--- title: "Machine condition monitoring | Nexus Observatory" description: "Unplanned stops of pumps, motors, fans and conveyors cost far more than planned repairs. Vibration, thermal and power sensing on every critical machine…" url: https://observatory.global/industries/industry/machine-condition/ publisher: Nexus Observatory Inc. updated: 2026-11-02 --- [Nexus Observatory](https://observatory.global/) / [Industry](https://observatory.global/industries/industry/) / [Specialized fields](https://observatory.global/industries/industry/fields/) / **Machine condition monitoring** # 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. [Plan a deployment](https://observatory.global/contact/deployment/) How it works [Station Builder](https://observatory.global/studio/builder/) **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. InstrumentsVibration 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. LinksPrivate 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](https://observatory.global/contact/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](https://observatory.global/studio/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](https://observatory.global/contact/field-service/) 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](https://observatory.global/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 againstISO 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](https://observatory.global/contact/sales-enquiry/) 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 deployment](https://observatory.global/contact/deployment/) [Open the Station Builder](https://observatory.global/studio/builder/) [Open the Studio](https://observatory.global/studio/) **01** The 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 **02** What 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. | Measurement | Where | Cadence | Sources | | --- | --- | --- | --- | | Machine vibration | Bearings of motors, pumps, fans, gearboxes and conveyors | Continuous, spectra on change | 12 | | Surface and connection temperatures | Thermal cameras on motors, drives and switchgear | Continuous | 3 | | Motor power and current | Drives and motor circuits | Continuous | 2 | | Condition and diagnosis records | Every monitored machine | On every change | 4 | **03** The 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 →](https://observatory.global/studio/builder/) 2. **02** Site A line or plant: every critical machine linked over a private cellular network to an edge node. [Plan a site →](https://observatory.global/contact/deployment/) 3. **03** Fleet Every plant of a manufacturer on one condition view, with shared diagnoses. [Managed offers →](https://observatory.global/industries/industry/solutions/) 4. **04** Network Condition data reach maintenance systems and equipment suppliers through open standards. [The open protocol →](https://observatory.global/protocol/) - **01** Vibration and condition monitor - **02** Energy and power-quality meter - **03** Thermal camera - **04** OT gateway (OPC UA, Modbus) - **05** Small cell (4G/5G) - **06** 5G core appliance (UPF/core) - **07** Edge node (Wedge) - **08** Fibre 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. **04** How 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. Machine condition monitoring: data path – of 10 01 Instruments Measurement with sensor identity andcalibration 02 Gateway 03 Field radio 04 Radio access 05 Core network 06 Node – Wrap in an observation envelope with timequality– Measure quality and uncertainty, attachquality flags– Buffer locally (store-and-forward when thelink drops) 07 Backhaul Commit with transactional outbox andpublish, delivered at least once 08 Site Consumer inbox deduplicates and applieseach record once into governed data 09 Data store Governed product through API, map orexport, correction-aware 10 Products OPC UAMIMOSAMQTT 01 Vibration and condition monitor Analogue I/O · RS-485 · Ethernet 02 Energy and power-quality meter SDI-12 · RS-485 · Ethernet 03 Thermal camera Ethernet 04 OT gateway (OPC UA, Modbus) Ethernet · RS-485 · CAN · AnalogueI/O 5G modems and routers Not in the reference kit 05 Small cell (4G/5G) Ethernet · Fibre · GNSS antenna ·1PPS/10 MHz 06 5G core