Predictive Maintenance Engine: the AI layer under every asset.
Gear Brain's predictive maintenance platform reads vibration, thermal, acoustic, and electrical signatures from rotating and reciprocating equipment, then tells maintenance teams what's about to fail, and when — not just that something looks unusual.
From raw sensor signal to a scheduled work order.
The engine doesn't just watch one number drift outside a threshold — it models the full degradation curve for each asset class and cross-checks against your maintenance history.
Vibration, temperature, current, and acoustic sensors stream through an on-site edge unit for low-latency inference.
Separate models per asset class — pumps, motors, gearboxes, compressors — trained on real failure signatures, not generic anomaly detection.
Each flag carries a failure mode, a confidence score, and a predicted window, so teams can triage instead of guess.
Work orders route directly into your existing maintenance system with a recommended action and parts list attached.
From site survey to live monitoring in four stages.
Asset survey
Our engineers catalogue critical equipment and existing sensor coverage on site.
Sensor & edge install
Vibration, thermal, and current sensors are fitted with an edge gateway for local inference.
Model calibration
Models run in shadow mode against your maintenance history to tune thresholds per asset.
Go live
Alerts route into your CMMS and dashboard, with our team monitoring alongside yours for the first 90 days.
What the engine monitors.
| Asset class | Signals monitored | Typical lead time | Common failure modes flagged |
|---|---|---|---|
| Pumps | Vibration, temperature, current | 2–4 weeks | Bearing wear, cavitation, misalignment |
| Motors | Current signature, temperature | 3–6 weeks | Winding degradation, rotor bar faults |
| Gearboxes | Vibration, acoustic, oil temperature | 2–5 weeks | Gear tooth wear, lubrication faults |
| Compressors | Vibration, thermal, pressure | 3–5 weeks | Valve wear, thermal drift, seal failure |
| Robot manipulators | Joint torque, vibration, cycle time | 1–3 weeks | Actuator wear, backlash, encoder drift |
Run a 90-day predictive maintenance pilot.
Start on your highest-risk assets and expand once the model proves out against your maintenance history.