India · UAE · 12 years of IoT engineering
info@mutechautomation.com·EN
Solutions/Industry 4.0/Predictive Maintenance
MT-I40-04 · Predictive Maintenance

Hear it before it breaks.
11 days earlier, on average.

LIVE·692 assets · 6 prevents YTD · 99.94% uptime

Wireless vibration sensors, MCSA current clamps and edge AI on a Cortex-M7 — fused with PLC process variables to predict failure by name, not just by threshold. We catch bearing faults, broken rotor bars and cavitation weeks before they trip a plant.

What we listen to
Triaxial vibrationMCSA · currentOil debrisProcess PV tapEdge AI · TFLiteISO 10816OPC-UASAP-PM · Maximo · Fiix
Sensoverse · Industry 4.0 — asset health monitor
Sensoverse/Industry 4.0/Automotive plant · Plant 04LIVE · 14:32 IST
SORT: SEVERITY ↓·412 ASSETS · 408 ONLINE
IDASSET · STATEHLTHRULVIB · LAST 7dISO
C-007
Air compressor 7URGENT · schedule replacement
586dD
P-204
Feedwater pump 04bearing freq spike · 2× shaft
6411dC
M-031
AHU drive M-031misalignment · 1× + 2× shaft
7138dB
F-202
ID fan 02imbalance trending up
81—B
G-114
Gearbox 1A—
89—A
P-118
Cooling pump 18—
92—A
P-220
Boost pump 20—
87—A
M-104
Stator-A motor 04—
94—A
Median early warn
11days
MTBF · vs baseline
+23%
Prevents · YTD
6
False positive
2.1%
// 412 rotating assets at one plant. One screen. Sorted by severity.
11d
Median early warning
+23%
MTBF improvement
6
Catastrophic prevents Y1
2.1%
False-positive rate
§01 — What this is

Most predictive-maintenance pitches are cloud dashboards over noisy data. Ours is engineering.

01

Edge AI · not cloud trips

Our anomaly model and RUL estimator run on a Cortex-M7 next to the sensor. Only the metadata — fault name, severity, recommendation — goes up. No LAN saturation, no internet dependency, no waiting on a cloud round-trip to know your bearing is failing.

02

Wireless retrofit · 4-min mount

5-yr battery sensors with magnetic mounts. Drop them on the motor or pump while it's running — no MCC trip, no shaft access, no cabling. Plant stays at full output during install. Critical assets get a PoE variant with 51.2 kHz sample.

03

Fault by name · not threshold

ISO 10816 bands tuned per machine class — not a generic vibration limit. The model flags BPFO, BPFI, BSF, FTF, broken rotor bars, cavitation, slugging by name and points at the FFT line that proves it. Reliability engineers stop arguing with the data.

§01 — Complete stack

End-to-end. Not just a device.

A solution is hardware in the field plus the infrastructure that makes the data useful — secure ingestion, a dashboard your team actually opens, and APIs to whatever runs your business.

L4
Apps & Dashboard
Role
Visualisation, role-based views, reports, alerts, ticketing
Tech
Sensoverse Web · Mobile · Open API · Webhooks
L3
Application Server
Role
Business logic, rules engine, analytics, ML, multi-tenant data isolation
Tech
Sensoverse Cloud · on-prem · hybrid · TimescaleDB · Postgres · ClickHouse
L2
IoT / Network Server
Role
Device management, message routing, decoding, OTA, downlinks
Tech
ChirpStack · MQTT broker · LwM2M · OPC-UA gateway
L1
Field — Predictive Maintenance (MT-I40-04)
Role
Sensors, actuators, edge compute, gateways
Tech
Modbus · OPC-UA · MQTT · Zigbee 3.0

// Deployments can run on Sensoverse Cloud, on your VPC, fully on-prem, or hybrid. Data residency: India (Mumbai) and UAE (Dubai) regions available.

§03 — What we monitor

Eight asset classes. One model family.

Pick a row — see what we listen to.

01 / 08 · Bearings & shafts

Triaxial vibration + temp · 25.6 kHz

ISO 10816-tuned bands per machine class. Edge AI detects inner-race, outer-race, ball-spin and cage frequencies — and flags them by name, not by generic threshold.

