Continuous control loop monitoring that detects wear and tear in your industrial machines, from a single asset to your entire facility
SID is your standalone predictive maintenance solution, designed for early detection of wear and tear and mechanical faults in industrial machines and systems. By continuously monitoring control loop behaviour, SID reveals what condition monitoring and vibration analysis cannot see, giving you time to act before failures impact production.
Whether you are monitoring a single critical asset or overseeing an entire facility, SID adapts to your needs. It connects to your existing infrastructure, requires no cloud connection, and delivers actionable insights within minutes of setup.
Your Added Value
- Compatibility: Works with any PLC, HMI, or edge device
- Flexibility: Not bound to any specific processes or machine types
- Mathematical certainty: Insights based on proven mathematical algorithms, not AI/ML
- Cloud independent: Operates without a cloud connection – your data stays local
- No extra hardware: Uses existing infrastructure – no additional sensors required
- Lightweight: No large data sets or raw data storage needed
- Scalable: Scales from single machine monitoring to complete facility overview
Inverse Control Loop Technology Explained
SID monitors the control loop variables, setpoint, actual value, and control signal that manage machine parameters such as temperature, pressure, movement, and flow. By inversely computing the controller gains from this data, SID detects changes in control loop behaviour that indicate mechanical wear, component degradation, or processing issues.
In a healthy system, the computed gain values remain stable. When a component begins to degrade, the gains shift in characteristic and mathematically traceable patterns – often months before a visible failure occurs.
These Four Categories of Anomaly Detection can be put into four categories:
- Gradual Change: A slow, trending shift in gain values indicating progressive wear
- Oscillation: Periodic fluctuations suggesting instability in the control loop
- Sudden Change: An abrupt shift pointing to a discrete event or component failure
- Transient Disturbance: Short-lived anomalies that may indicate emerging issues
Product Information
- Inverse Control Loop Analysis based on mathematical algorithms
- Scales from a single machine to a full facility
- OPC-UA / MQTT passive data gathering
- No external cloud connection — fully local operation
- No additional sensors required
- Any PLC, HMI, or edge device
- The Baliso Graph, an intuitive control loop health display
- Configurable tolerance with warning and critical severity levels
- Asset Alert Summary, Alert Trend
- Report, Fleet Report
- Estimated cost of failure per machine for prioritised maintenance
- Complete view of assets within minutes
- Full diagnostics hub at entry-level prices
We have created the Baliso Graph: SID’s signature visualisation. A simple, intuitive graph that gives you the most important insights immediately. It displays live data points showing changes in the control loop gains over time, separated into the set, actual, and control-variable components.
Because error and fault margins vary by industry, the graph lets you define the tolerance parameters you are most comfortable with. This ensures relevant, actionable alerts without overloading you with unnecessary alarms.
SID provides a unified dashboard that gives you full visibility across your monitored assets. Track the status of every machine and its associated control loops from a single view. Each machine displays live information on loop status, active alerts, and severity levels, enabling fast, informed decision-making.
When gains deviate outside your configured tolerance, SID immediately prompts you with a warning. Alerts are classified by severity, warning or critical, and each comes with a timestamp and the estimated monetary impact of the issue. This helps you prioritise maintenance based on real operational cost, not guesswork.
SID’s reporting function consolidates your facility’s performance into three comprehensive modules designed to uncover issues, trends, and performance gaps:
Asset Alert Summary: Get a clear overview of all active and resolved alerts. This report highlights equipment issues requiring immediate attention.
Alert Trend Report: A timeline-based report that visualises alert frequency over time, revealing patterns, recurring issues, and operational blind spots.
Fleet Report: The big picture. This high-level report covers all monitored machines, pinpointing which machines and control loops are underperforming, empowering you to prioritise maintenance with precision.
Setting up SID is fast and intuitive. Identify the machines you want to monitor, configure your control loops, and adjust tolerances to match your operational needs. You choose how many loops to monitor per machine and can update the configuration at any time.
Within minutes, SID delivers a complete view of your monitored assets, control loops, and active alerts. You can also define the estimated cost per failure event and outline the appropriate response, which gives you clear insight into how each machine affects your overall operational costs.
SID operates 100% locally with no external cloud connections and no data leaving your network. It gathers data passively via OPC-UA / MQTT and requires no raw data storage or large data sets. The underlying mathematical approach is inherently privacy-preserving: the computed gain values do not convey sensitive information about your operations or production processes.
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We are fully committed to providing our customers with the very best products and customer service. We believe in going the extra mile to ensure that each customer is satisfied with our products and solutions. We have the experience and the reputation in the field to deliver the products customers need to expedite their projects and assure quality every step of the way.