03 · The sizing
Channel count is not a flat package
Every sensor points to a bearing to monitor and a fault to detect. Three rules, applied in order.
Rule 1
Every bearing in the drivetrain
Motor, gearbox, driven component. An uninstrumented bearing is a fault the system will never see.
Rule 2
Two radial directions
Horizontal + vertical per bearing housing. Most faults — unbalance, misalignment, bearing defects — show up here.
Rule 3
Axial where there is thrust
Motor coupling side and gearbox output only — to avoid multiplying channels unnecessarily.
Channel count
Channel breakdown per machine
| Machine | Vib. | Temp. | Speed | Channels |
|---|---|---|---|---|
| Ball Mill (× 2) | 16 | 4 | — | 20 |
| Crusher (× 2) | 8 | 2 | — | 10 |
| Cyclone Pump (× 4) | 6 | 2 | 1 | 9 |
| Full fleet | 72 | 20 | 4 | 96 |
60 channels
Priority Phase 1 · 2 mills + 2 crushers
96 channels
Full fleet extension · + 4 cyclone pumps
The extension requires no redesign: adding IMx-8 modules and licenses, server and network unchanged.