Edge-To-Cloud Technical Architecture

The 4-Step Industrial Intelligence Pipeline

From high-frequency physical sensing to multi-protocol edge ingestion, time-series foundation AI models, and deterministic SCADA actuation.

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STEP 01
Sense
10 kHz vibration velocity, acceleration, surface thermography, and electrical current sensors.
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STEP 02
Connect
Zero-intrusive Modbus RTU/TCP, OPC UA, MQTT, and PLC connectors with offline buffer resilience.
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STEP 03
Predict
Deep learning inference (Chronos, TimesFM) for bearing spalls, rotor imbalance, and RUL estimation.
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STEP 04
Act
Real-time 3D control room digital twin, PLC safety interlocking, and automated WhatsApp/ERP tickets.
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0101 · High-Frequency Telemetry

Physics-grade sensing. Microsecond precision.

High-frequency telemetry captures mechanical stress before heat or audible noise appears. Continuous sampling at 10 kHz.

1
Option A: Plug-and-Play Wireless Pucks
Magnetic mount, 10 kHz triaxial vibration, surface temp, IP68 rated, 5-year battery life. Deployed in minutes without wiring.
2
Option B: Connect Existing Sensors
Integrate directly with your installed 4–20 mA loops, IEPE accelerometers, RTD probes, and current transformers via edge gateways.
⚡4–20 mA Loops
📡IEPE Accelerometers
🌡️RTD PT100 Probes
📶Wireless Pucks
🛡️IP68 Rated
🔋5-Year Battery
Motor-04
DE Bearing
1.82 mm/s
NDE Bearing
0.94 mm/s
Stator
46.5°C
Coupling
2.31 mm/s
Shaft
1,485
Oil Sump
52.1°C
0202 · Edge & Protocol Integration

Talks to every machine.
Guaranteed safe.

Seamless ingestion across all major industrial protocols and PLC platforms with zero disruption to active control logic.

Zero-Disruption Architecture
Read-only access via isolated physical optical taps or dedicated secondary Ethernet ports. Cannot write back to safety-critical PLC logic.
Supported Industrial Protocols & PLCs
Siemens S7, Allen-Bradley, Modbus TCP/RTU, OPC UA, MQTT Sparkplug B, Profinet, BACnet, Ethernet/IP, Fanuc, Beckhoff.
OPTION APlants with Existing Automation

Edge Appliance (On-Premise)

Ruggedized industrial PC installed in your control cabinet. Local inference with 45-day offline buffer.

Docker / KubernetesWindows ServiceOPC-UA ClientMQTT Sparkplug B
OPTION BOlder or Greenfield Facilities

Direct Gateway (Cloud/Hybrid)

Encrypted TLS 1.3 tunnel to your private AWS/Azure/GCP tenant. Zero incoming ports required.

IP68 Wireless PucksDual SIM 4G/5G Uplink45-Day Local SSD BufferDIN Rail Mount
Interactive Industrial Data Bus

Live Protocol Conduit & Telemetry Stream

Edge Bus Synchronized (300 Hz)
Stage 1: Shop Floor Telemetry
Siemens S7-1500 PLC
OPC-UA / PROFINET
Active
Allen-Bradley GuardLogix
EtherNet/IP CIP
Active
Legacy Motor / Modbus RS-485
RTU Holding Regs
Active
Wireless Vibration Puck #08
BLE 5.2 / Sparkplug B
Active
Vexron Edge Nexus
TLS 1.3 Air-Gapped Proxy
Packet Rate:12,480 / sec
Stage 3: Predictive ML Intelligence
V
Vexron Intelligence Hub
ACTIVE INFERENCE
TimesFM 200M Foundation Model
REAL-TIME PIPELINE
Zero-Lag Telemetry Processing
DISPATCH TRIGGER
Auto-Create WhatsApp Work Order
Click to inspect supported protocol drivers:
OPC-UAEnterprise Standard
Sample Rate: Up to 20,000 samples/secLatency: < 8 ms

Encrypted object-oriented industrial standard with native X.509 certificate validation and zero-loss semantic structures.

PLUG-AND-PLAY WITH:
Siemens S7-1200/1500Beckhoff TwinCATIgnition SCADAAVEVA Wonderware
LIVE REGISTER PAYLOAD SYNTAX:ns=2;s=Turbine01.Vibration.Bearing_DE_RMS
01. ZERO WRITE COMMANDS

100% Read-Only Safety

Physical and logical isolation prevents any interference with machine safety interlocks.

02. DUAL-NIC AIR GAP

Air-Gapped & OT Isolated

Plant floor network remains completely separated from corporate IT networks.

03. 45-DAY STORE & FORWARD

45-Day Offline Store-and-Forward

Zero telemetry lost during Internet outages. Local edge buffers sync automatically upon reconnection.

