Description

Product Overview

MachineEar Industrial is an AI-powered acoustic monitoring and predictive maintenance platform designed for plant managers, reliability engineers, and industrial maintenance teams. Leveraging Gemini 2.5 Flash and high-frequency acoustic envelope demodulation through the Sensifai LiteLLM Gateway, MachineEar diagnoses critical rotating machinery faults from sound and vibration in under 3 seconds.

The Problem

Unplanned production line shutdowns cost manufacturers an average of ,000 per hour in lost throughput, emergency labor, and secondary machine destruction. Up to 70% of mechanical machinery failures originate in rolling element bearings and motor imbalances that emit distinct ultrasonic and acoustic distress frequencies 2 to 4 weeks prior to thermal seizure. Traditional vibration accelerometers require expensive fixed cabling (,000+ per machine), specialized vibration analysts, and days of turnaround time.

The Solution

MachineEar Industrial transforms any standard smartphone microphone, digital audio recorder, or industrial IoT acoustic probe into an AI vibration specialist. By capturing a 5 to 10-second acoustic recording, MachineEar demodulates the sound into Fast Fourier Transform (FFT) harmonic spectrums, calculates ISO 10816-3 vibration severity, checks Ball Pass Frequencies (BPFI/BPFO), identifies cavitation shockwaves, and outputs an actionable maintenance action plan.

Key Capabilities

• Bearing Micro-Spalling Detection: BPFI, BPFO, and ball pass defect identification in the 2.5 kHz - 5 kHz acoustic band.
• Shaft Alignment & Unbalance Analysis: 1X and 2X rotational speed harmonic tracking flagging coupling offset.
• Centrifugal Pump Cavitation Sentry: Broadband ultrasonic vapor collapse detection preventing impeller erosion.
• Microphone & Audio Ingestion: Supports live microphone capture, WAV, MP3, M4A, OGG, and video vibration recordings.
• Actionable Maintenance Work Orders: Itemized mechanical recommendations with recommended reinspection windows.
• Sensifai Wallet Metering: Pay-as-you-go micro-metering at €0.05 per scan with instant deduction.
• Non-Diagnostic Industrial Advisory: Conforms to REQ-007 industrial predictive maintenance standards.