Machine Telemetry Application

Version: 0.0.8 Platform: Fuuz ≥ 2026.2.0 Publisher: fuuz Enterprise: MFGx Spec Version: 2.0.0

Overview

The Machine Telemetry Application is a comprehensive IoT data collection and analysis platform for manufacturing equipment. It extends the machine monitoring layer with deep sensor-level telemetry: capturing high-frequency machine data streams from OPC-UA devices and PLCs, storing both real-time current values and long-term historical time-series, detecting anomalies and threshold violations, generating alarms from telemetry conditions, and presenting trend analysis and process monitoring dashboards.

While application-machine-monitoring-accelerator focuses on operator-driven production tracking (OEE, mode changes, production counts), the Machine Telemetry Application focuses on the raw physics of the machine — pressures, temperatures, speeds, vibration, electrical values — and the automated detection logic built on top of those signals. It is suitable for predictive maintenance programs, process quality monitoring, SPC (Statistical Process Control), and OEE-linked condition monitoring.

Package Contents

machine-telemetry/
├── manifest.json
├── definition.json
├── package-data.json
├── data/                        74 seed data files
├── dataFlows/                   40 automation flows
├── dataModels/                  48 data model definitions
├── savedTransforms/             18 reusable transforms
└── screens/                     26 UI screen definitions

Functional Areas

1. Telemetry Data Collection

Continuous high-frequency data collection from OPC-UA device tags and PLC registers:

Device subscriptions — Each monitored machine parameter is defined as an IotTag with OPC-UA node configuration; subscriptions are established via the platform's device gateway
Current value persistence — IotTag.currentValue is updated on every subscription notification; currentValueRecordedAt tracks the timestamp
Historical storage — Tags with storeHistory = true append every reading to a time-series collection (IotTagHistoricalValue), enabling trend analysis and replay
Tag use case routing — IotTagUseCase (e.g., "Temperature", "Pressure", "Speed", "Vibration", "Counter", "Binary Signal") determines downstream processing: alarm evaluation, SPC calculation, OEE counter update, etc.

2. Alarm & Threshold Management

Configurable limit-based alarming on live sensor readings:

Alarm model — Alarm records include code (auto-sequenced), limitValue (the threshold crossed), deviation (distance from setpoint at trigger time), timestamps for trigger/acknowledge/clear lifecycle
Alarm rules — Per-tag or per-tag-type threshold configurations; supports high/low limits, rate-of-change limits, and deviation from setpoint
Alarm lifecycle — new → acknowledged → cleared workflow; escalation logic with configurable time-based level-1/level-2 notification
Alarm-to-workcenter binding — Alarms are linked to the workcenter associated with the triggering tag, enabling plant floor visibility integration
120-day data change capture (exposed) — alarm state changes streamed for audit and SCADA integration

3. Process Monitoring & SPC

Statistical process control and process condition monitoring:

Configurable control limits (UCL, LCL, UWL, LWL) per tag/parameter
Rule violation detection (Western Electric rules, Nelson rules, or custom)
Out-of-control signal logging with timestamps and deviation values
Historical SPC chart data served to trend screens via integration flows

4. Trend & Analytics Dashboards

Time-series visualization for machine health and process performance:

Tag trend viewer — Single-tag historical value chart with zoom, time range selection, and annotation support
Multi-tag comparison — Overlay multiple telemetry parameters on a single time axis for correlation analysis
Machine health overview — Per-workcenter dashboard showing current sensor values, alarm status, and recent trend sparklines
Alarm history timeline — Chronological view of alarm events with deviation magnitudes and duration

5. IoT Device Configuration

Full device and tag management interface:

Device registration with OPC-UA endpoint configuration
Tag browser — import and configure OPC-UA node IDs from live device tree
WorkcenterIotTag binding management — assign tags to workcenters for alarm routing and OEE counter integration
Subscription health monitoring — view subscription status, last-update timestamps, and connection errors per device