0303 · Predictive AI Models

Foundation models catch anomalies weeks before failure.

Google TimesFM 2.5

Google Research
What it does

Zero-shot time-series foundation model. Predicts bearing degradation curves across multiple horizons without task-specific retraining.

How it works

Ingests raw vibration & temperature waveforms → outputs Remaining Useful Life (RUL) forecasts 7–48 days ahead with confidence intervals.

Telemetry In
Prediction
0404 · Autonomous Operations

Real-time visibility. Instant action. The modern Industrial Operating System.

Interactive workflows (O-Graph), multi-horizon AI forecasting (Chronos), and direct enterprise dispatch (SAP, SMS, WhatsApp).

Interactive Cockpit Preview
vexron-console / workflows
300 Hz Node Cluster Active
Visual Industrial Logic Orchestrator

O-Graph Automation Canvas (n8n / Node-RED Architecture)

Example:
STAGE 1 · TRIGGER
Temperature > 88°C (Critical Limit)
Listens to 10 kHz vibration bursts, Chronos ML probability thresholds, or PLC safety registers.
STAGE 2 · LOGIC / MATHPython 3.13
Python Code Runner: Dynamic Thermal Dissipation Rate
Executes sandboxed NumPy / Fourier transforms to eliminate false alarms and compute root cause.
STAGE 3 · ACTION BUS3 Executed
✓Siemens S7-1500 PLC: Throttle Motor to 15%
✓WhatsApp Dispatch: Urgent Shift Briefing
✓SAP S/4HANA: Create Emergency Work Order
TRIGGER TYPESSensor, ML, Acoustic, Cron
EXECUTION SPEED< 14ms Sub-second Loop
SANDBOXED RUNTIMEPython 3.13 / Node.js
AUDIT FOOTPRINT100% Immutable JSON Log
Platform Architecture

Full-Stack Industrial Operating System

Engineered for mission-critical steel mills, refineries, chemical plants, and heavy manufacturing.

Visual Automation

O-Graph Visual Node Canvas

Drag-and-drop node orchestrator with Purple Triggers, Amber Bifurcations (True/False handles), and Green Multi-System Actions.

Enterprise & Field

20+ IT / OT Connectors Hub

Native Google Workspace (Gmail, Calendar, Sheets, Drive), Slack, Teams, Jira, ServiceNow, Modbus TCP, OPC-UA, and Siemens S7.

a Cybs Product · Make in India

120Hz Sub-Second Physics

Real-time 120 Hz edge streaming with full on-premise data privacy and Zero Unplanned Downtime Guarantee.

WebGL Three.js

3D Spatial Twin & 2D Blueprint

Interactive plant models with camera presets (Angle, Top, Front), dynamic thermal heatmap shading, and 2D floor schematic view.

Chronos & TimesFM

Sensor Forecasting Bands

Dual foundation models generating probabilistic p10/p50/p90 confidence ribbons for forward bearing degradation curves.

PLC Grounded RAG

Prescriptive AI Copilot

Industrial AI grounded in live PLC registers and OEM manuals with 1-click execution of automated setpoint adjustments.

ESP32 & DIN-Rail

Edge Hardware & Gateways

Hardware fleet monitoring of ESP32 Edge Lite pucks, DIN-rail industrial Modbus gateways, and Dual-SIM 4G/5G failover.

Root Cause Attribution

Explainable AI & SHAP RCA

Decomposes spectral signatures into exact mechanical fault frequencies: BPFO, BPFI, BSF, and FTF cage defects.

Energy Intensity

ISO 50001 Sustainability & SEC

Specific Energy Consumption (kWh/tonne) tracking, peak load shaving, and automated compressor unloader waste elimination.

Lubrication Analytics

Acoustic Bearing Ultrasound

High-frequency decibel sound-pressure envelope analysis identifying early friction wear before temperature rise occurs.

Non-Invasive CT

Motor Current Analysis (MCSA)

Stator winding asymmetry and rotor bar broken fault detection non-invasively through standard split-core current sensors.

Air-Gapped Reliability

45-Day Store & Forward Buffer

Onboard SSD cache guarantees 100% zero telemetry loss during plant network dropouts with automatic backlog sync upon reconnection.

Interactive WebApp Sandbox

Test-Drive the Full Vexron Cockpit Live

Experience our interactive 3D digital twins, real-time vibration alarms, AI copilot diagnostics, and OEE telemetry right inside your browser.

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Next Step: Real-World Industry Validation

See how this architecture deploys on real factory machinery

Explore 3D cutaways and operational ROI across steel mills, automotive stamping presses, power turbines, and chemical pumps.

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Ready for Zero Downtime?

Stop guessing when machines will fail.

Connect your facility. Unlock continuous predictive intelligence. Protect your revenue weeks in advance.

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