Condition-Based Monitoring

Sound familiar?

  • "Why did that motor burn out? There was no warning."
  • "We're replacing bearings on a schedule. Some are still good, some fail early."
  • "The PLC has all this data. Can't we use it?"

Reacting to failures is expensive. Monitoring conditions and predicting problems saves money.

The Problem

Fixed-interval maintenance means replacing parts that are still good (waste) or missing parts that are about to fail (breakdowns). Your machines have sensors generating data, but it's not being used for maintenance decisions.

What OpexMX Condition Monitoring Does

Collects machine parameter data and triggers alerts when things go wrong so you can fix problems before they cause failures.

What You Can Monitor

  • Temperature - Motors, bearings, electrical components
  • Vibration - Rotating equipment, pumps, fans
  • Pressure - Hydraulic and pneumatic systems
  • Flow - Cooling, lubrication, process flows
  • Current - Motor load and power consumption
  • Runtime - Equipment utilization and cycle counting

Set Thresholds, Get Alerts

Define warning and alarm levels. Get notified when thresholds are breached. Take action before failure occurs.

Connect Your Machines

API endpoint accepts data from PLCs, gateways, and sensors. Works with Modbus, MQTT, OPC UA via middleware.

How Machine Integration Works

PLC/Sensor → Gateway/Middleware → OpexMX API → Dashboard + Alerts

Your gateway reads industrial protocols and posts values to OpexMX:

POST /api/machine-parameter-values
{
  "machineParameterId": "MOTOR_TEMP_1",
  "value": "85",
  "createdAt": "2025-12-04T07:24:20.069Z"
}

Who Uses This?

RoleWhat They Care About
Reliability EngineersEarly warning of degradation
TechniciansInsight into what to check first
PlannersData-driven maintenance intervals

Pro Tips

  • Start with critical, high-impact assets
  • Set thresholds based on OEM recommendations plus experience
  • Validate alerts to minimize false positives
  • Review parameter effectiveness regularly
  • Integrate with shift schedules for alert routing

Integrations

  • Assets: Link parameters to equipment
  • Tickets: Auto-generate from threshold alerts
  • Analytics: Analyze trends and patterns
  • Preventive Maintenance: Adjust intervals based on condition