Deterministic high-speed acquisition and local AI inference: running air-gapped on DIN rails with FPGA DSP, dual isolated Ethernet, and sovereign Merkle audit ledger.
Acts as the central nervous system of plant reliability. Ingests high-frequency acoustic emission (Stage 1), accelerometers (Stage 2), velocity and current (Stage 3), and temperature/displacement (Stage 4), computing cross-domain failure correlations locally.
Combines a dedicated Xilinx Artix-7 FPGA for nanosecond-deterministic analog sampling with an 8-core industrial ARM application processor. The FPGA directly controls eight 24-bit delta-sigma ADCs with zero jitter, computing windowed FFTs and envelope filters in hardware before passing processed spectral features to the local Linux Real-Time Kernel (PREEMPT_RT). Local AI models classify failure patterns entirely within the plant security boundary.
8x IEPE / 4-20mA / ±10V Inputs → 2.5 kV Galvanic Isolation Barrier → 8x Dedicated 24-bit Delta-Sigma ADCs → Artix-7 FPGA Direct Memory Access (DMA) → Linux PREEMPT_RT Kernel Buffer → On-device Edge AI Agent → Merkle Audit Ledger.
Provide minimum 50 mm vertical airflow clearance above and below the chassis heatsink fins
Connect dual isolated 24 VDC power feeds from separate uninterruptible power supply (UPS) circuits
Verify solid ground bond from chassis lug to cabinet master earth bar with heavy braided strap
Connect dual Gigabit Ethernet ports to segregated OT (LAN1) and IT/Demilitarized (LAN2) networks
Snap the aluminum chassis securely onto standard 35mm symmetrical DIN rail inside the local instrumentation cabinet. Connect Primary Power (24 VDC) to Terminal PWR1 and redundant backup power to Terminal PWR2. Terminate the safety earth grounding strap directly to the chassis ground lug with < 1 Ω impedance to earth.
Multi-variate dynamic state vector clustering
Simultaneous correlation of rising 1X vibration, 50 Hz stator slot sidebands, and bearing cap thermal slope
Order tracking with 1/rev keyphasor pulse interpolation
Sharp amplitude peak and 180° phase inversion during transition across rotor critical natural frequencies
Hardware bias voltage window comparator (< 2V or > 18V)
Instantaneous DC bias collapse triggering an instrumentation loop alert without false mechanical trips
FPGA peak buffer threshold trigger (< 50 microsecond latency)
Ultra-fast transient pressure and acceleration spikes stored in high-resolution pre-trigger ring buffers
Executes all signal conditioning, envelope demodulation, and AI inferencing on bare metal inside the client plant. Cryptographically signs every processed telemetry block and anomaly event into a local Merkle audit tree. Synchronizes bi-directionally with Optruss AssetCore CMMS without sending unencrypted raw data over external clouds.
The core sensing workhorse for rotating machinery: capturing bearing race spalling, gear mesh harmonics, and mechanical unbalance up to 12 kHz.
Rapid zero-cabling deployment for Balance of Plant assets: monitoring radial, axial, and tangential vibration with 5-year battery life and long-range LoRaWAN telemetry.
The gold standard for fluid-film hydrodynamic bearings: measuring absolute shaft dynamic displacement, radial vibration, axial thrust position, and phase reference up to 10 kHz.
The earliest warning system on the P-F curve: detecting sub-micron lubrication film degradation, microscopic metal-to-metal contact, and pressurized gas leaks at 38 kHz.
Zero-downtime non-intrusive electrical monitoring from the MCC: diagnosing motor broken rotor bars, stator turn faults, and mechanical eccentricity via high-resolution current demodulation.
Continuous non-contact optical temperature telemetry: monitoring bearing housing caps, rotating kiln shells, electrical busbars, and furnace refractories up to 600°C.
Benefit from sub-millisecond edge FFT processing, early P-F curve anomaly detection, and automated CMMS work order generation.
