Industrial machine and facility monitoring

The equipment that causes the most trouble is usually the equipment nobody can see: a booster pump in an outbuilding, a compressor behind the line, a tank at the far end of the yard. Genesis puts a cellular controller on those points without a cabinet, a mains feed or a run of conduit, reads the instruments already fitted to them, and raises an alarm on the phone of whoever is on shift.

Who puts these on a plant

The hardware is the same in all three cases. What changes is who owns the data and who gets woken up when a threshold is crossed.

Plant and factory operators

The machines that matter are rarely the ones with a panel next to them. Pump houses, compressor rooms, tank farms and outbuildings sit off the plant network, and the first sign of a problem is a call from production. Genesis puts a reading and an alarm on those points without pulling conduit to them.

Machinery and equipment builders

Your customers now ask what the machine reports and whether there is an app before they sign. Building a firmware and cloud team to answer that is a two-year detour from the machine you already make. A controller that fits in the panel you already ship is a shorter route.

Facility and utility engineers

HVAC plant, boosted water, compressed air and standby generation are spread across a site and monitored by walking to them. Condition data and threshold alerts routed to whoever is on shift removes most of that walk, and the points that justify it are usually the ones furthest from a socket.

What a Genesis reads on an industrial site

Any instrument speaking RS485 Modbus RTU, analogue, digital, I2C, 1-Wire, SDI-12 or UART connects to any of the four ports, and the protocol is assigned from the dashboard rather than fixed at the factory. Four ports on the Genesis industrial IoT controller, one on Genesis Lite where a location has a single point worth measuring.

Energy and power

Three-phase meters and CT-based measurement over RS485 Modbus RTU. Consumption per machine or per feeder, so a rising baseline shows up before the bill does.

Pressure and flow

Pressure transducers on hydraulics, compressed air and water mains. Flow meters on utility lines. A leak shows first as flow that never returns to zero overnight.

Temperature

Digital and RS485 temperature probes on process fluids, bearings, panels and rooms. Threshold and rate-of-change alerts rather than a chart nobody opens.

Level

Ultrasonic, radar and hydrostatic level sensors on tanks, sumps and wet wells. One controller can carry several tanks and keep each one on its own location.

Machine status and run hours

Digital inputs on run signals, fault relays and door interlocks. Run hours accumulate against the asset, which is what maintenance intervals are actually scheduled on.

Control outputs

Relay and latching-relay outputs to start a pump, open a valve or trip an isolator, with dwell and rules held on the device so it still acts during a network outage.

From a reading to a technician on site

Readings on their own change nothing. These are the parts of OmniCloud that a maintenance team touches daily, and they are there on the first day rather than as a later module.

Asset dashboards

One view per machine or per area: current readings, run state, run hours, last alarm. Built for someone standing in a plant room on a phone, not for a control room screen.

Thresholds and alarms

Per-sensor minimum and maximum with hysteresis, routed by push notification and email. Acknowledgement is recorded against the alarm so a shift handover shows what was already seen.

Trends and reports

Readings held at full resolution and exported to XLSX for the people who will put them in a report anyway. No re-typing numbers out of a chart.

Location-level separation

Location is bound to the sensor rather than the controller, so one unit reaching two rooms keeps the two rooms apart in every chart and every export.

Remote configuration

Reading interval, transmit interval, thresholds and what each port reads are all changed from the dashboard after the unit is installed. Nobody drives out to re-flash anything.

Access control across companies

The site owns the hardware and the service contractor is granted visibility into the units they maintain. Neither party buys the device twice and neither sees the other customers.

Where Genesis sits relative to your PLCs

A PLC runs the machine on a deterministic scan cycle with a safety rating behind it, and that is the right tool for the job. Genesis covers the points between the machines, where a panel build and a mains feed cost more than the measurement is worth. It reads its own instruments, holds its own output rules, and hands everything to a cloud your team and your contractors can both reach.

For what building that data path yourself costs in engineer-months, read our breakdown of AWS IoT Core.

Questions we get from plant engineers

Which industrial sensors does Genesis connect to?

Any instrument that speaks RS485 Modbus RTU, an analogue voltage output, a digital signal, I2C, 1-Wire, SDI-12 or UART connects directly, and over fifty types are supported today. Each of the four ports is assigned a protocol from the dashboard, so a single unit can carry a Modbus energy meter and an analogue pressure transducer at once.

Does it replace my PLC or SCADA?

No, and it should not be sold as one. A PLC has a deterministic scan cycle, IEC 61131-3 logic and a safety rating, and Genesis has none of the three. A PLC runs the machine. Genesis covers what sits between the machines: distributed points with no cabinet, no mains feed and no panel build, where running a PLC and its infrastructure is uneconomic.

What if the site has no network where the equipment is?

That is the case Genesis is built for. It connects over 4G-LTE on its own, without a gateway or a LoRaWAN network in between, and runs on battery and solar where there is no socket. Where there is plant Wi-Fi it will use that instead.

What happens when connectivity drops?

Readings are written to local storage and sent in order on the next successful transmit, so an outage leaves no gap in the record. Output rules and dwell timing run on the device, so a valve or contactor still operates while the link is down.

Can one controller cover equipment in more than one room?

Yes. Location is bound to the sensor rather than to the controller and stamped on each reading when it is written, so two rooms served by one unit stay separate in every chart, report and export, and moving a sensor later does not rewrite its history.

How does it fit our network security policy?

Cellular units are not on your network at all, which is usually the shortest path through an approval. Where Wi-Fi is used the device connects outbound over TLS and never needs an inbound rule or a port opened towards it.

Is the platform in production?

Yes. OmniCloud has been in continuous production since 2023 and carries millions of sensor readings a month from deployed controllers, on the same hardware and the same cloud sold here.

Tell us what is not being watched

The useful first message is a list: which equipment, which instruments are already fitted to it, and whether those points have power and cellular coverage. We answer with what a Genesis would read there and what the install involves.

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