Tool

PdM sensor & signal selection matrix

An interactive mapping form and template to capture asset failure modes, recommended sensors, mounting guidance, sampling and preprocessing choices, tag naming, and estimated data needs. Standardizes PdM selections, saves mappings for pilots and rollouts, and stores results for integration with MES/SCADA and analytics.

Interactive Tool

PdM sensor & signal selection matrix

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.

Unique identifier from CMMS or asset register.
Short human-friendly name (e.g., 'Line 3 A/C Compressor').
Plant, cell or bay where the asset is installed.
How critical is this asset to operations? Helps prioritize sensors and sampling frequency.
Describe the failure(s) this signal should detect (e.g., bearing wear, misalignment, electrical insulation breakdown).
What decision will this signal support? (This affects fidelity, latency, and retention.)
Choose the physical or logical signal (vibration, temperature, pressure, current, speed, position, etc.).
E.g., ICP accelerometer (piezoelectric), RTD/thermocouple, Hall-effect current sensor, ultrasonic air-leak sensor, encoder.
If known, add model number or vendor to simplify procurement and calibration.
Be specific: exact location on asset, mounting surface prep, required stud or adhesive, cable routing, environmental protection (IP rating).
Give a numeric suggestion and rationale (e.g., Nyquist margin for expected fault frequencies). For event-based signals, note trigger conditions.
How much data to buffer at the edge before forwarding (helps with connectivity issues).
Choose the minimal preprocessing needed before transmission or edge analytics.
Specify physical units (m/s^2, °C, psi, A, V, mm, counts, etc.).
Follow your naming standard. If you have no standard, use: <AssetID>.<Measurement>.<Location>.<SignalType> (e.g., CMP01.VIB.DE.RMS). This field helps mapping into MES/SCADA and analytics.
Rough estimate to help IT size storage and network; include metadata and overhead. If unknown, leave blank.
Recommended interval and responsible role for calibration or verification.
What automated or manual checks will confirm signal health? (e.g., expected range, noise floor checks, timestamp continuity, unit mismatches).
Should the system generate alerts when validation checks fail?
Where will this signal be consumed first? Helps plan mapping and security.
Notes about network segmentation, encryption, or compliance boundaries (e.g., do not send PII off-site).
Is the mapping ready for a pilot installation?
Helps rollouts prioritize which mappings to deploy first.
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Anything else the integrator, reliability engineer, or data scientist should know.
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