Haltless
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Haltless is an industrial predictive maintenance software platform designed for operational technology (OT) and discrete manufacturing environments. The platform continuously assesses machine health to detect mechanical, thermal, and electrical degradation before equipment failures cause unplanned downtime. Core Architecture & Data Ingestion Haltless connects directly at the OT network layer using native industrial protocols, including OPC UA and Modbus TCP. It ingests high-frequency operational telemetry directly from PLCs, CNC controllers, drives, and condition-monitoring sensors without requiring disruptive hardware retrofits or intermediary supervisory layers. Key Capabilities Condition Monitoring & Anomaly Detection: Real-time analysis of vibration, current draw, and temperature patterns against baseline operational parameters. Failure Mode Identification: Automatic correlation of sensor drift and anomalies with specific failure signatures (e.g., bearing fatigue, cavitation, misalignment, drive degradation). Remaining Useful Life (RUL) Estimation: Predictive modeling that estimates component degradation timelines to support proactive maintenance scheduling. CMMS & EAM Integration: Direct export of health scores, anomaly events, and diagnostic telemetry into existing maintenance management systems. Deployment & Security Haltless supports on-premises and edge gateway deployments compatible with air-gapped industrial control networks (Purdue Model Levels 1–3), avoiding mandatory external cloud routing. It is protocol-agnostic and designed to scale across heterogeneous multi-vendor machine footprints.
Haltless is an industrial predictive maintenance platform designed for manufacturing and automation assets. Connecting natively via OPC UA and Modbus TCP, it streams operational telemetry directly from PLCs, CNC controllers, drives, and sensors without requiring cloud lock-in or hardware retrofits. The platform continuously analyzes high-frequency vibration, electrical load, and thermal patterns against baseline operational behavior. Automated diagnostics isolate mechanical and electrical failure signatures, such as bearing wear, misalignment, and cavitation, before equipment faults trigger emergency line stoppages. Haltless delivers Remaining Useful Life (RUL) estimates and feeds real-time machine health scores directly into existing CMMS and EAM workflows. Engineered for edge gateway and on-premises deployment, it operates securely across air-gapped industrial networks (Purdue Model Levels 1 to 3).
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What is Haltless?
Haltless is an AI-driven predictive maintenance platform purpose-built for industrial automation and mission-critical manufacturing assets. Most shop-floor platforms stop at tracking downtime after it happens. Haltless prevents the halt entirely. By ingesting high-frequency telemetry at the OT layer via native OPC UA and Modbus TCP, Haltless detects subtle thermal, electrical, and vibration degradation patterns long before your PLC or CNC controller throws an alarm code. No bloated MES workflows. No forced cloud lock-in. Haltless delivers edge-ready asset intelligence that isolates failure signatures, predicts Remaining Useful Life (RUL), and feeds actionable health scores straight into your existing CMMS. Deployed in hours. Built to scale across every machine, site, and shift. Protocol-agnostic. Air-gap and enterprise-OT secure. Engineered to keep production moving without interruption.