±16 g triaxial accel
25.6 kHz sample · FFT on edge
Inner / outer / ball / cage detection
5-yr battery (Zigbee)
§04 — Why not the others

Handheld rounds catch faults after they happen.

Most plants still run quarterly vibration rounds with a handheld analyser. Cloud-only services moved the data online but kept the same lag. Edge AI on a wireless sensor closes the loop — continuous monitoring, no cloud dependency, fault by name.

The old way

Handheld rounds + cloud

CoverageQuarterly · 1 reading
LatencyUp to 90 days
Early warningDays · sometimes hours
ComputeCloud round-trip
LAN loadHigh · raw waveforms
Fault namingGeneric threshold alarm
MuTech · edge AI

Continuous · on-device

Coverage24/7 · every revolution
Latency<1 s edge alert
Early warning11 days median
ComputeCortex-M7 on sensor
LAN loadMetadata only · <10 kB/day
Fault namingBPFO · BRB · cavitation · …
§03 — Dashboard & analytics

What your team sees.

Live KPIs, drill-downs, scheduled reports, and role-based access — out of the box. Custom widgets and white-label themes available.

Assets monitored
412
Pumps · motors · gearboxes
Anomalies (24h)
9
All triaged
OEE (line 3)
78%
Yest. 81%
MTBF gain
+23%
Pre-deploy baseline
Insights produced
  • 01ISO 10816 vibration severity bands per asset
  • 02Predictive maintenance scoring + RUL estimate
  • 03OEE breakdown: availability / performance / quality
  • 04Root-cause walks linking events across the line
  • 05Spares forecast tied to anomaly trend
Alerts & events
  • Vibration band C/D
  • Bearing temp > limit
  • Anomaly score > 0.85
// Channels: SMS · Email · WhatsApp · webhook · ITSM
§04 — Security & infrastructure

Built for plant & campus IT.

Industrial sites have non-negotiables — segmentation, audit trails, and the ability to run when the WAN drops. We design for that on day one.

Transport
TLS 1.3 device → cloud. Mutual auth via X.509 or pre-shared keys. LoRaWAN 1.0.4 / NB-IoT carrier-grade encryption end-to-end.
Identity
Per-device certificates, automated rotation. RBAC + SSO (SAML / OIDC). Audit log of every operator action.
Data
AES-256 at rest. Tenant isolation at row + schema level. Configurable retention, GDPR / DPDP-aware exports and deletes.
OTA &amp; ops
Signed firmware, staged rollouts, rollback. 24×7 monitoring, on-call, runbooks. SLA up to 99.95%.
Deploy
Sensoverse Cloud (default), private VPC, on-prem (air-gapped), or hybrid. Mumbai & Dubai regions.
Compliance
ISO 27001 controls, SOC 2 Type II in progress. Vendor / penetration test reports under NDA.
§05 — Use cases

How customers use it.

Real applications, real outcomes. Every site is engineered — these are reference deployments to anchor a conversation.

ManufacturingUSE-01
Scenario
Automotive plant — vibration + temp on 412 rotating assets
Outcome
MTBF +23% on critical pumps; 2 catastrophic-failure prevents in Y1
ProcessUSE-02
Scenario
Cement plant kiln drive monitoring
Outcome
Bearing failure predicted 11 days ahead; planned shutdown
UtilityUSE-03
Scenario
Pump-station network — vibration + flow correlation
Outcome
Cavitation events detected and root-caused
§07 — Devices used

What ships in the box.

Vibration sensors, MCSA clamps, oil-debris probes, edge AI gateway, PLC tap and the Sensoverse platform. Sized to your plant — talk to engineering for a one-call scoping.

Model
Role
Key specs / note
MT-VIB-01
Wireless vibration + temp sensor
Triaxial ±16 g · 25.6 kHzFFT on edge · ISO 10816 bandsZigbee 3.0 · 5-yr battery

Mounts on motor / pump / fan in under 4 minutes. Magnetic or threaded stud. IP67.

MT-VIB-PoE
Wired vibration sensor
Triaxial ±16 g · 51.2 kHzModbus TCP + RTUPoE 802.3af · IP67

For high-frequency critical assets — gearboxes, high-speed compressors, BFW pumps.

