Everything PulseVault does

The sensor unit

A single compact unit fits to the machine and carries every channel it measures. It mounts externally — magnetically, bracketed or cable-tied — and its probes clip to the points that matter. Nothing is wired into the control panel.

The unit reports roughly every 60 seconds over Wi-Fi. That interval is configurable remotely, so a machine that needs closer watching can be sampled harder without anyone visiting the floor. Between reports it keeps counting pulses continuously, so throughput is totalled rather than sampled.

• Two independent thermocouple inputs for process temperature
• A pulse input for line speed, cycles and output counting
• Three-axis vibration sensing with event detection
• Ambient temperature, humidity, barometric pressure and light level
• Set up from a phone browser — no app required to commission a unit

Machines, sensors and channels

Three words are used precisely throughout the portal. A machine is a piece of equipment — Extruder 06. A sensor is a unit fitted to it. A channel is one thing being measured — Zone 3, or line speed.

Limits are set per channel, because Zone 3 and Zone 5 are not the same thing and should never share a threshold. A machine can carry several sensors, and each sensor can report many channels, so a large machine is described accurately rather than averaged into a single number.

Limits and alerts

Every channel takes four thresholds: warning and critical, upper and lower. A zone that runs too cold is as much a problem as one that runs too hot, and both are caught.

One excursion raises one alert, and will not re-raise while it is unresolved. This matters more than it sounds — a long drift on a busy machine would otherwise generate a hundred messages and train everyone to ignore them. When the channel returns inside its limits, a resolution notice closes the loop.

Notification channels

Alerts go out by WhatsApp, email, in-app notification and phone push. You choose which people receive which severity, and escalation policies move an unacknowledged alert up the hierarchy on a delay you set.

• Reply ACK on WhatsApp to acknowledge and stop escalation
• Reply SNOOZE 1h through 24h to silence a sensor temporarily
• Reply STOP to unsubscribe from alerts entirely
• Every acknowledgement is recorded against the person who made it, and where they made it

Product recipes

Different products run at different temperatures. Rather than editing thresholds by hand every changeover, save a named set of limits per product per machine and switch the line over in one action.

The active product is also attached to the analytics, so runtime and speed figures are reported in the context of what was actually being made.

Shifts, breaks and maintenance windows

Alerts respect how the plant actually runs. Scheduled maintenance windows suppress alerts for a machine that is deliberately down. Shift boundaries and breaks stop a cooling machine from waking somebody at 6am.

This is the difference between a system that people keep and one they mute after a fortnight.

Analytics

The same readings that raise alarms build a record of how the plant runs.

• Runtime and downtime, per machine and per day
• Actual speed against the target for the product being run
• OEE — availability and performance, with shift and product context
• Production by shift, so patterns between crews become visible

Reports and export

Scheduled email summaries go out daily, weekly or monthly, with configurable sections so the report says what your plant cares about. Any channel over any period can be exported as CSV or JSON — the data is yours, and it leaves in a format a spreadsheet or a data team can use.

Over-the-air firmware updates

Units are updated remotely, without a site visit and without taking a machine out of service. Your administrator approves which firmware version the fleet is allowed to run, so updates happen on your schedule rather than ours.

Users, roles and audit

Five roles, from read-only viewer up to administrator — including a notification-only contact role for people who need the alerts but will never log in. Every configuration change is written to an audit trail, so who changed a limit and when is never in question.

Illustrative data

Integration

API keys and endpoints let an existing MES or ERP read machine and product state, or switch the active product automatically when a job changes. If your systems already know what is being made, PulseVault does not need to be told twice.