PdM sensor & signal selection matrix

{ "Title": "PdM sensor & signal selection matrix", "IntroductionHtml": "

Purpose: Capture the minimal, consistent information needed to turn equipment failure modes into dependable PdM signals. Use this form during pilot design, sensor selection, and integration planning so teams have a single source of truth for sensor placement, sampling, preprocessing, tag names, and validation checks.

How to use: Fill one record per measurement (for example: drive-end vibration RMS, bearing temperature, spindle current). Be specific about location and mounting. Provide an expected data rate and validation checks so analytics and IT teams can size pipelines and alerts. Save the mapping; the platform will store it for rollouts, exports, and reporting.

", "SubmitLabel": "Save mapping", "SuccessMessage": "Mapping saved. You can create another mapping or export saved mappings from your domain.", "DataType": "PdMSensorSignalMapping", "SchemaVersion": "1.0", "Fields": [ {"Key": "asset_id", "FieldType": "text", "Label": "Asset ID", "HelpText": "Unique identifier from CMMS or asset register.", "Required": true}, {"Key": "asset_name", "FieldType": "text", "Label": "Asset name / description", "HelpText": "Short human-friendly name (e.g., 'Line 3 A/C Compressor').", "Required": true}, {"Key": "location", "FieldType": "text", "Label": "Location / area", "HelpText": "Plant, cell or bay where the asset is installed.", "Required": false}, {"Key": "criticality", "FieldType": "select", "Label": "Operational criticality", "HelpText": "How critical is this asset to operations? Helps prioritize sensors and sampling frequency.", "Required": true, "Options": [{"Value": "high", "Label": "High"}, {"Value": "medium", "Label": "Medium"}, {"Value": "low", "Label": "Low"}]}, {"Key": "failure_mode", "FieldType": "textarea", "Label": "Primary failure mode(s) to detect", "HelpText": "Describe the failure(s) this signal should detect (e.g., bearing wear, misalignment, electrical insulation breakdown).", "Required": true}, {"Key": "decision_use", "FieldType": "select", "Label": "Primary decision/use case", "HelpText": "What decision will this signal support? (This affects fidelity, latency, and retention.)", "Required": true, "Options": [{"Value": "pdm", "Label": "Predictive maintenance (PdM)"}, {"Value": "oee", "Label": "OEE / availability"}, {"Value": "downtime_root_cause", "Label": "Downtime RCA"}, {"Value": "quality", "Label": "Quality control"}, {"Value": "other", "Label": "Other"}]}, {"Key": "measurement", "FieldType": "select", "Label": "Measurement type / signal", "HelpText": "Choose the physical or logical signal (vibration, temperature, pressure, current, speed, position, etc.).", "Required": true, "Options": [{"Value": "vibration", "Label": "Vibration"}, {"Value": "temp", "Label": "Temperature"}, {"Value": "pressure", "Label": "Pressure"}, {"Value": "current", "Label": "Current"}, {"Value": "voltage", "Label": "Voltage"}, {"Value": "flow", "Label": "Flow"}, {"Value": "position", "Label": "Position / displacement"}, {"Value": "other", "Label": "Other"}]}, {"Key": "recommended_sensor", "FieldType": "text", "Label": "Recommended sensor type / technology", "HelpText": "E.g., ICP accelerometer (piezoelectric), RTD/thermocouple, Hall-effect current sensor, ultrasonic air-leak sensor, encoder.", "Required": true}, {"Key": "sensor_model", "FieldType": "text", "Label": "Suggested sensor model / vendor", "HelpText": "If known, add model number or vendor to simplify procurement and calibration.", "Required": false}, {"Key": "mounting_guidance", "FieldType": "textarea", "Label": "Mounting guidance and orientation", "HelpText": "Be specific: exact location on asset, mounting surface prep, required stud or adhesive, cable routing, environmental protection (IP rating).", "Required": true}, {"Key": "sampling_rate_hz", "FieldType": "number", "Label": "Suggested sampling rate (Hz)", "HelpText": "Give a numeric suggestion and rationale (e.g., Nyquist margin for expected fault frequencies). For event-based signals, note trigger conditions.", "Required": true}, {"Key": "buffer_seconds", "FieldType": "number", "Label": "Local buffer / retention seconds", "HelpText": "How much data to buffer at the edge before forwarding (helps with connectivity issues).", "Required": false}, {"Key": "preprocessing", "FieldType": "select", "Label": "Recommended preprocessing", "HelpText": "Choose the minimal preprocessing needed before transmission or edge analytics.", "Required": true, "Options": [{"Value": "raw", "Label": "Raw samples (no preprocessing)"}, {"Value": "filtered", "Label": "Filtered (bandpass/highpass)"}, {"Value": "fft", "Label": "FFT / spectral"}, {"Value": "rms", "Label": "RMS / envelope"}, {"Value": "moving_avg", "Label": "Moving average / decimation"}, {"Value": "other", "Label": "Other"}]}, {"Key": "units", "FieldType": "text", "Label": "Units", "HelpText": "Specify physical units (m/s^2, °C, psi, A, V, mm, counts, etc.).", "Required": true}, {"Key": "tag_name", "FieldType": "text", "Label": "Proposed tag / signal name", "HelpText": "Follow your naming standard. If you have no standard, use: ... (e.g., CMP01.VIB.DE.RMS). This field helps mapping into MES/SCADA and analytics.", "Required": true}, {"Key": "expected_data_rate_kb_per_day", "FieldType": "number", "Label": "Estimated data rate (KB/day)", "HelpText": "Rough estimate to help IT size storage and network; include metadata and overhead. If unknown, leave blank.", "Required": false}, {"Key": "calibration_schedule", "FieldType": "text", "Label": "Calibration / verification schedule", "HelpText": "Recommended interval and responsible role for calibration or verification.", "Required": false}, {"Key": "validation_checks", "FieldType": "textarea", "Label": "Validation and health checks", "HelpText": "What automated or manual checks will confirm signal health? (e.g., expected range, noise floor checks, timestamp continuity, unit mismatches).", "Required": true}, {"Key": "health_alerting", "FieldType": "yesno", "Label": "Enable health alerting", "HelpText": "Should the system generate alerts when validation checks fail?", "Required": true}, {"Key": "integration_target", "FieldType": "select", "Label": "Primary integration target", "HelpText": "Where will this signal be consumed first? Helps plan mapping and security.", "Required": true, "Options": [{"Value": "scada", "Label": "SCADA"}, {"Value": "mes", "Label": "MES"}, {"Value": "cloud_analytics", "Label": "Cloud analytics / data lake"}, {"Value": "edge_analytics", "Label": "Edge analytics"}, {"Value": "other", "Label": "Other"}]}, {"Key": "security_constraints", "FieldType": "textarea", "Label": "Security / compliance constraints", "HelpText": "Notes about network segmentation, encryption, or compliance boundaries (e.g., do not send PII off-site).", "Required": false}, {"Key": "pilot_ready", "FieldType": "yesno", "Label": "Pilot-ready?", "HelpText": "Is the mapping ready for a pilot installation?", "Required": true}, {"Key": "priority", "FieldType": "scale", "Label": "Priority (1 low - 5 high)", "HelpText": "Helps rollouts prioritize which mappings to deploy first.", "Required": true, "ValueOptions": {"Min": 1, "Max": 5}}, {"Key": "notes", "FieldType": "textarea", "Label": "Additional notes / comments", "HelpText": "Anything else the integrator, reliability engineer, or data scientist should know.", "Required": false} ] }