Ultron — Predict Failure Before it Happens

PLANT HEALTH

Gateway IP updatedrack-gw-01: 152.56.10.114 to 192.168.30.11

98/100

+8.0 pts

ASSET DISTRIBUTION

CRITICAL0

AT RISK0

NEUTRAL0

HEALTHY7

FINDINGS6 open

Prioritized engineering events

SSE Faulty R1MEDIUM

High vibration. Inspect bearing and check alignment.

Motor DE Vibration 3.15 mm/s RMS on 1.178% CONF.

SSE Faulty R1MEDIUM

High vibration. Inspect bearing and check alignment.

Motor NDE Vibration 2.85 mm/s RMS on 2.178% CONF.

SSE Faulty R1MEDIUM

Motor Power threshold exceeded. Review channel trend and confirm the threshold.

Motor Power 27.0 kW on 5.178% CONF.

SSE Faulty R1MEDIUM

High vibration. Inspect bearing and check alignment.

Gearbox Output Vibration 2.95 mm/s RMS on 7.178% CONF.

SSE Faulty R2MEDIUM

Pressure out of range. Verify valve position and line pressure.

Melt Pressure 9.95 MPa on 2.178% CONF.

RACK-01-SIMHIGH

Speed deviation. Review channel trend and confirm the threshold.

Speed Channel Configuration 1824 rpm on 5.192% CONF.

BEFORE ITHAPPENS

PREDICTIVE MAINTENANCEREIMAGINED

PREDICT FAILURE. BEFORE IT HAPPENS.

Ultron console plant overview — 3D plant map, plant health 98 of 100, findings feed and health score history

One screen for the whole plantLive · 98/100 · 6 open findings

THREE LAYERS. ONE EARLIER WARNING.

What is happening now?

Diagnosis

Bring vibration, temperature, current, pressure and other signals into one view of machine health. Identify deviations, anomalies and recurring fault patterns as they develop.

Live · Bearing 82°C = abnormal vs this machine's normal

What is likely to happen next?

Prognosis

Combine historical and live data to understand how a fault is developing. Identify the component at risk, assess urgency and estimate a failure window where the data supports it.

Forecast · Window 19–26 days, spread shown

What are individual signals missing?

Advanced Prognosis

Detect changes in the relationships between load, vibration, current and temperature. Surface early signs of deterioration even when individual channels still read as normal.

Multivariable · Healthy-vs-observed divergence

FROM MACHINE DATA. TO MAINTENANCE DECISIONS.

0 msSensor head

Vibration, temperature, current, speed — off the machine itself.

IEPE · 4–20MA · PT100

+8 msEdge microcontroller

Samples, timestamps and publishes over TLS.

ESP32-S3 · 10 HZ · QOS 1

+21 msMQTT broker

One topic per channel, persistent session.

RESAMPLE · FLAG · MERGE

+180 msIngest & scoring

Normalise, quality-flag, score, forecast.

1 GRID · 10 HZ · AUDITABLE

+310 msConsole

Repaints in place — the same push you can subscribe to.

WEBSOCKET · NEVER POLLED

End to end 0 msBudget 1000 ms · always inside

Machine-agnostic by design

START WITH ONE MACHINE. SCALE ACROSS THE PLANT.

Cement works at sunset — one of the industries Ultron protects — **Any factory.**Cement · Steel · Food · Chemicals · Power · Textiles · Auto

Reliability team reviewing an Ultron condition report together — **Any team.**Engineers · Planners · Directors — one shared truth

Sensors→PLC / DCS→SCADA / Historian→Ultron · Predictive Intelligence

Ultron sits above or alongside existing automation as an intelligence layer — no redesign of the underlying control infrastructure.

Cement & mineralsSteel & metalsFood & beverageChemicals & pharmaPower & utilitiesTextiles & paperAutomotiveWarehousing