Work follows the plant’s safety and lockout rules, private network spectrum is licensed under local rules, and connecting to plant systems goes through change control. Every approval is kept with the plant record. Approvals are tracked site by site, so nothing waits unseen. 5

4. 04 Build

   Build and configure

   Sensors, gateways, cameras, small cells, the core and node are configured, nodes enrolled with their identities and the machine model and severity limits loaded. Everything runs together before shipping. Test results travel with the kit to the site. Nothing ships until the whole kit has passed its tests together.

5. 05 Install

   Install during stops

   Crews fix sensors on bearings and motor circuits during planned stops, mount cameras and small cells, install the node and connect to the plant network. Every sensor is labelled with its machine and position. The site record is updated before the crew leaves.

6. 06 Commission

   Commission against the baseline

   Each node proves its identity. Readings are compared with the portable baseline, alarm levels are set from the standard and the machine’s own history, and diagnoses are reviewed with the maintenance team. Results are signed and kept with the site record. 14

7. 07 Operate

   Fix before failure

   Maintenance teams see every machine’s condition and diagnosis. Work orders are opened with the evidence attached, repairs are planned into stops, and every failure avoided or found is kept for the reliability review. Reports for owners and funders come from the same record. 2

8. 08 Maintain

   Learn from every repair

   Findings from each repair confirm or correct diagnoses, sensors are checked on routine rounds, software updates roll out in rings, and diagnosis rules improve with the plant’s history. Spares and procedures travel with the crews. Maintenance history stays with each site for its whole life.

06Data products and integration

What it delivers, to whom, and into which systems.

Data products

• Machine condition and diagnosesMaintenance and reliability teams
• Work orders with evidencePlanners
• Availability and avoided failuresPlant managers
• Condition dataEquipment suppliers under service contracts

Integration

• Maintenance managementDiagnoses open work orders in the plant’s maintenance system.
• Plant systemsCondition data reach the historian through OPC UA.
• SuppliersCondition data are shared with suppliers where contracts say.

Exchanged through OPC UA, MIMOSA, MQTT.

07Questions buyers ask

Before you scope it.

Do we need new cabling?

No. The private network connects machines wirelessly.

How early does it warn?

Typically weeks before failure for bearing wear.

Will it diagnose or just alarm?

It diagnoses common faults and shows the evidence.

Can our analysts use their own tools?

Yes. Data are open through standard interfaces.

08Resources

The sources behind this page.

Public standards, regulations and guidance, cited where they apply. Each applies only where its jurisdiction or scope does.

1. 1ISO 20816-1: Mechanical vibration, measurement and evaluation of machine vibrationInternational Organization for Standardization
2. 2ISO 17359: Condition monitoring and diagnostics of machines, general guidelinesInternational Organization for Standardization
3. 3ISO 18434-1: Condition monitoring and diagnostics of machines, thermographyInternational Organization for Standardization
4. 4ISO 13374: Condition monitoring and diagnostics of machines, data processing, communication and presentationInternational Organization for Standardization
5. 5IEC 62443: Security for industrial automation and control systemsInternational Electrotechnical Commission

09Related

Use cases and solutions.

10Industry: specialized fields

Other fields of this industry.

Bring us the site.

Plan a deployment, configure a station, model it in the Studio or talk to sales. The form names who receives your details.