Plug & Play – ready in one hour
Software pre-installed at the factory. Browser access – no installation on a computer. Automatic IO-Link sensor detection and visualisation generation from IODD files.
WaveFlow System Solutions 4.X
MachineMonitor is a complete machine and production process monitoring system — operating in real time and enhanced with artificial intelligence algorithms for automatic anomaly detection. Also available as a classic monitoring system without the AI module.
System architecture
MachineMonitor combines proven IO-Link technology with artificial intelligence algorithms. You can run it as a classic parameter monitoring system – or immediately with the predictive anomaly detection module.
The result is an installation that monitors the machine continuously and autonomously warns before a failure occurs – without requiring data interpretation by experts.
Wide range of sensors (vibration, temperature, pressure, humidity). Wired or wireless connection – standard 3-wire M12 cable, range up to 20 m (wired) or 10 m (IO-Link Wireless).
Local data recording from 50 ms, retention up to 5 years, Micro SD card up to 128 GB. CSV export, REST API, MQTT – integration with Grafana, databases and higher-level systems.
The AI algorithm learns the normal operating profile of the machine. Live Prediction compares each measurement with the pattern and immediately flags deviations – without analysts or specialised personnel.
Real-time browser-based visualisation. Trends, history, alarms. Automatic SMS and e-mail notifications – the right person is informed first.
Measurable parameters
Compatible with all IO-Link sensors regardless of manufacturer. Automatic device detection and visualisation generation from IODD files.
Monitored machines: bearings, gearboxes, motors, fans, pumps, linear drives, conveyors, spindles, presses, elevators, electro-spindles.
Connectivity options
Standard unshielded 3-wire cable, M5/M8/M12 connectors, range up to 20 m. Integration with Profinet, EtherNet/IP, CC-Link, Modbus TCP, REST API, MQTT.
2.4 GHz ISM, range up to 10 m, up to 40 devices/master, BER 10⁻⁹. Cycle time 5 ms/1B. Ideal for moving parts and tools on robots.
CSV export
REST API
MQTT
Grafana
Cloud / On-premise Local DBArtificial intelligence
Machine learning algorithms eliminate the need for manual data analysis. The system distinguishes normal deviations from real threats on its own – without analysts.
The system records data from a normally operating machine for a selected number of seconds or minutes. The operator clicks a single button.
The algorithm learns the multidimensional normal operating profile – taking all measured parameters into account simultaneously. Training takes only a few seconds.
Each new measurement is compared with the model. The machine receives a status of OK or ANOMALY along with the deviation margin and ratio.
Anomaly detection triggers automatic SMS and e-mail notifications to the appropriate people – no one needs to watch screens.
Data & visualisation
Data from MachineMonitor is displayed on production dashboards, stored in databases and sent as alerts – all automatically, without staff intervention.
Continuous recording of the anomaly margin makes it possible to detect slowly growing changes before they become a failure. Red zone = threshold exceeded – immediate alert.
Continuous vibration velocity measurement on all three axes. Automatic A/B/C/D zone classification. Pre-alarm and main alarm threshold configurable per machine.
Local database with up to 5 years of retention. CSV export. Integration with Grafana, MES/ERP systems, cloud or on-premise environments.
CSV REST API MQTT Grafana
MES / ERP
Cloud On-premiseKey features
MachineMonitor is designed with users in mind who have no specialist knowledge of data analysis or vibration diagnostics. The system works independently.
Software pre-installed at the factory. Browser access – no installation on a computer. Automatic IO-Link sensor detection and visualisation generation from IODD files.
Training the AI model is a matter of a single click. The system learns the machine's normal operating profile on its own – without data engineers or analysts.
IO-Link wired and IO-Link Wireless in one system. Free choice of installation topology. Ideal for moving parts, robots and hard-to-reach measurement points.
Detecting an anomaly or exceeding the alarm threshold triggers an immediate alert to the appropriate people. No one needs to monitor screens.
Vibration monitoring compliant with standards. Automatic A/B/C/D zone classification for rotating machines. Configurable pre-alarm and main alarm threshold.
Cloud-independent, data stored locally. No recurring licence fees. Scalable by adding additional Base Unit modules.
Early anomaly detection enables planned maintenance instead of reacting to failures. Direct impact on OEE and maintenance cost indicators.
Central management of multiple MachineMonitor units from a single dashboard. Ideal for modernising existing machine fleets without replacing sensors.
Multi-level user and permission management. Data processed locally – full control over sensitive production information.
Real-world applications
System ready to work with a wide range of machines and processes – from CNC machine tools to packaging lines, hydraulics and electro-spindles.
Case studies
MachineMonitor can operate as a retrofit system — IO-Link sensors are mounted directly on existing machines without interfering with their control systems. This allows monitoring of the process, measuring machine operating time and controlling cycle times in facilities that do not plan to replace their machine fleet.
Project support
We are with you from needs analysis through deployment to post-warranty service. No need to engage external integrators.
Interested in implementation?
Every MachineMonitor implementation starts with an analysis of your needs – sensor selection, feasibility assessment and project pricing. Contact us to discuss the details.
More information is available on desktop or tablet.
