24-bit / 50 kS·s⁻¹
Per-channel IEPE acquisition — bearing energy visible down to ~12 RPM.
Deployment · wired
Every sample. Every revolution. Nothing missed.
Wired EtherCAT hosts acquire 24-bit vibration at 50 kS·s⁻¹ per channel, score it locally and drive physical I/O in under a second. One host runs the wired stack — never wired and wireless together.
Factory floor → edge → cloud
One digitized line replaces a wiring closet
Each machine digitizes its own sensor signal at the source, so a single Ethernet cable can daisy-chain from machine to machine instead of running dedicated analog wire back to a cabinet.
Digitized signal (EtherCAT) Legacy analog wiring Cloud syncSwitch modes above to compare wiring
A host runs the wired stack or the wireless stack — one logic set per IPC. Mixed plants run one host of each; both publish into the same HMI and the same northbound protocols.
What the cable buys you
Full-rate, uninterrupted signal and deterministic control — the deployment for critical rotating assets.
< 1 s
Local reaction on relays, tower lights and switches. No cloud round trip.
10× faster install
EtherCAT daisy-chains machine to machine on one Ethernet cable.
Continuous
Uninterrupted streaming and logging, not duty-cycled snapshots.
The wired signal chain
From accelerometer to plant system, on hardware you own.
IEPE sensors
Industrial accelerometers, including extreme-temperature variants from −270 °C to +800 °C.
24-bit DAQ card
One acquisition channel per sensor — the reason wired costs more per point, and why it sees more.
EtherCAT backbone
Sub-microsecond Distributed Clock sync, up to 65,535 nodes, daisy-chained across machines.
Beckhoff IPC
Linux host running alarms, DSP, AI and egress — plus FSoE 'Black Channel' SIL 3 safety when required.
Let the AI find it. Then prove it with the data.
The autoencoder watches continuously and flags the anomaly; the post-processing suite is how you diagnose it — on months of full-rate captures.
Long-horizon logging on the node — compression-first storage keeps months of history, so the evidence is still there when the AI points at it.
01
Configure the AI
Point it at the machine. The autoencoder learns that asset's own normal — no expert spectra setup.
02
The AI flags it
Machine Stress Index climbs out of band. Watch → Warning → Danger, locally, in under a second.
03
Then you investigate
Open the captures around the event and run the post-processing that answers why.
Post-processing toolkit — on demand, on the recorded data
FFT spectrum
harmonics, BPFO / BPFI lines
STFT waterfall
how the spectrum evolved
Power spectral density
broadband energy
Demodulation
envelope, early bearing defects
Cepstrum
sideband families, gear mesh
Spectral kurtosis
where the impulsiveness lives
Time domain
the raw waveform itself
Six capabilities on a wired host
Core services ship on every node. DSP and AI are add-ons that trade sensor capacity for intelligence.
Core
Metrics & alarms
RMS, Peak and Kurtosis computed continuously against ISO 10816-3 bands, driving physical outputs in under a second.
Add-on
High-speed DSP
Full-rate FFT, STFT waterfalls, power density, envelope demodulation, cepstrum and spectral kurtosis on raw 24-bit captures.
Add-on
Edge AI
An autoencoder learns each machine's normal and returns a 0–100 Machine Stress Index — trained and scored on the IPC itself.
Core
Storage & egress
Local time-series database per node. Buffers through outages, then forwards over OPC UA, MQTT, Modbus TCP or HTTPS.
Core
HMI & operations
HTTPS web HMI with Admin/Operator RBAC, edge health, live logs, and offline update with one-click rollback.
Optional
Fleet dashboards
Optional Azure aggregation across sites — $24 per sensor per year. Switch it off and the edge keeps running.
Wired capacity — CX9240 to C6030
One wired 24-bit channel costs roughly two wireless sensors' worth of compute. Each add-on trims capacity, not features.
- CX924029–48 wireless · 14–24 wired
- C601557–96 wireless · 29–48 wired
- C602586–144 wireless · 43–72 wired
- C6030114–192 wireless · 57–96 wired
with DSP + AI metrics only
| IPC | Metrics only | DSP + AI | Role |
|---|---|---|---|
| CX9240 | 24 | 14 | Compact DIN-rail embedded PC |
| C6015 | 48 | 29 | Ultra-compact industrial PC |
| C6025 | 72 | 43 | Modular industrial PC |
| C6030 | 96 | 57 | High-performance industrial PC |
Wired channels need a 24-bit / 50 kS·s⁻¹ acquisition card each — but EtherCAT daisy-chaining usually takes most of that back in cabling and labour.
No cabling route to the asset? Compare the wireless deployment — same edge stack, duty-cycled capture.