Failure Mode Detection
Use Cases
Four failure modes Gearcadence detects before they cost you a shift. Each with a specific frequency signature and typical advance warning window.
4–21d
Typical advance warning range
Documented failure signatures
What we detect — and how
CNC Turning / Machining Center
Failure mode
Spindle bearing outer race defect
Lead time
6–14 days advance warning
Signal
BPFO frequency at 4.1× shaft speed
Stamping Press
Failure mode
Eccentric bearing wear — slide misalignment
Lead time
4–10 days advance warning
Signal
Impulse energy rise at press TDC
Gearbox / Reducer
Failure mode
Gear tooth pitting, mesh irregularity
Lead time
7–21 days advance warning
Signal
GMF sideband growth in FFT
Hydraulic Power Unit
Failure mode
Pump cavitation and valve seat erosion
Lead time
3–7 days advance warning
Signal
Ultrasonic emission + pressure ripple correlation
Downtime vs. planned maintenance
An unplanned failure costs 5–8× more than a planned one. Every time.
4–8 hrs
Typical unplanned downtime per failure event in discrete manufacturing — including diagnosis, parts sourcing, and restart
45–90 min
Planned maintenance window for the same repair when executed during a scheduled window with parts on hand
2–4×
Typical emergency parts premium when ordered on next-day freight vs. standard lead-time purchase order
See which of your machines qualify for a pilot.
Tell us your equipment types and we'll confirm detection signatures before you commit.