12 reviews

Machine Condition MonitoringVibration monitoring for gearboxes, fans, motors, pumps, etc.

Space-grade measurement technology was brought into machine condition monitoring. Accurate, highly reliable, easy to use, and cost-effective real-time condition monitoring solution. Our condition-based monitoring solution is ideal for any kind of rotating machinery such as electric motors, gearboxes, pumps, etc.

Measure and monitor vibration, and temperature with the greatest possible precision and get the right results. Highly integrated hardware and software that just works out of the box.



Strain and Stress

Strain and Stress







Quarter Bridge

Quarter Bridge

Half Bridge

Half Bridge

Full Bridge

Full Bridge





Counter and Encoder

Counter and Encoder



High-speed video

High-speed video

Thermal video

Thermal video







Machine Condition Monitoring highlights

Ready To Use High-level Web-based Software

The Dewesoft Machine Condition Monitoring software includes a web-based overview of the machinery state, indispensable for quick decision making.

In-depth Machine Condition Analysis Features

Thousands of software features relevant to PdM experts are available including FFT-analyzer, time-domain analysis, orbit plot, order tracking, waterfall diagram, trend statistics, enveloping, bearing fault detection.

Historian Time-series Database

Historical data can be permanently stored in a Historian database on a local or cloud server and can be used for trends as well as for later in-depth analysis and root cause identification.

Connectivity With OPC UA

Data can be integrated into any 3rd party control system using the OPC UA protocol.

Data Access From Anywhere

Data can be accessed from the client’s local computer, mobile phone devices, control system or remotely via a pre-configured web browser application.

Unlimited Input Channels

Our DAQ systems offer virtually unlimited input channel configurations and our DAQ software can perform machine condition monitoring analysis on any or all of them at the same time.

Totally Distributed System

Dewesoft DAQ devices are designed to be distributed under any condition. EtherCAT technology allows devices to be placed near the sensors and connected with a single cable for power, data, and synchronization. The cable can span up to 100m between DAQ nodes or virtually unlimited using EtherCAT to fiber optic converters.

Any Sensor

Input amplifiers offer support for any velocity, accelerometer, temperature, pressure, and any other types of sensors needed to detect rotating machinery issues.

Software included

Every Dewesoft data acquisition system is bundled with award-winning DewesoftX data acquisition software. The software is easy to use but very rich and deep in functionality. All software updates are free forever with no hidden licensing or yearly maintenance fees.

Lifetime Free Software Upgrades and Support

The software package is always evolving and new features are being added. We offer lifetime FREE software upgrades and technical support to all our users.

Dewesoft quality and 7-year warranty

Enjoy our industry-leading 7-year warranty. Our data acquisition systems are made in Europe, utilizing only the highest build quality standards. We offer free and customer-focused technical support. Your investment into the Dewesoft solutions is protected for years ahead.

Condition-Based Monitoring (CBM)

Machine condition monitoring (or condition-based monitoring - CBM) is the process of monitoring conditions in critical machinery while in operation (vibration, temperature, etc.), in order to identify a significant change that is indicative of a developing fault or malfunction. It is a major component of predictive maintenance.

Dewesoft is a leading provider of high-end data acquisition systems (DAQ), DAQ software covering test and measurement applications in different industries. We also offer low-cost, high-performance, totally distributed, and easy-to-use machine condition monitoring systems for condition-based monitoring.

The solution suits applications such as permanent condition-monitoring of gearboxes, fans, motors, blowers, and any other rotating machinery in automotive, mining, pulp, paper, iron, steel, chemical, cement, oil and gas, facility management, and power generation.

This cost-effective solution enables production facility owners to start permanent monitoring of critical equipment with high ROI. Ultimately, it helps reduce production downtime, lowers maintenance and repair costs, and increases company profitability.

Why Is Permanent Monitoring Needed?

Using condition monitoring techniques is the only way to understand the condition of your machines in detail and to be able to perform the right maintenance at the right time.

For example: imagine how vulnerable would people be without the sensing ability.

US Department of Energy: The efficiencies of mechanical equipment, in general, can be increased typically 10 to 15 percent by permanent condition monitoring and scheduled maintenance.”

What Parameters Can We Measure and Observe?

  • Temperature monitoring

  • Vibration monitoring

  • Strain monitoring

  • Pressure monitoring

  • Rotational speed monitoring

  • Force monitoring

What Faults Can We Detect?

  • Bearing faults

  • Overheating

  • Shaft un-balance

  • Detached mounting

  • Gear-tooth failure

  • Load misalignment

  • Stator excentricity

  • Other machine catastrophic failures

Why Dewesoft?

