Platform Architecture
The Platform
From raw sensor data to a ranked maintenance action — the full signal processing and alerting stack built for plant floor reality.
Layer 1
Sensor & Protocol Connectivity
OPC-UA, Modbus TCP, MQTT, and direct REST API — Gearcadence speaks the protocols already on your floor without middleware rewrites. Works with existing sensors on your equipment or new clip-on hardware we specify. No proprietary sensor required.
Layer 2
Continuous Anomaly Detection
Time-series ML models trained per machine class. Vibration frequency decomposition, envelope analysis, statistical process control — running continuously, not on a 5-minute poll. No manual threshold-setting. No spreadsheet of alarm setpoints to maintain.
Layer 3
Prioritised Alert & Work Order Engine
Anomalies scored by severity, time-to-failure confidence, and production criticality. Not every deviation is a fire drill. Gearcadence ranks your maintenance queue so the highest-risk machine gets the first wrench. Outputs to CMMS, ERP, email, or SMS — wherever your maintenance team works.
Gearcadence is not a CMMS and is not a replacement for one. It is the detection layer that tells your CMMS what work to schedule — before the machine stops telling you itself.
