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Condition diagnostics and monitoring

Summary

Wertek AI's condition diagnostics and monitoring covers two complementary modes over the same asset: on-demand diagnostics (the technician captures vibration, ultrasound, or thermography with the phone, or uploads signal files, and the AI returns a health index, failure modes, severity, and recommended actions) and continuous monitoring (wireless sensors that feed alerts with a full lifecycle, inspection routes with a mobile checklist, and a per-equipment health index). It is the layer that turns the asset's digital identity into maintenance decisions.

The problem it solves

Traditional condition analysis demands expensive instruments, scarce analysts, and reports that arrive weeks after the measurement. Meanwhile, unplanned downtime keeps happening between visits from the specialist. And typical continuous-monitoring systems produce threshold dashboards that fill up with repeated alarms nobody attends to. Wertek AI lowers the barrier to entry (the phone and affordable sensors as capture instruments), puts AI-assisted interpretation in the same flow, and treats each alert as an incident with a history — onset, escalation, and recovery — instead of an endless list of notices.

What it does — on-demand diagnostics

  • Capture from the phone: a guided flow in the mobile app — scan the asset (QR/NFC), choose the signal type, capture, and send for analysis. Supported ultrasound applications: bearings, steam traps, partial discharge, and leaks.
  • Vibration signal upload: upload measurements and signal files (audio/waveform and accelerometer data) from the web ("Upload") or the app, associated with the asset and the measurement point.
  • AI analysis: the platform returns a health index, probable failure modes, severity, and recommended actions per measurement.
  • Bearing analysis: a catalog with more than 30 common bearings and a failure-frequency calculator (BPFO, BPFI, BSF, FTF) with markers over the FFT spectrum and motor-speed presets by number of poles.
  • Pneumatic leak detection by ultrasound: a leak estimator, audio capture, and leak surveys from the app, with a list of leaks found on web and mobile ("Leaks").
  • Thermography: upload of thermal images with capture parameters (emissivity with presets for more than 25 materials, reflected temperature, distance, humidity). The Vision AI advanced thermal analysis module is available on the Enterprise plan.
  • Instrument catalog: more than 75 ultrasound, vibration, and thermography instruments pre-loaded (SDT, UE Systems, Fluke, SKF, FLIR, among others) to document what the measurement was taken with; you can also register your own instruments.

What it does — continuous monitoring

  • Wireless sensors: production integration with Banner vibration and temperature sensors (QM30VT3) via the Banner DXM gateway, with sensor auto-discovery (they connect and appear on the platform to be assigned to measurement points), an ISO 10816-based health index, and an alarm engine.
  • Inspection routes (CBM): route creation, execution with a checklist from the mobile app, execution history, and scheduling from the web (the "Routes" section of the maintenance module).
  • Alerts with a lifecycle: each anomalous condition is handled as an incident with onset, escalation, and recovery states — not as loose notices. A unified alert center on web and mobile, with notification preferences and quiet hours.
  • The alert lands on the equipment it is about: conditions are attributed to the asset the condition is about, not the device that reported it — a power-quality problem detected by the meter lands on the panel that meter measures; what the drive detects about its load lands on the driven motor or blower. A sensor with a dying battery never shows up as a "sick machine": instrument health is recorded on the instrument, never as a fault of the equipment it watches. The provenance (which instrument detected it, which asset it is about) travels with every incident.
  • Protective trips with the cause pointed out: when a drive trips on protection (overcurrent, earth fault, output short), the event stays on the drive — which did its job — and the platform generates a recommendation about the probable cause on the driven equipment (check motor and cable insulation, check mechanical load), so the work order points at what actually needs fixing.
  • Three state axes, not one: the platform distinguishes alarm severity, equipment health, and data quality (good / uncertain / bad), and tells "off" apart from "no data" — stopped equipment does not raise false process alarms, and on assets with connected energy metering, equipment with no data is not shown as healthy.
  • Health and reliability index: operational health, incidents, and reliability views by plant, area, and asset criticality.
  • Equipment-specific monitoring: dedicated panels for variable-frequency drives (VFDs) and compressors, with indicators by equipment type. See also Drive Service Intelligence.
  • Field observations: findings with photo, description, severity, and tags, tied to plant/area, as universal field evidence.

Benefits

  • Less dependence on outside specialists: your own team captures and gets a first interpretation in the same flow; the specialist is reserved for the cases that warrant it.
  • Early detection: continuous monitoring watches between inspections; CBM routes structure what the sensor doesn't cover.
  • Actionable alerts, not noise: the incident lifecycle avoids the alarm fatigue of threshold dashboards.
  • Full traceability: each measurement stays in the asset's history with its capture parameters and instrument, useful for audits and trend analysis.
  • Low cost of entry: phone + affordable sensors instead of dedicated instrumentation as the only path.

Experience on the web platform

In the Diagnostics group of the menu: Measurements (history and detail with spectra and AI results), Upload (signal file upload), Leaks (leaks detected by ultrasound), Timeline (asset events), Observations, and Monitor (live sensor monitoring, when the sensors module is active). Alerts live in Alerts (Overview group) and aggregated health in Event Intelligence and Operational Health (Intelligence group). Sensors are managed in Assets & Equipment → Sensors and routes in Maintenance → Routes.

Experience on the mobile app

The mobile app is the capture instrument: a capture flow by signal type (ultrasound with an external microphone, vibration, thermography from camera/gallery), a leak estimator and leak surveys, a bearing calculator, analysis results with per-measurement detail, inspection route execution with a checklist, the alert center, a notifications inbox, and operational health, incidents, and reliability views. It also includes a quick motor check using the phone's magnetometer (experimental feature). Everything starts by scanning the asset's QR/NFC.

Availability by plan

The on-demand diagnostics functions (measurements, signal upload, leaks) require the Technical plan or higher. Inspection routes and inventory require Monitoring or higher. Continuous monitoring with wireless sensors is contracted as an add-on module per measurement point (based on sampling frequency and connectivity), and Vision AI thermal analysis is an Enterprise plan feature. Individual diagnostics modules (vibration, ultrasound, thermography) also exist for focused needs. Exact amounts and combinations in Plans and pricing.

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