We helped many companies to:

  • Drop repair costs by 32% on average

  • Reduce maintenance costs by 52% on average

  • Increase plant life

  • Increase revenue by 17% on average

  • Reduce spares inventories by 26% on average

  • Increase personnel safety

  • Cost savings in general

How Do We Help?

Every Condition Based Monitoring project flows through different phases in which strategic choices are made. If made in the right way, it will bring you the desired results.

Dewesoft system integrator companies will guide you through several critical stages delivering you a fully customized Turn-Key Condition Based Monitoring solution ensuring improved safety, availability and efficiency of your production plant.

Distributed Hardware

Dewesoft introduced the latest machine condition monitoring hardware:

  • IOLITE-2xASI: data acquisition device with two vibration input channels (with 40 kS/s sampling speed per channel) for interfacing with two ASI-1xVIB-50g vibration probes and one digital input channel for connecting an RPM sensor (tacho).

  • ASI-1xVIB-50g: a 1-axis high bandwidth (10 kHz) and low noise vibration sensor probe which also includes a temperature sensor and 3-axial low-speed accelerometer for orientation identification.

The solution is designed for applications where distributed measurements of limitless numbers of perfectly synchronized vibration and temperature measurements are of the essence and where cost plays a significant role. Fast and easy mounting of devices is facilitated by using RJ45 connectors. The solution is bringing the DAQ device very close to the sensor eliminating long analog cables and thus reducing noise pick-up and cost.

IOLITE Data Acquisition Systems

IOLITE is our family of measurement devices with single- or multi-channel general data acquisition with a wide range of input types with 24-bit resolution and 20 kS/s sampling speed. Several I/O modules are available for the measurement of voltage, current, strain gauge, vibration (IEPE and MEMS), temperature - universal thermocouple and RTD, digital I/O, and more.

Devices can be easily daisy-chained with a single Ethernet cable with up to 50m node-to-node. EtherCAT communication ensures perfect synchronization between devices.

IOLITE rack units (R8, R8R, and R12) are designed for applications where a larger amount of channels is needed at the same spot while being part of a wider EtherCAT measurement network. All rack units feature a secondary EtherCAT bus that can be used for parallel real-time data output to a 3rd party control & protection system.

KRYPTON Rugged Data Acquisition Systems

KRYPTON DAQ devices feature 3-8 measurement inputs in a rugged, waterproof, and high-temperature range package for harsh environments. Devices can be daisy-chained between each other using a single rugged cable with Lemo connectors for power, data, and synchronization.

KRYPTON devices are meant to be used in the harshest environment while fitting into the same EtherCAT chain as IOLITE devices. 

System Architecture

Dewesoft Data Acquisition systems, with their wide range of analog and digital inputs, offer support for almost any kind of 3rd party sensor. Digital and analog output devices provide the ability to drive actuators or switches. 

All EtherCAT compatible devices (IOLITE, KRYPTON) can be connected to the same network giving the possibility to build a virtually unlimited channel chain by using a single cable delivering power, synchronization, and data. The whole EtherCAT chain is synchronized to 1us no matter the distance. Node-node distances can be up to 100m

All the raw data from data acquisition devices are collected and processed by measurement units running the DewesoftX Machine Condition Monitoring software. Processed data is sent over the TCP/IP network to the server. Data can be accessed and viewed on the client PC or stored in the time series database (Historian) and served to SCADA systems or Cloud Software using standard interfaces such as OPC UA to truly support Industry 4.0 applications

Condition Monitoring Applications

Dewesoft condition-based monitoring solution is perfect for several applications in:

  • Pulp & Paper: Blowers, conveyor belts, chippers, chip classifiers, refiners, pressure screens, screw conveyors, agitators, nip monitoring, felt rollers, etc.

  • Iron & Steel: Raw material handling machines, conveyor belts, ship unloaders, galvanization plants, stack reclaimers, continuous casters, cranes, rolling mills, annealing machinery, and also pumps, fans, and gearboxes, etc.

  • Automotive: Wind Tunnels, Air handling units, and pumps in paint shops as well as presses and transfer presses, etc.

  • Cement: Crushers, gearboxes, conveyor belts, separators, fans, raw mills, ball mills, elevators, and blowers.

  • Industrial plant and facilities: Gearboxes, UPS, AC, electric motors, fans, pumps.

Customer Testimonials

Dewesoft's solution modularity and flexibility have given us more opportunities and improved our CBM applications. Compact, easy to install and really powerful.

