Products · Predictive Maintenance
Fix it before it breaks
IO-Link condition-monitoring sensors on your critical machines, watched continuously against a learned baseline — so failures become planned service windows instead of breakdowns.
How it works
From sensor to service window
No black box and no cloud dependency — sensors you can buy from any distributor, logic you can inspect, alerts where your team already looks.
Instrument
IO-Link vibration, temperature and current sensors clip onto motors, gearboxes and pumps. The IO-Link masters drop straight onto your existing PROFINET — no rewiring the plant.
Baseline
Weeks of normal running teach the system what healthy looks like for each machine — every speed, every product, every season.
Watch
Live readings are compared against the baseline continuously: rising vibration RMS, temperature drift, changing current signature.
Predict
When a machine starts walking away from its baseline, you get a service window — not a 2 am breakdown. Alerts go to the HMI, email or your CMMS.
What we monitor
Start where a breakdown hurts most
A pilot is one IO-Link master and a handful of sensors on the machine that keeps your maintenance manager up at night.
Motors & gearboxes
Bearing wear, imbalance and misalignment show up in vibration weeks before failure. Temperature and current confirm the story.
Pumps & fans
Cavitation, blocked lines and impeller damage have distinct signatures — caught early, they cost a seal kit instead of a pump.
Conveyors & bearings
Hot bearings and rising drive current flag failing rollers and tensioning problems on the lines that never get looked at — until they stop.
Why IO-Link
Smart sensors, dumb-simple rollout
Diagnostics built in
IO-Link sensors report their own health, signal quality and parameters — not just a raw value. The PLC sees a failing sensor before it lies to you.
No plant rewiring
IO-Link masters sit on your existing PROFINET. Standard 3-wire sensor cable, no shielded analogue runs, no junction-box archaeology.
One sensor, two jobs
The same sensors serve control and condition monitoring — the temperature interlock you needed anyway becomes a health signal for free.
Works with the AI assistant
Condition data feeds straight into the AI Maintenance Assistant's Connected tier — so your team can ask "why is P-201 trending up?" and get an answer grounded in the actual readings.
Start with one critical machine
Pick the machine whose failure costs you a shift. We'll instrument it, baseline it, and show you what it's been trying to tell you.
Plan a pilot