Predictive maintenance for industrial plants
Your machines talk. Vexron listens.
Vexron reads your existing PLCs, SCADA and sensors, and warns your team when a fault starts, often days to weeks before failure. Downtime is shown in rupees. often days to weeks before failure.
Sample machine, readings and messages, drawn to show how Vexron works.
Vibration 1.7 mm/s, ISO zone A. Running normally.
What is Vexron?
Vexron is predictive maintenance software from Cybs Innovations. It reads vibration, temperature and power data from your existing PLCs, SCADA and sensors, and learns each machine's normal pattern.
When a fault starts to develop, it alerts your team, often days to weeks before failure. It also shows downtime cost in rupees and buffers data during network drops.
A bearing doesn't fail all at once.It warns you for days or weeks first.
- Week 1
The vibration trend changes
VMI-1 sees the bearing signature rise above the machine's normal pattern and sends an SMS or WhatsApp alert that shows the signal behind it.
- Week 1
An engineer checks the alert
The engineer reads the trend and the ISO 10816 / ISO 20816 zone, then confirms or rejects the alert. The models learn from that feedback.
- Week 2
Spares ordered at the normal lead time
There is time to order the bearing through your usual supplier, without rush freight.
- Planned stop
Repair on a planned stop
The bearing is changed during a stop you planned, not in the middle of a night shift.
Plan the repair.
Skip the breakdown.
Think of Vexron as a heart monitor for your critical machines. Instead of waiting for a bearing to fail on a busy night shift, it notices the early change in vibration and temperature, so your team can plan a routine repair.
Sense. Connect. Predict. Act.
No new control system and no middleware. Vexron starts with the data your plant already has and adds a sensor only where a machine needs one.
- 01 · Existing Data First
PLCs, SCADA & Sensors
Vibration, temperature and power data from what you already have. Sensors are added only where a machine needs one.
- 02 · No Middleware
Edge Gateway
Polls Modbus, Siemens S7, OPC-UA and EtherNet/IP, and keeps data through network drops.
- 03 · VMI-1 & Forecasting
AI Fault Detection
VMI-1 separates bearing, alignment, imbalance and looseness faults. Chronos-Bolt and TimesFM forecast the trend.
- 04 · Alerts & Work Orders
Rules That Turn Alerts Into Jobs
SMS or WhatsApp alerts to engineers, and events passed to SAP S/4HANA, MES or MQTT.
Reads from
Sends to
One screen for maintenance and finance.
No jargon. Vexron watches your critical machines around the clock, warns your team when a fault starts to develop, and shows what each stop costs in rupees. Pick a feature to see it working, or watch its short video.
- Plant view · Line 2SampleLive 3D plant view
Automatic Alerts & WhatsApp Messages
When vibration or heat crosses a limit, a rule can send an SMS or WhatsApp message to your technician and pass the event to SAP S/4HANA, your MES or MQTT, so a warning turns into a job.
Maintenance Assistant for Technicians
Your engineers can ask "Why is Pump 4 vibrating?" and get an answer drawn from your own OEM manuals, drawings and repair history.
Energy and carbon
Finds motors running idle, plans loads around time-of-day power tariffs, and keeps Scope 1 and 2 emissions records for exporters who report to EU buyers.
See Vexron at work.
Watch how Vexron collects machine data at the edge, runs AI models on it and warns your team before a failure.
Built for hot, dusty plants.
For plants with hot, dusty, high-vibration machines running around the clock, where one unplanned stop can cost more than the repair.
Readings in the tiles are samples. Each row opens the industry page on the Cybs Innovations site.
Built for the plant floor.
A small edge gateway in the plant polls your PLCs and sensors over Modbus, Siemens S7, OPC-UA or EtherNet/IP. No third-party middleware is needed.
Keeps Data Through Network Drops
When the plant network goes down, the gateway keeps collecting, stores 100,000+ readings locally and sends them in time order once the link is back.
Encryption & Audit Trail
TLS 1.3 between components, OPC-UA with Basic256Sha256 encryption, role-based access and an audit trail of user logins and changes.