appliance (UPF/core) Ethernet · Fibre · BMC 07 Edge node (Wedge) Ethernet · Fibre · USB · RS-485 ·BMC 08 Fibre terminal Fibre · Ethernet Site MQTT 5 with Sparkplug B Governed data store Versioned, correction-aware Machine condition and diagnoses Work orders with evidence Availability and avoided failures Condition data RS-485 · Modbus RS-485 · Modbus Ethernet Ethernet 5G NR Ethernet Ethernet Ethernet Fibre From the instrument to the published product: each band is a tier, each connector names its interface, and the numbers match the bill of materials. Hover or focus a block to trace its path; scroll or step to follow one observation. | Item | Equipment | Data ports | Protocols | Power in | | --- | --- | --- | --- | --- | | 01 | **Vibration and condition monitor** Accelerometer-based vibration and temperature sensor for rotating machinery and structural condition monitoring. | Analogue I/ORS-485Ethernet | Modbus, OPC UA, MQTT 5 | 12 V DC | | 02 | **Energy and power-quality meter** Meter for voltage, current, power, energy and power quality at a site or on a feeder. | SDI-12RS-485Ethernet | Modbus, IEC 61850 (MMS, GOOSE), DNP3 (IEEE 1815), MQTT 5 | 12 V DC | | 03 | **Thermal camera** Long-wave infrared camera for fire detection, equipment hot spots and night monitoring. | Ethernet | RTSP with ONVIF profiles, MQTT 5 | PoE | | 04 | **OT gateway (OPC UA, Modbus)** Read-only bridge from industrial fieldbuses and controllers (Modbus, OPC UA, DNP3, IEC 61850, CAN) to the site network, behind a security boundary. | EthernetRS-485CANAnalogue I/O | OPC UA, Modbus, DNP3 (IEEE 1815), IEC 61850 (MMS, GOOSE), MQTT 5 | 24 V DC | | 05 | **Small cell (4G/5G)** Integrated base station (radio, baseband, antenna) for private LTE or NR on a local licence, shared-spectrum or leased route. A CBRS CBSD is a small cell that also registers with a spectrum access system. | EthernetFibreGNSS antenna1PPS/10 MHz | 3GPP NR air interface, 3GPP E-UTRA air interface, IEEE 1588 PTP, O-RAN E2, A1, O1 | PoE, 48 V DC, AC mains | | 06 | **5G core appliance (UPF/core)** Local 5G standalone core with user-plane function and local breakout, so site traffic stays on site. | EthernetFibreBMC | 3GPP 5G core service-based interfaces, DMTF Redfish | AC mains, 48 V DC | | 07 | **Edge node (Wedge)** Rugged edge node that boots from signed media, attests itself and establishes a site cell from little or no infrastructure. | EthernetFibreUSBRS-485BMC | MQTT 5, DMTF Redfish, IEEE 1588 PTP, NTP with NTS, OPC UA | 12 V DC, 24 V DC, 48 V DC, AC mains | | 08 | **Fibre terminal** Optical network terminal or media converter that lands fibre backhaul at a site. | FibreEthernet | IEEE 1588 PTP | 12 V DC, 48 V DC, AC mains | How it scales 01 Instruments Arbitrary qualified sensors and instruments whosemeasurements are ingested with calibration, units,geometry, time, custody and uncertainty. ×n 02 Node The minimum useful deployable unit: server, ruggedappliance, radio node, sensor gateway, satelliteterminal, AI, scientific, vehicle or virtual node. Node Node agent 03 Site The minimum independently operable localgovernance and failure domain: one or more nodesplus local network, identity, policy, evidence,storage, products and operator surfaces. SITE Node Node Node ×n 04 Cluster An optional scale or specialisation domain forscheduling, shared storage, accelerators or datalocality. CLUSTER ×n 05 Fleet Coordinates plans, acknowledgements,convergence evidence, update campaigns andcorrection propagation across nodes and sites. FLEET Fleet controller ×n 06 Federation An exchange of products, capabilities, events orwork across approved, independently administeredtrust domains, using explicit trust, policy,data-locality, version and correction contracts. TRUST DOMAIN TRUST DOMAIN TRUST DOMAIN ×n Verifier Applications Data in the field Telemetry Control Data upstream Control Data upstream Control Exchange Evidence Events Exchange The smallest deployable unit is one node; the same unit is replicated to meet the demand. Nodes form a site, sites may form a cluster, sites and clusters are coordinated as a fleet, and fleets exchange across independently administered trust domains. Each plane is a separate channel with its own open binding. **Data