Detect bearing wear and thermal drift early
Presses, mills, forges, and crushers handle the most extreme operating conditions in manufacturing. Bearing wear and thermal drift on a single press can cost six figures in repairs. Haltless detects the tell-tale signatures days before catastrophic failure, so maintenance is planned, not reactionary.
EQUIPMENT WE MONITOR
Four asset families that ship with day-one connector support. No proprietary sensors, no custom integration sprint.
Forging and stamping presses monitored on ram velocity, cylinder pressure, and accumulator charge cycles.
Hot and cold rolling stands tracked through work-roll bearing vibration, mill spring, and motor current.
Drop hammers and crank presses read on tup velocity, anvil shock signatures, and oil temperature.
Jaw and cone crushers, ball and SAG mills tracked through liner-wear-driven amplitude shifts and motor draw.
FAILURE MODES WE CATCH
Three deterministic detectors run in parallel against every reading. These are the failure modes they tend to flag early in this industry.
Velocity drift on roll-stand and crusher bearings flagged days before catastrophic seizure.
EWMA-tracked oil temperature rise finds pump degradation and contamination before the press misses a stroke.
Z-score on motor current under load catches winding faults and contactor degradation hours before the trip.
INDUSTRY CONTEXT
Heavy manufacturing operates under the toughest mechanical conditions: presses cycle at thousands of strokes per shift, mills run continuous-duty, and crushers chew through abrasive feed. A single bearing failure on a finishing stand costs six figures in repairs and a day of mill downtime. Haltless catches the slow-moving signatures days early, opens the work order in your CMMS, and keeps every signoff in a tamper-evident audit trail.
Vibration, thermal, and current signatures flagged before they cascade into a stoppage.
A 40MB Python agent runs on any Linux box next to your existing PLCs. No new sensors required.
Open APIs and pre-built connectors for SAP, Maximo, ServiceNow, and Jira route alerts straight into work orders.
Connect Haltless to your existing PLCs, run a pilot on up to ten machines, and see the explainable health score on your own equipment. No new hardware, no proprietary sensors, no consultants.