Sandro Berchiolli, CEO, ISE Srl

 I was impressed by the professional approach of Dewesoft personnel. After a thorough investigation, they installed their permanent CBM solution that not only works but it saves a lot of money and time at my customers. On average they saved more than 40% on repair costs and increased the revenue by 15%. Amazing performance!

Mauricio Fachinetti, Managing Director, TOPFIBRA

Dewesoft product line is a perfect fit for high fidelity, distributed CBM monitoring applications. What I really liked about Dewesoft, on top of their product line, is their very professional and quick response support team.

Fadi Lama, YLE GmbH

Condition Monitoring Software

The Dewesoft machine condition monitoring software is unique on the market. It combines PC client software with in-depth machine condition analysis features, relevant for PdM expert engineers. It also offers a high-level web-based software layer with an overview of data of the machinery state, appropriate for quick decision making, and a Historian time-series database for permanent storage of the data.

Dewesoft machine condition monitoring software user interface is translated into all major languages - English, Spanish, Portuguese, Chinese, Japanese, Korean, German, Italian, French, Russian, and others. 

Learn more about Dewesoft machine condition monitoring software.

Condition Monitoring Software

The Dewesoft machine condition monitoring software is unique on the market. It combines PC client software with in-depth machine condition analysis features, relevant for PdM expert engineers. It also offers a high-level web-based software layer with an overview of data of the machinery state, appropriate for quick decision making, and a Historian time-series database for permanent storage of the data.

Rotor Balancing

After the monitoring software detects unbalance, the DewesoftX DAQ software offers a rotor balancer module that provides an intuitive step-by-step approach to balancing the rotors:

  • Single or dual-plane balancing on-site

  • Simple step-by-step procedure

  • Rich visualization

  • Weight splitting

  • Storage of influence vectors

Bearing and Gear Analysis

Enveloped acceleration is used to demodulate high-frequency acceleration spikes into the characteristic bearing and gear mesh frequencies.

A large database of bearings is readily available and open to additional entries by the user.

The software module identifies the frequencies of interest in the spectrum for each part of the bearing.

Software Architecture Overview

Calculations on raw data are performed on measurement units running DewesoftX software offering thousands of features including:

  • Integration (acceleration to velocity) or derivation (displacement to velocity) of any acquired channel

  • Low- and high-pass filters

  • Order tracking (cont. & run-up / shut-down)

  • Envelope detection

  • Tracking filters

  • Octave band analysis

  • Torsional, rotational vibration

Measurement units can either provide raw data for further display and calculations to the Client PC or in a reduced format to the Historian Database for permanent storage.

Historical data available in the Historian time database can be displayed using the Web client or PC client. The web client interface is accessible from any web browser, making it a cross-platform and mobile solution. It provides an overview of the most important machine health data and its trend over time. It also provides email alerts.

PC Client is running a standard DewesoftX Machine Condition Monitoring Software offering a detailed display of calculation results from the database including:

  • Acceleration, velocity, and displacement measurements

  • 3D Spectrum Trend

  • Envelope detection

  • Run-up/Coast-down analysis

  • Torsional and rotational vibration analysis

  • Octave Band Analysis

  • Machine Elements identification

Continuous and Run-up / Coast-down Monitoring

The order tracking software module supports both typical analysis types:

  • Continuous - constant RPM

  • Run-up / coast-down - increasing/decreasing RPM during machine start and stop routines

The monitoring software automatically detects the operation mode and provides order domain data over time during continuous operation and over RPM during run-up and coast-down.

Order amplitude values over time or over RPM can be extracted in their own channels that can be used for further computation.

Industry 4.0 (IIoT) Connectivity With OPC UA

Cloud Software

Cloud Software infrastructure is available for graphical representation of the machine state. Visualization and monitoring technology of long-term trends is available. On top of that thresholds and alarms are available to be used in combination with e-mail or SMS notifications.

The user interface can be easily customized according to customers' requirements. The data is streamed from the Dewesoft DAQ software running on the local PC over OPC into a database. The database can run on a local server or in the cloud.


Data transfer from Dewesoft to SCADA is straightforward by using the Dewesoft OPC UA Server or Client modules. In this case, Dewesoft software acts as a SCADA server or client, depending on the requirements set by the customer.

Industrial communication protocols

Several industrial interfaces and protocols are open either to serve or read data. OPC UA, Siemens S7, MODBUS, Serial communication, and EtherCAT/Ethernet communication protocols are supported as optional upgrades.

Acceleration, Velocity, and Displacement

Any number of the acquired channel can be integrated (acceleration to velocity) or derived (displacement to velocity). Acceleration, velocity, and displacement channels are preconfigured for machine monitoring needs.