MT-CURR-3P
MCSA current sensor
Split-core CTs (5–4000 A)Per-phase spectrum 0–10 kHzModbus + onboard FFT

Clamps on motor leads at the MCC. No shaft access. Detects broken bars + stator faults.

MT-OIL-DBR
In-line oil debris sensor
Ferrous + non-ferrous countViscosity + tempModbus RTU · DN15–DN50

Inline on gearbox oil loop. Pairs with vibration for true gear-tooth wear severity.

MT-EDGE-AI
Edge AI gateway
Cortex-M7 + TFLite MicroAnomaly + RUL model on deviceLocal 30-day buffer

Runs the model on the gateway — no cloud round trip, no LAN saturation, works offline.

MT-PLC-TAP
PLC / SCADA tap
Modbus · EtherNet/IP · Profinet · OPC-UARead-only by defaultISA-95 mapping

Pulls process variables (flow, pressure, speed) to fuse with vibration. No PLC firmware change.

MT-GW-MESH
Wireless mesh gateway
Zigbee 3.0 + LoRaPoE + 4G fallbackUp to 250 wireless sensors

One per ~250 monitored assets. Forms the mesh that carries spectra + RUL metadata to cloud.

Sensoverse — Industry 4.0
Asset health platform
Fleet view + per-asset deep-diveWork-order to CMMSOEE + MES hooks

Operator console for reliability team. Drills from fleet → asset → spectrum → recommended action.

§08 — Specifications

Engineering data.

// Indicative — full datasheet on request.

Vibration sensorTriaxial ±16 g · 25.6 kHz wireless · 51.2 kHz PoE
Frequency rangeDC–10 kHz typical · 25 kHz on PoE variant
Models on edgeAnomaly · RUL · ISO 10816 zone · bearing fault family
Current sensing3-phase CT 5–4000 A · MCSA per-phase 0–10 kHz
Oil debrisFerrous + non-ferrous count · viscosity · temp
CommsZigbee 3.0 · LoRa · BLE 5 · Modbus RTU / TCP · OPC-UA
Battery5-yr typical · 10-yr (low-rate) · field-replaceable
MountM6 stud · magnetic · epoxy · adhesive (per asset)
Operating temp−40 °C → +85 °C (sensor) · 0 °C → +60 °C (gateway)
EnclosureIP67 sensor · IP54 gateway · ATEX option (Zone 2)
Edge computeCortex-M7 + TFLite Micro · 30-day local buffer
IntegrationOPC-UA · MQTT · REST · CMMS connector (SAP, Maximo, Fiix)
StandardsISO 10816 · ISO 17359 · ISA-95 mapping
CertificationsCE · BIS · FCC · ATEX Zone 2 variant
§09 — Deployments

Where it's running, right now.

Manufacturing412 assets
since 2023

Automotive manufacturer · Central India

Automotive plant · press / paint / assembly
412
assets monitored

MTBF +23% on critical pumps and fans. Two catastrophic-failure prevents in Y1 — feedwater pump and AHU drive flagged 11 days and 38 days ahead.

ProcessKiln drives
since 2024

Cement plant · Rajasthan

Cement plant · kiln + cooler + raw mill
184
assets monitored

Kiln-drive bearing failure predicted 11 days early — planned shutdown saved ~₹3.4 Cr in lost output and emergency-fabrication cost.

UtilityPumps
since 2024

Municipal Corporation · Pump network

Water distribution · 14 pump stations
96
assets monitored

Cavitation events root-caused on three stations; pump replacement schedule rebuilt around real wear, not service hours. NRW dropped a further 1.4%.

§10 — Pilot

Instrument 20 critical assets in 2 weeks.

Send an asset list and we'll come back with a sensor map, sample reports and a fixed-price quote within 48 hours. Pilots run for 90 days — at the end we hand you a list of named faults and the dates we predicted them.

Commercial — how we sell it
MOQ20 sensors / pilot
Lead time2–3 weeks
Warranty2 years on hardware
Made inIndore, India
EngineeringOn-site install + model tuning
Pilot20 critical assets · 90 days