Detect changes
ThermalDIAG can continuously evaluate temperature rises, current curves, vibration metrics as well as digital and analog signals against project-specific rules. This makes trends, recurring deviations and gradual changes visible.
ThermalDIAG
Understand temperature, current, vibration and operating states together.
ThermalDIAG is a local on-premise system for industrial plants where thermal condition, electrical load, mechanical vibration and machine signals need to be monitored, evaluated and documented together.
ThermalDIAG and ThermalDIAG Analytics are in the test and validation phase. ThermalDIAG has also been technically tested on the UniPi Edge E410 ARM64 reference platform; introductory prices and licensing models are defined; deployment and use are agreed for each project.
Benefits
Individual measurements become a traceable operating context.
Investigate faults traceably
An incident collects rule context, measurements, timestamps, actions and evidence so operators and technicians do not need to reconstruct events from separate sources.
Document clearly
Tickets, snapshots, work notes, measurements and reports support a structured workflow from the first alarm to the completed inspection.
Measurement service
Agree the measurement and evaluation
After technical consultation, you can commission a time-limited measurement with a documented evaluation. The measurement setup, duration and prerequisites are set out in an individual quotation.
- 1. Define the question
- Describe the plant, observed condition, relevant operating phases and intended measurement objective together.
- 2. Check feasibility
- Check available sensors, signals, interfaces and a suitable IPC test environment.
- 3. Agree the measurement
- Only if prerequisites are suitable, agree on the measurement setup, period, access rights and controlled procedure.
- 4. Assess results professionally
- Document data quality, observations, limitations and next steps.
Development status and testing
Prepare for local use with a technical review.
ThermalDIAG can be ordered for local use after technical assessment. Configuration, scope and delivery dates are set out in the individual quotation.
- Local software for a suitable Linux test environment.
- Hardware selection and sizing remain project-specific; the UniPi Edge E410 is a tested ARM64 reference platform.
- The documented V1.318 software build was installed on the ARM64 reference platform and technically checked after installation.
- Adaptation to customer-owned hardware after technical review of the hardware and system environment; suitability must be assessed for each project.
- Define the scope of possible setup and sensor integration only after technical consultation.
System requirements
Suitable IPC hardware for local operation.
ThermalDIAG runs locally on a suitable Linux industrial PC (IPC). The exact sizing depends on the number of cameras, measurement points, signals, recording duration and required integration.
Already tested: Ubuntu 22.04 with 4 GB RAM in WSL environments, on Linux PCs and on an OnLogic CL260. These tests do not establish guaranteed production capacity.
Provisional system requirements for test and pilot installations
- CPU: Linux-based x86_64 systems and the UniPi Edge E410 ARM64 reference platform have been technically tested. Other hardware requires a project-specific suitability check.
- Operating system: Ubuntu 22.04 LTS or a currently supported Ubuntu LTS version is recommended. Ubuntu 22.04 has actually been tested; this does not mean other versions have been tested.
- Memory: at least 4 GB RAM; 8 GB or more is recommended.
- Storage: at least 32 GB total SSD/eMMC capacity for small test and pilot installations. The operating system, application, database and evidence all occupy this space.
- Network: at least one Ethernet interface with 100 Mbit/s. Required bandwidth depends on camera count, data rate and other devices. For larger installations or higher data volumes, 1 Gbit/s is recommended, not a minimum.
- Production sizing, including storage requirements, and long-term operational suitability still require validation. 24/7 operation requires suitable industrial hardware and separate load and endurance tests.
Select I/O for the measurement task
- Digital inputs (DI): define the number and electrical characteristics according to the required status and enable signals.
- Digital outputs (DO): provide only for required, authorized actions; assess the number and characteristics for each project.
- Analog inputs (AI): select the number and ranges to suit the sensors, for example 0–10 V or 4–20 mA.
- RS-485: check a suitable interface and required protective measures when using relevant devices.
- I/O connection: directly on the IPC or through compatible external modules. There is no general minimum I/O channel count.
Interface
The key operating states at a glance.
The images show interface examples, not customer references or validated example measurements.
Shared signal context
Thermal, electrical and mechanical changes on the same time base.
Visualization separates temperature history, analog inputs, vibration, digital states and numeric variables into clear bands. Signal aliases and technical names remain visible together.
Temperature
Thermal-camera ROIs and other temperature measurements show local thermal changes.
Current and analog values
Current, voltage and other analog channels are grouped by compatible unit for meaningful comparison.
Vibration
Velocity, acceleration, frequency, kurtosis and crest factor support mechanical condition monitoring.
Digital states
Camera I/O and multiple Modbus gateways provide time-aligned inputs, outputs and relay states.
Reference sensors
Banner QM30VT2 and Seneca T201DCH100-OPEN are supported reference configurations. Naming, units and scaling are verified for each project.
Shared interaction
The tooltip shows the nearest value for every visible curve, with a colour marker and an individual timestamp when sample times differ. Each series keeps its source visible.
In operation
What ThermalDIAG makes visible for operators.
- Organize plant areas, cameras, measurement points and I/O signals by project.
- Capture temperature, current, voltage, vibration metrics as well as digital and analog signals.
