Deployment · wireless

Cut the conduit. Own the airwaves.

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Conceptual wireless architecture. Validate RF range, wall penetration, interference, gateway count, protocol support, and lifecycle with a site survey.

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Official ecosystem hardware

Backed by Beckhoff, not by us alone

Every SensorDataFabrics node runs on a standard Beckhoff industrial PC — CX9240 to C6030 — with TwinCAT and EtherCAT underneath. If we disappeared tomorrow, your hardware, spares and support contracts would still come from a global automation vendor you can already buy from.

20+ yr: documented long-term IPC availability
€1.75 bn: annual revenue, 5,700+ staff worldwide
75+: countries with local Beckhoff support
1980: PC-based control pioneer, still independent

TwinCAT 3 runtimeEtherCAT · 65,535 nodesDistributed Clocks · sub-µs syncFSoE SIL 3 safety optionOff-the-shelf lead times

What dropping the cable buys you

Retrofit coverage across assets that were never worth trenching for — with the same edge intelligence.

No cabling

Mount the sensor, pair it with the gateway, done — retrofit without shutting the line.

LoRaWAN

Long-range ChirpStack network server running on your own edge host.

Raw waveform

VibraSens wireless sensors still capture raw data — duty-cycled, fewer points per capture.

Lowest cost/point

No acquisition card per channel, so more assets fit the same budget.

The wireless signal chain

Sensor to plant system, with the network server inside your own plant.

VibraSens sensors

Battery-powered wireless accelerometers, magnet or stud mounted on the asset.

LoRaWAN gateway

Long-range radio link across the plant — no home-run cabling, no conduit work.

ChirpStack on the IPC

The network server runs on your edge host, so payloads never transit a vendor cloud.

Beckhoff IPC

Same Linux stack: alarms, DSP, AI scoring, storage and egress. Physical I/O optional.

Let the AI find it. Then prove it with the data.

The autoencoder runs on every reporting interval; when it flags an asset, pull the logged captures and diagnose with the full post-processing suite.

Anomaly log showing the Machine Stress Index trend crossing watch, elevated and critical thresholds on a wireless LoRaWAN node, with component wear location analysis — Anomaly log on the edge HMI — the Stress Index climbs through watch and elevated bands on a wireless node, flagged at the next reporting cycle.

Duty-cycled captures are buffered on the sensor and forwarded to the node — the evidence is there when the AI points at it, even across kilometers of LoRaWAN.

Train on the captures

The autoencoder learns each machine's normal from duty-cycled raw waveform captures — fewer points than wired, same learning loop, no expert setup.

AI flags it between intervals

Stress Index climbs through Watch → Warning → Danger. The edge HMI raises the alarm at the next reporting cycle — no cloud round trip.

Then you investigate

Pull the logged captures around the event and run the same post-processing toolkit — FFT, envelope, cepstrum — on the raw data.

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 wireless host

Identical services to a wired node — the difference is data density, not features.

Core

Metrics & alarms

RMS, Peak and Kurtosis per reporting interval, checked against ISO 10816-3 bands at the edge.

Add-on

High-speed DSP

FFT, STFT, power density, envelope demodulation and spectral kurtosis on duty-cycled raw captures — fewer points than wired, same tools.

Add-on

Edge AI

The same autoencoder Machine Stress Index (0–100) with Watch / Warning / Danger stages, trained on the IPC.

Core

Storage & egress

Local time-series database, outage buffering, and northbound OPC UA, MQTT, Modbus TCP or HTTPS.

Core

HMI & operations

Same HTTPS web HMI, RBAC, edge health, live logs and offline update with rollback.

Optional

Fleet dashboards

Optional cloud aggregation, entirely optional and not required to run the edge.

Honest limits

Wireless is not a lesser product — it is a different data budget.

Raw waveform
Yes — duty-cycled captures on demand or on schedule
Deep DSP
Yes — fewer points per capture than a wired channel
Continuous streaming
No — reporting intervals, not a permanent stream
Physical I/O reaction
Optional, slower than the sub-second wired path
Acquisition hardware
Gateway only — no per-channel DAQ card

Wireless capacity — CX9240 to C6030

A wireless sensor costs about half the compute of a wired channel, so the same IPC covers twice the assets.

Sensor capacity per IPC — each add-on costs 20% of it

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

Wireless sensor capacity per Beckhoff IPC
IPC	Metrics only	DSP + AI	Role
CX9240	48	29	Compact DIN-rail embedded PC
C6015	96	57	Ultra-compact industrial PC
C6025	144	86	Modular industrial PC
C6030	192	114	High-performance industrial PC

Need continuous, full-rate capture on a critical asset? See the wired EtherCAT deployment.

Ready to size a wireless fleet? Open the wireless configurator.