in the field**: MQTT 5 with Sparkplug B; connectors for LoRaWAN, OPC UA and instrument buses. **Telemetry**: OpenTelemetry OTLP. **Control**: TLS 1.3 with mutual authentication; protobuf messages over gRPC or HTTP/2. **Data upstream**: At-least-once publication with repeat-safe keys over the control channel or NATS JetStream; QUIC MAY be used on lossy links. **Evidence**: DSSE-signed in-toto statements; SLSA provenance; SCITT transparency receipts. **Events**: Event envelopes mapped to CloudEvents 1.0; channels described in AsyncAPI 3. **Exchange**: OpenAPI 3.1; the OGC API family; SensorThings; STAC; WIS 2.0. **05** From 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. **06** Data products and integration ## What it delivers, to whom, and into which systems. Data products - **Machine condition and diagnoses** Maintenance and reliability teams - **Work orders with evidence** Planners - **Availability and avoided failures** Plant managers - **Condition data** Equipment suppliers under service contracts Integration - **Maintenance management** Diagnoses open work orders in the plant's maintenance system. - **Plant systems** Condition data reach the historian through OPC UA. - **Suppliers** Condition data are shared with suppliers where contracts say. Exchanged through OPC UA, MIMOSA, MQTT. **07** Questions 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. **08** Resources ## The sources behind this page. Public standards, regulations and guidance, cited where they apply. Each applies only where its jurisdiction or scope does. 1. **1** [ISO 20816-1: Mechanical vibration, measurement and evaluation of machine vibration](https://www.iso.org/) International Organization for Standardization 2. **2** [ISO 17359: Condition monitoring and diagnostics of machines, general guidelines](https://www.iso.org/) International Organization for Standardization 3. **3** [ISO 18434-1: Condition monitoring and diagnostics of machines, thermography](https://www.iso.org/) International Organization for Standardization 4. **4** [ISO 13374: Condition monitoring and diagnostics of machines, data processing, communication and presentation](https://www.iso.org/) International Organization for Standardization 5. **5** [IEC 62443: Security for industrial automation and control systems](https://webstore.iec.ch/) International Electrotechnical Commission **09** Related ## Use cases and solutions. [Solution Mine, plant and port site monitoringSlope radar, tailings monitoring, dust and water, and site connectivity for operations and closure.Solutions for industry →](https://observatory.global/industries/industry/solutions/#industrial-site-monitoring) [Solution Private Wireless as a ServiceStandalone private 5G or LTE for a site, campus, port or mine: radios, core, SIMs, spectrum route and operations.Solutions for industry →](https://observatory.global/industries/industry/solutions/#private-wireless) [Solution Edge inference for infrastructureModels running beside the instrument on video, radar and sensor streams for assets and hazards; only results move upstream.Solutions for industry →](https://observatory.global/industries/industry/solutions/#edge-inference) **10** Industry: specialized fields ## Other fields of this industry. [Specialized field Chemical and process plantsGas detection, stack emissions, thermal imaging and site weather at chemical and process plants, joined in one record for safety, environmental permits and the people living nearby.The full field →](https://observatory.global/industries/industry/process-plants/) [Specialized field Factory energy managementMetering of electricity, gas, steam, compressed air and water by line and machine, so factories cut energy use, prove savings and meet energy audit and management duties.The full field →](https://observatory.global/industries/industry/energy-management/) [Specialized field Workplace dust, noise and heatFixed and wearable sensing of dust, gases, noise and heat stress on factory floors, so health and safety teams keep exposure below limits and act where it rises.The full field →](https://observatory.global/industries/industry/workplace-exposure/) ### Bring us the site. 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