- Connect compatible, configured devices through Modbus TCP or direct Modbus RTU.
- Record DI counter history and use counter values in rule conditions; reset supported counters under controlled, logged conditions.
- Check digital output writes by readback; this does not confirm the mechanical effect of a connected actuator.
- Distinguish minimum, maximum and average temperatures of supported camera ROIs.
- Monitor multiple Modbus gateways and their I/O channels by project.
- Create a new Modbus gateway in a controlled way as a disabled configuration with no implicit channels.
- Evaluate rules with conditions, filters and actions.
- Calculate numeric variables using integer MOD or decimal FMOD; an invalid divisor is handled as a controlled error.
- Configure pulse sequences without the former 1,000-pulse limit; each pulse and pause remains limited to 1 to 3,600 seconds.
- Copy a rule, including its conditions, filters and actions, into a new disabled rule without copying runtime or incident history.
- Create incidents when defined states occur.
- Provide evidence, snapshots, action diagnostics and reports.
- Support tickets for inspection, measurement, repair or feedback.
- Show health information for runtime, cameras, I/O, rules and jobs, and acknowledge previous failures without deleting their result or audit history.
- Pause runtime in a controlled way and resume with fresh measurement and rule state while retaining measurement, incident and audit history.
- Deliver voice actions through Piper on the Linux host or as offline audio and a visual message in an enabled browser.
- Review storage usage and free space read-only and request local recovery backups; restore remains limited to the same compatible IPC and the protected host command line.
- Store data locally without mandatory cloud operation.
Licence status and resumption
A clear state instead of silent processing.
The licence page displays the current status in colour and warns when no more than 14 days remain.
- When the licence is expired or invalid, data acquisition and normal automation stop without a grace period.
- Tasks that have not started are discarded. A pulse already in progress finishes its current pulse time, returns to its configured state and is not repeated.
- After a valid licence is installed, data acquisition and rule evaluation resume automatically from fresh data. Hold times, delta data, count windows and earlier event conditions from before the interruption are not reused.
- Existing measurement, incident and audit data remain available.
Typical use areas
For plants where temperature alone does not explain enough.
The examples describe possible applications, not proven customer deployments. Suitability depends on sensors, data recording and plant conditions.
Motors, bearings and drives
Temperature, phase current, vibration metrics and machine state are viewed together so load-dependent or mechanical anomalies become easier to classify.
Control cabinets and connection points
Thermal image data can be combined with current, switching or enable information for terminals, relays, load circuits and distributions.
PV, inverters and battery storage
ThermalDIAG supports combined views of temperature, signal state and measurements in plants with changing operating states.
Cooling sections, pumps and fans
When temperature rise, flow, enable or switching state must be interpreted together, ThermalDIAG keeps the relevant data in one history.
Pilot measurements and temporary diagnostics
Not every project needs to become a permanent system immediately. ThermalDIAG can also be used as a time-limited measurement and diagnostics setup.
Structured incident work
Incidents and tickets help turn an alarm into a traceable task with responsibility, measurements, notes, evidence and completion.
Project workflow
From observed condition to reliable evidence.
The following sequence describes project-specific setup after technical consultation and agreement on the order.
1. Clarify the starting pointWhich component is abnormal? Which signals matter? Are there shifts, cycles, load changes or recurring events?
2. Define measurement and signal conceptCameras, measurement points, current and vibration sensors, digital signals, analog values and required evidence are matched to the concrete question.
3. Set up the system locallyThermalDIAG is installed as a local web-based application. The exact setup depends on plant, roles, measurement task and safety framework.
4. Support operation and evaluationData is monitored, incidents are handled and results are documented. If needed, the rule strategy is adjusted or checked with Analytics.
Rule function
Rule-based functional and endurance tests.
ThermalDIAG rules connect measurements, states and approved reactions without classic program code. In addition to alarms, this supports project-specific test and auxiliary procedures that are not safety-related.
A prepared digital output can, for example, actuate a moving component. One or two limit switches provide position feedback while a numeric variable counts cycles and temperature, current or vibration is monitored. This keeps it traceable when and under which conditions a deviation occurs.
A deviation may be detected in the next rule evaluation cycle. Approved actions are then executed through their respective action processing. Calculated numeric variables can be used in subsequent rule evaluations. There is no deterministically guaranteed response time for detection or execution.
Technical scope:
- 3 condition types: direct value, delta and temperature rate, using digital input and output states, analog values, camera temperatures, sensor values and numeric variables.
- 3 filters: schedule, previous incident within a time window, and activation count within a time window.
- 11 actions: create event, e-mail, voice, snapshot, set output, cancel pending output, set impulse, stop impulse, set Torch/LED, cancel pending Torch, and calculate a numeric variable.
Boundary: ThermalDIAG runs on a Linux IPC and is not a real-time system. Rule evaluation typically operates in the seconds rather than milliseconds range. ThermalDIAG does not replace a PLC or safety controller. Safety functions, emergency stop, protective interlocks and time-critical end-position monitoring must operate independently.
Physical outputs may only be enabled by qualified personnel after a project-specific review of the electrical, mechanical and safety-related conditions.