Machine monitoring with software
How can machine data be processed meaningfully in measurement technology? Together with Status Pro, we have developed a web application for detailed processing and configuration of sensor data.
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Branche: Finanzdienstleistungen
Umsatz: 1 Mio.
Mitarbeiter: 40.000
Hauptsitz: Berlin
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Imagine you are a nurse on the night shift. Most patients are asleep and stable. But some have oxygen deficiency, high blood pressure or fever. You're all alone and have to monitor hundreds of patients. Without technical aids.

This is exactly the challenge that machine measurement manufacturer Status Pro faced with its customers. Only we're not talking about human patients here, but machines or real estate, some of which are far apart doing their work. Most machines are fine most of the time. But it is, quite literally, vital to know early on whether a machine's condition is deteriorating. And not only when it is too late and the patient can no longer be saved.

Status Pro used its know-how in measurement technology to develop modern sensors that measure the "pulse beat" of the machines. However, measuring the values does not solve the challenge. The same applies here as with the nurse: She is not helped if only important vital parameters are measured. In addition, the data must always be made available to her reliably and in real time. With a large number of patients, it is important that she is made aware of the patients in critical condition and directly receives important additional information about the patient concerned, such as the illness and the attending doctor.

This in turn can be projected to the challenge of Status Pro and its clients: Successful monitoring requires:

1. reliable machine data;
2. fast and stable processing of the data;
3. intuitive information provision with a focus on critical cases;
4. relevant context for troubleshooting.

In addition, the necessary knowledge is often distributed across multiple stakeholders. For example, machine measurement engineers have the know-how on sensors, electrical machine builders on machines, and production line operators on production processes. This results in a high communication and coordination effort, especially when problems occur.

Complementary software for processing, visualizing and configuring sensor data was to address this complex challenge and increase added value for customers.

The solution approach

In the project, a solution for machine monitoring was developed. The focus is on software for processing, visualizing and configuring sensor data that is complementary to the sensors.

With the software, the various stakeholders can monitor their machine without having to be physically on site. The machine builder can immediately see which machine is potentially in a critical state. He receives all the information relevant to indicating and rectifying the problem (e.g. location of the affected machine, contact persons, images and historical measurement data). He can then take the necessary steps to correct the problem.

Key considerations include the following:

• Data security and sovereignty
Machine data is often sensitive data. Competitive advantages can be generated from the ownership and availability of the data. Accordingly, the developed software ensures that in the multi-tenant architecture, sensitive data is stored only in the customer's own database.

• One-stop-shop
The software is not intended to be just a simple monitoring interface, but the main point of contact for machine monitoring. Accordingly, the software was developed as a bidirectional application: In addition to providing and visualizing sensor data, the application also enables sensor configuration. This specification simplifies monitoring and maintenance. For example, alarm limits can be set individually and measurement intervals can be defined.

• Intuitive and mobile use
Classic industrial software is often synonymous with cumbersome user interfaces and complicated, desktop-heavy programs. Status Pro's forward-thinking approach was to be underpinned by a modern and intuitive user interface. As in hospitals, monitoring is often done not only from the desktop, but from anywhere. Accordingly, the user interface and underlying infrastructure of the software is designed for mobile use from anywhere. At the same time, the implementation as a responsive web app has no restrictions on the security and scalability of the software. So, the best of both worlds.


Als Spezialist im Bereich Maschinenmesstechnik hat Status Pro das Marktpotenzial für die digitale Maschinenüberwachung erkannt. Dabei sorgt die Kombination aus der Erfahrung in Hardware Programmierung von Status Pro und der skalierbaren und flexiblen Softwareentwicklung von SIDESTREAM für die perfekte Symbiose für das Projekt.

Nachdem Status Pro bereits die Hardware entwickelt und den Marktbedarf validiert hatte, wurde SIDESTREAM ins Boot geholt, um nach modernen Softwarepraktiken eine robuste und nachhaltige Lösung zu entwickeln. Nach einer initialen Konzeptionsphase wurde das Projekt über mehrere Monate in zweiwöchigen Sprints entwickelt. Dabei sorgte der folgende Entwicklungsplan dafür, dass die Kunden frühzeitig die Software sehen und feedbacken konnten:

  • Die Entwicklungsphase I dient dem Aufbau einer Infrastruktur und dem initialen “Durchstich” der Datenübertragung von Sensor zur Webapplikation.
  • In der Entwicklungsphase II wurden die Bedienung der Webapplikation verbessert und weitere Funktionen hinzugefügt.
  • In der Entwicklungsphase III wurden Infrastruktur und Backend auf Live-Gang Level gebracht: So muss die Anwendung auf große Mengen von Sensordaten skalieren und die Sicherheitsstandards der Kunden erfüllen.

Damit wird eine Marktreife erreicht und die Software wird betrieben und inkrementell weiterentwickelt, sodass alle Bedürfnisse der Kunden nach und nach abgedeckt werden können.

SPIoT for electrical machine builders

Technology Deep Dive

Die gesamte Software wurde mit dediziertem Backend und Datenbank pro Kunde für ein Kubernetes Cluster entwickelt. Über einen MQTT Broker werden Sensordaten zur Verfügung gestellt, ausgelesen und anschließend zum richtigen Kunden-Stack geroutet. Diese Infrastruktur sorgt dafür, dass die Anforderungen an Nutzbarkeit, Skalierung, Sicherheit und Datensouveränität gleichermaßen erfüllt werden.

Jeder dedizierte Firmen-Stack besteht dabei aus den folgenden Komponenten:

  • PostgreSQL Relationale Datenbanken zur Verwaltung aller Daten: TimescaleDB Plugin zur Verarbeitung großer Mengen an Sensordaten
  • User Management über gotrue: Nutzerdaten werden in PostgreSQL DB gespeichert
  • VueJS Webanwendung
Matthias Reineke
Head of Department | DKB

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