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IND-008 Manufacturing · condition monitoring Edge FFT · retrofit · industrial
Diagnostic station for rotating equipment: edge FFT, trend analysis, and early warning — without touching machine control.
Edge FFT
spectrum analytics
Multi‑sensor
vibration + temp
Retrofit
parallel path
Dashboard
trends + alarms
Situation
A legacy plant saw sporadic failures on rotating equipment. There was no reliable data basis to detect precursors (vibration, temperature drift) during operation.
Replacing machine control was not an option. The plant needed an independent retrofit diagnostic path with measurable signals and a clear alarm concept.
Goal: condition monitoring with edge analytics (FFT), trend and event history — to enable planned maintenance and spare-part lead time.
Approach
1
1 Analysis
Signal capture & failure patterns
- Defined measurement points and sensor types (vibration/temperature) per asset
- Captured first data in operation; compared spectra and trend curves
- Defined alarm criteria: thresholds + frequency-band patterns
2
2 Hardware
Edge nodes & diagnostic station
- Rugged edge node as a parallel measurement system (no PLC changes)
- kHz-range vibration sampling; temperature as slow trend
- Local buffering and secure KPI transport
3
3 Embedded
Firmware: FFT + feature extraction
- On-device FFT and band-energy KPIs
- Event detection (anomaly vs. normal) with hysteresis
- OTA path for thresholds and model tuning
4
4 Cloud
Backend & dashboard
- Stored time series for KPIs and alarms
- Dashboard: trends, spectra, alarm history per asset
- Notification chain for maintenance escalation
5
5 Go‑live
Operation & calibration
- Calibrated alarms in parallel run (reduced false positives)
- Maintenance gets actionable signals: what/where/which pattern
- Prepared the path to scale to more assets
How the solution works
Sensors (vibration · temperature)
↓
Edge FFT (KPIs · events)
↓
Secure transport (telemetry · alarms)
↓
Time series store (trends · history)
↓
Dashboard (spectra · alarms)
Results
Condition monitoring as an independent retrofit path (no PLC change)
Edge FFT reveals precursor patterns and reduces data volume
Clear alarm history and trend data for maintenance planning
Scalable to more assets with the same sensor types
Technologies
Edge FFTCondition monitoringTime seriesOTA updatesVibration analyticsIndustrial dashboard
Vibration/temperature signals — but no data basis?
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