The software offers a very simple way to display and visualize acceleration, velocity, and displacement waveform, and spectrum plots, all in real time.

Integration and derivation channels can be reconfigured in detail:

  • Freely settable high-pass and low-pass filters (type, order, frequency)

  • Freely settable sampling and FFT resolution for each signal - enable high-frequency resolution in the band of interest with a low number of lines

Spectrum Trend 3D Graph

Frequency spectrum data over time represents key information about the machine’s behaviour. DewesoftX 3D graph visual component is, therefore, an indispensable tool for continuous condition monitoring.

Both frequency and order domains can be displayed on the 3D graph.

Advanced 3D graph functionalities include:

  • Linear or logarithmic amplitude scale

  • Surface or line representation

  • Full-time history or selected time interval display

Dewesoft Historian - Database Storage

The Historian software package provides a time-series database for long-term data storage. The database can be either located locally, on the remote server or in the cloud. The solution is based on the InfluxDB time-series database open source project.  

Historian provides several useful features for your historic data:

  • Raw and reduced data: while raw data is always stored in the measurement unit for an in-depth analysis, the Historian takes the role of long-term reduced data storage in the cloud database.

  • Data safety and retransmit: if the connection between the measurement hardware and the database is lost, the data is safely stored locally on the measurement unit and then retransmitted to the database when the connection is available.

  • Trending and Analysis: Historical data can always be recalled and loaded from the Historian database and used for trend analysis as well as for in-depth analysis and root cause identification.

Tracking Filters - Advanced Spectrum Analysis

Tracking filters​​​​​​​ allow you to track specific orders of the rotating frequency. 

This allows to only extract the signal around a specific order band into a separate channel.

The extracted channel can be converted into the frequency domain and subtracted from the original spectrum. This allows the user to remove frequency bands specific to a certain machine part from the spectrum and analyze only the remainder of the spectrum in a separate channel.

Octave Band Analysis

Octave band analysis is used for condition monitoring based on a machine sound footprint over a wide frequency range. Dewesoft octave analysis solution meets all of the IEC and ANSI Class I specifications for octave filters.

Octave Band Analysis core features:

  • True octave analysis

  • Synthesized analysis

  • Resolution up to 1/24 octave

  • Frequency sound weighting

  • Frequency averaging

Web Client for Overview and Alerts

The web client interface is accessible from any web browser, making it a cross-platform and mobile solution. It provides an overview of the most important machine health data and its trend over time.

Alarm and alert levels can be set on each display and tied to email/SMS notifications.

The solution is based on the Grafana open source project which was enhanced by Dewesoft to support features like vector display (FFT) and selective loading of historical data which dramatically speeds up the loading of long-term data in the displays.

Torsional and Rotational Vibration

Torsional vibrations are quite often a source of issues and faults on long shafts. The rotational and torsional vibration provides an in-depth analysis of torsional angle behavior between two ends of a shaft as well as into the vibration of the rotating velocity.

  • Easy sensor setup; no need for the same sensor type on both ends

  • Access to all data: resulting channels used in further calculation

  • Advanced math: input filters, rotational DC filters

  • Order tracking analysis integration

Orbit Analysis with Orbit Plot

Orbit analysis is a necessary tool for vibration analysis of rotating machinery. The process is essentially an extension of time waveform analysis plotting time-domain data from a pair of orthogonal probes on an orbit graph with consideration for the physical location of the proximity probes.

Out of the box, Dewesoft Orbit Analysis Solution packs the entire set of industry-proven analysis metrics, supporting calculation and graphical representation of:

  • Raw orbit

  • Averaged orbit

  • Filtered orbit

  • Polar plot

  • Bode plot

  • Shaft centerline

  • Full-motion graph

  • Clearance circle

  • Runout compensation

  • Reference orbit

  • Complete set of waterfalls.

Integration Into 3rd-party Enterprise Software

SCADA, CMMS, or ERP systems can be connected to the Dewesoft Historian service over the MQTT messaging protocol or directly to the InfluxDB database using its API.

The Historian acts as an MQTT broker, enabling data stream to a 3rd party MQTT client.

InfluxDB database provides a well-documented open API that is easy to implement and enables historical data access, typically for integration into machine learning software.

Frequency Spectrum Machine Elements Identification

The software allows for simple identification of machine parts in the frequency spectrum:

  • Input and output shafts

  • Bearings

  • Gears

Machine parts are defined by their characteristic multiplier of the base RPM. Harmonic markers help distinguish between harmonic and base frequencies. Markers can be used with any quantity on the horizontal axis:

  • Frequency in Hz

  • Rotational speed in RPM or CPM

  • Order

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