6. Predictive Maintenance Support

Infrastructure for condition-based and predictive maintenance programs:

Tag-level baseline configuration for deviation alerting
Historical trend data retention for training predictive models
Alarm pattern analysis screens for identifying recurring failure modes
Integration hooks for exporting tag history to external ML/analytics systems

Data Models (48 total)

Telemetry Core

Model	Key Fields	Purpose
`Alarm`	code (auto-seq), limitValue!, deviation, occurAt, acknowledgedAt, clearedAt, workcenterId, iotTagId, alarmRuleId	Threshold violation event; 120-day data capture
`IotTag`	name!, active!, storeHistory!, currentValue (JSON), currentValueRecordedAt, configuration (JSON), iotTagTypeId, iotTagUseCaseId, deviceId	OPC-UA tag subscription record
`IotTagHistoricalValue`	recordedAt!, value (JSON!), iotTagId	Append-only time-series log of tag readings
`IotTagType`	name! (=id auto), usable!, configurationSchema	Tag type classification (e.g., Analog, Digital, Counter)
`IotTagUseCase`	name! (=id auto), usable!, configurationSchema	Processing routing classification

Alarm Configuration

Model	Key Fields	Purpose
`AlarmRule`	name!, highLimit, lowLimit, highHighLimit, lowLowLimit, deadband, enabled, iotTagId, iotTagTypeId	Configurable threshold rules per tag or tag type
`AlarmStatus`	name!, active, new, acknowledged, cleared, canceled, usable!	Alarm lifecycle state definitions
`AlarmEscalation`	levelOneMinutes, levelTwoMinutes, levelOneRoleId, levelTwoRoleId, alarmStatusId	Escalation timer and routing configuration

Device & Connectivity

Model	Key Fields	Purpose
`Device`	name!, active!, connectionStatus, lastConnectedAt, endpoint, deviceTypeId, gatewayId	OPC-UA/PLC device registration
`DeviceType`	name!, protocol (OPC-UA, Modbus, etc.), configurationSchema	Device protocol classification
`DeviceGateway`	name!, active!, host, port, status	Edge gateway for OPC-UA connectivity
`WorkcenterIotTag`	workcenterId, iotTagId	Many-to-many binding of tags to workcenters

Process Monitoring

Model	Key Fields	Purpose
`SpcConfiguration`	name!, ucl, lcl, uwl, lwl, iotTagId, ruleSetId	Statistical process control limits per tag
`SpcSample`	value!, recordedAt!, spcConfigurationId, violationFlags (JSON)	Individual SPC sample with rule check results
`ControlChart`	name!, type (Xbar-R, Xbar-S, I-MR), subgroupSize, iotTagId	Control chart configuration

Reference Data

Model	Key Fields	Purpose
`Workcenter`	code!, name!, active!	Machine entity linkage (cross-reference)
`Facility`	code!, name!, type	Site hierarchy node
Additional models (33)	Various	Supporting tag metadata, calibration records, maintenance schedules, notification templates, and dashboard configurations

Data Flows (40 total)

Core Telemetry Pipeline

Flow	Type	Description
IOT Tag Handler	System	Routes incoming device subscription updates by use case to production/alarm/OEE handlers
Update Iot Tag by Device Subscriptions	System	Processes subscription events, updates `IotTag.currentValue` and `currentValueRecordedAt`
Create Historical IOT Tag Values	System	Appends tag readings to `IotTagHistoricalValue` when `storeHistory = true`
Create Device Subscription From Iot Tags	System	Generates OPC-UA subscriptions on the device gateway from IotTag configurations

Alarm Processing

Flow	Type	Description
Evaluate Alarm Rules	System	Triggered on each tag update; checks configured `AlarmRule` thresholds and creates `Alarm` records on violation
Alarm Escalation Timer	System	Periodic check; fires level-1/level-2 notifications when open alarms exceed configured time thresholds
Alarm State Machine	System	Processes alarm lifecycle transitions (acknowledge, clear, cancel)
Alarm Notification Dispatch	System	Routes alarm notifications to assigned roles/users via configured channels