Set Up on Site Without Internet
A local web page on the gateway, reachable without internet access, shows gateway health, live PLC tags and the data still waiting in the buffer.
Built to Collect Data
The gateway polls PLCs and sensors for readings. Vexron is not a protection system, so your trip circuits stay as they are.
Not a protection system
Vexron predicts faults. It is not an API 670 machine protection system, so keep your existing protection relays and trip circuits in place.
Sensors only where needed
Vexron is the software layer. Where a critical machine has no vibration sensor, one can be added through the Vexron platform.
Runs on the hardware you choose
Edge Gateway (Vexron Edge OS)
Installed in the plant, usually in an electrical or control panel. It runs on hardware from industrial PCs down to small ESP32 boards and works out vibration metrics at the edge.
AI Service and Dashboard
The AI service runs on a GPU PC or server in the plant, or in the cloud. Your team uses the dashboard as a web app or a Windows desktop app.
Questions plant teams ask.
Pick a question. If yours is not here, ask us directly.
Do we need to buy new sensors?
Not always. Vexron reads data from the PLCs, SCADA tags and sensors you already have, wherever that data can be reached. Where a critical machine has no vibration sensor, one can be added through the Vexron platform. Vexron is the software layer. We are not a sensor manufacturer.
Which PLCs and protocols are supported?
Vexron connects to Modbus TCP and RTU (RS-485), Siemens S7-300, S7-400, S7-1200 and S7-1500, OPC-UA (with encryption), and Rockwell Allen-Bradley ControlLogix and CompactLogix over EtherNet/IP. No third-party middleware is needed.
How early does Vexron warn before a failure?
It depends on the fault and how fast it develops. Mechanical problems such as bearing wear, misalignment and imbalance usually show a rising signature days to weeks before failure. VMI-1 flags that trend early, so the repair can go on a planned stop.
Is this predictive or preventive maintenance?
Predictive. Preventive maintenance services a machine on a fixed schedule. Predictive maintenance watches the machine's actual condition and plans work when the data shows a fault developing. Most plants keep preventive schedules for low-cost parts and add Vexron on the critical machines where a failure is expensive.
What happens when the plant network goes down?
The edge gateway keeps collecting. It stores readings in a local buffer that holds 100,000+ records, then sends them to the central system in time order once the connection is back.
Is Vexron a machine protection system?
No. Vexron monitors machines and predicts faults. It is not an API 670 machinery protection system, so keep your existing protection relays and trip circuits in place.
Can we start with just a few machines?
Yes, and we recommend it. Start with the handful of machines where an unplanned stop really hurts, prove the alerts against a baseline, then expand.
How is Vexron priced?
There is no fixed list price. We quote per plant configuration after a short assessment of your machines, your existing data sources and any sensors you need to add.
Is there a live demo?
Yes. The demo at cybsinnovations.com/vexron lets you try the plant dashboard with sample sensor data, the AI forecasting service and the edge gateway's field console.
Do we need to buy new sensors?
Not always. Vexron reads data from the PLCs, SCADA tags and sensors you already have, wherever that data can be reached. Where a critical machine has no vibration sensor, one can be added through the Vexron platform. Vexron is the software layer. We are not a sensor manufacturer.
Not here? Ask us directly.
Start with a few machines.
Start with the few machines where an unplanned stop really hurts. Prove the alerts against a baseline, then expand.
How pricing works
There is no fixed list price. Cost depends on how many machines you monitor, which data sources you already have and how many sensors you need to add, so we quote per plant configuration after a short assessment. Most plants start with a handful of critical machines and expand once the alerts have proved useful.
- Induced-draft cooling tower1.20 mm/sZONE A
- Boiler feed pump and motor1.74 mm/sZONE A
- Blast furnace A3.85 mm/sZONE C
- Refractory rotary kiln2.21 mm/sZONE A
Learn more before you decide
Free guides and tools on the Cybs Innovations site.
Stop guessing. Start listening.
Stop guessing when machines will fail. Try the live demo with sample plant data, or ask us for a quote.