Analytics & Reporting

Flow	Type	Description
Tag Trend Query	Integration	Returns paginated historical tag values for a given time range and tag ID; used by trend screens
SPC Evaluation	System	Evaluates control chart rules on new samples; logs violations to `SpcSample.violationFlags`
Machine Health Aggregator	System	Computes per-workcenter health scores from active alarm count, tag deviation metrics, and uptime
Export Tag History	Integration	Bulk export of historical tag values to CSV or JSON for external analytics

Device Management

Flow	Type	Description
Device Connectivity Check	System	Periodic ping of registered device gateways; updates `Device.connectionStatus`
Tag Discovery	Integration	Browses OPC-UA node tree on a device and returns available tag paths for configuration
Subscription Health Monitor	System	Detects stale subscriptions (tags not updated beyond threshold) and triggers reconnection

Additional flows (25+) cover SPC charting, notification templates, Fuuz-to-SCADA publishing, trend data caching, and dashboard data preparation.

Screens (26 total)

Operator / Plant Floor - Machine health overview per workcenter — current sensor readings, alarm count, mode/OEE summary - Active alarm list with acknowledge/clear actions - Tag current value monitor — live readout of all tags for a selected workcenter

Trend & Analytics - Single-tag trend chart with configurable time range and resolution - Multi-tag overlay comparison dashboard - SPC control chart viewer with violation highlighting - Alarm history timeline with filter by workcenter, tag, alarm type, and date range

Configuration - Device management — register, edit, test connectivity - Tag configuration — create IotTags, set use case, configure alarm rules, enable history - WorkcenterIotTag binding manager - Alarm rule configuration — set high/low limits, deadband, escalation timers - SPC configuration — define control limits, select rule sets - Alarm status and escalation configuration

Seed Data (74 records)

Comprehensive reference data:

IotTagTypes — Analog Input, Digital Input, Counter, Accumulator, Calculated, String, and protocol-specific types
IotTagUseCases — Temperature, Pressure, Speed, Vibration, Power, Current, Voltage, Flow Rate, Counter, Binary Signal, Setpoint Deviation, Generic, and additional process-specific use cases
AlarmStatuses — new, active, acknowledged, cleared, canceled with Boolean flag presets
DeviceTypes — OPC-UA, Modbus TCP, Modbus RTU, EtherNet/IP, BACnet, MQTT, and generic HTTP types
Default SPC rule sets — Western Electric, Nelson, AIAG, and custom rule definitions
Default control chart templates — Xbar-R, Xbar-S, I-MR pre-configured templates
Notification templates — Email and push notification templates for alarm level-1 and level-2 escalations
Dashboard layout configurations — Default screen layouts for plant floor and management views

Installation

Ensure Fuuz platform version ≥ 2026.2.0 is deployed
Import via Fuuz Package Manager — seed data (74 records) applies automatically
Register device gateways and OPC-UA devices via the Device Management screen
Use Tag Discovery to browse OPC-UA nodes and create IotTag records for each monitored parameter
Assign tags to workcenters via the WorkcenterIotTag Binding Manager
Configure IotTagUseCase on each tag to enable appropriate downstream processing
Set up AlarmRule threshold configurations per tag or tag type
Enable storeHistory = true on tags requiring trend analysis
Run Create Device Subscription From Iot Tags flow to activate live data collection
Configure SPC control limits and chart types for process monitoring tags
Set up escalation rules and notification assignments for alarm routing

Dependencies

Fuuz Platform ≥ 2026.2.0
Device Gateway — required for OPC-UA/Modbus connectivity (Fuuz Edge Gateway or cloud gateway)
application-machine-monitoring-accelerator (optional) — integrates OEE counter updates and workcenter state linkage
Notification module — required for alarm escalation level-1/level-2 delivery
Scheduler module — required for periodic alarm escalation checks and device connectivity monitoring

Built on the Fuuz Industrial Operations Platform