Sonora
A Factory’s Early Warning System
In any large manufacturing facility, there are numerous pieces of equipment on which the plant’s productivity depends. These include motors, compressors and pumps. Each performs its own function, and no one can predict when one of them will fail.
SONORA is designed to alert production staff in advance of an impending problem. Once you receive the notification, you have approximately two weeks before the system shuts down.
This AI-powered solution enables the distinction between normal vibration and the early signs of compressor blade failure or engine misfire.
Nothing is as costly as unplanned breakdowns.
The solution has already been trialled by a number of manufacturers, including Volkswagen Polska, Freda, Industrial Fun and many others.
SONORA is designed to alert production staff in advance of an impending problem. Once you receive the notification, you have approximately two weeks before the system shuts down.
This AI-powered solution enables the distinction between normal vibration and the early signs of compressor blade failure or engine misfire.
Nothing is as costly as unplanned breakdowns.
The solution has already been trialled by a number of manufacturers, including Volkswagen Polska, Freda, Industrial Fun and many others.
Improved Reliability of Your Production Process
Sonora is your factory’s early warning system, using advanced sensors to detect mechanical damages in rotating equipment before they escalate.
Trusted by 50+ manufacturers, it’s designed for reliability in harsh conditions.
Trusted by 50+ manufacturers, it’s designed for reliability in harsh conditions.
Monitored Equipment
MOTORS
GEARBOXES
COMPRESSORS
FANS
PUMPS
BEARINGS
HOW DOES IT WORK?
1. Sensor regularly acquires vibration data , shares it with a nearby router and data is moved to the cloud for analysis
2. Sonora cloud analytics algorithms immediately analyse collected data and creates actionable reports, insights and alerts
3. Developed insights are showcased on the web dashboard and alerts are shared via email/sm
2. Sonora cloud analytics algorithms immediately analyse collected data and creates actionable reports, insights and alerts
3. Developed insights are showcased on the web dashboard and alerts are shared via email/sm
QUICK AND EASY STARTUP
No contextual information about the equipment is required. The sensor can be installed in less than a minute.
DOWNTIME - 0 MIN
Plan your repair work at a convenient time when operations are not running. Reduce downtime due to mechanical joint failures to zero.
INFORMATION ABOUT FAULTS, NOT SHOCKS
The system informs you about real impending faults, not vibration shocks caused by random impacts around the equipment.
INSTANT ROI
Thanks to favourable pricing, the return on investment can be immediate, starting from the very first month of system use.
DATA ANALYSIS
The system uses advanced algorithms to detect consistent patterns while filtering out random vibration spikes, ensuring only genuine faults are reported. It operates autonomously without requiring equipment context or calibration, enabling immediate fault detection and timely maintenance decisions.
Watch this overview video to find out how Sonora works and helps prevent production issues.
Watch this overview video to find out how Sonora works and helps prevent production issues.
Asset Overview
Access a summary of asset health statuses and group details for a quick assessment of the overall fleet condition.
Asset View
Explore detailed information about a specific asset, including health status and installation data for in-depth monitoring.
Raw Data and Features
Presentation of measurement data and features, allowing easy analysis of asset performance trends.
Defects Logs
Concise overview of identified defects, including notification and verification details, to monitor asset health effectively.
Examples of Typical Cases Where Problems Have Been Prevented
PACKAGINGBECKER COMPRESSOR VANE WEAR DETECTED
CLIENT
Vilpak
COMPANY OPERATIONS
Paper Packaging Production
EQUIPMENT TYPE
Becker compressor (vacuum pump)
Vilpak
COMPANY OPERATIONS
Paper Packaging Production
EQUIPMENT TYPE
Becker compressor (vacuum pump)
DIAGNOSED ISSUE
In April 2026, Sonora detected increasing vibration levels on a Becker compressor at Vilpak, with clear harmonic activity around 350 Hz and a rising RMS trend over several weeks. The vibration pattern indicated possible bearing wear or impeller-related degradation.
Following the alert, Vilpak performed an inspection and identified significant wear of the compressor vanes, measuring approximately 6 mm. Despite bearings and the rotor appearing visually intact, all vanes showed uniform wear, confirming the source of the vibration. After replacing the worn components, vibration levels decreased immediately, validating the detected fault.
RESULTS
Early detection of vane wear enabled timely maintenance before the issue escalated into more severe compressor damage. By identifying the defect at an early stage, Sonora helped prevent costly repairs, ensured continued operation, and reduced the risk of unplanned downtime.
FURNITUREMOTOR BEARING WEAR
CLIENT
Freda
COMPANY OPERATIONS
Furniture production
EQUIPMENT TYPE
UV processing line motor (Hymmen)
Freda
COMPANY OPERATIONS
Furniture production
EQUIPMENT TYPE
UV processing line motor (Hymmen)
DIAGNOSED ISSUE
In February 2026, Sonora detected increasing vibration levels on a motor in the Hymmen UV processing line, with rising RMS values and growing noise across the frequency spectrum. The data indicated developing tool wear or early-stage bearing deterioration.
Initial inspection suggested that elevated vibration could be partially influenced by a mechanical interference, where the drive belt was contacting a nearby structural element. However, continued monitoring showed a steady increase in RMS values, reaching levels close to critical thresholds, along with clear harmonic activity at shaft frequency – indicating progressing bearing wear.
Based on the observed trend and increasing vibration levels, the motor was replaced. The defect was validated as bearing-related deterioration.
RESULTS
Continuous monitoring enabled early identification and tracking of increasing vibration levels, allowing maintenance teams to act before reaching critical thresholds. By distinguishing between temporary mechanical interference and actual bearing degradation, Sonora supported accurate diagnosis and timely motor replacement, preventing further equipment damage.
AUTOMOTIVEBELT IMBALANCE ON GRINDING MACHINE
CLIENT
Volkswagen Polska
COMPANY OPERATIONS
Automotive manufacturing
EQUIPMENT TYPE
Grinding machine drive (belt-driven motor)
Volkswagen Polska
COMPANY OPERATIONS
Automotive manufacturing
EQUIPMENT TYPE
Grinding machine drive (belt-driven motor)
DIAGNOSED ISSUE
In April 2026, Sonora detected vibration patterns indicating belt imbalance on a grinding machine drive. The data suggested misalignment or uneven wear of the drive belts, prompting a recommendation to inspect the belt system.
Immediately after receiving the alert, maintenance personnel inspected the machine and confirmed increased vibration through manual checks. The machine was stopped, and the drive belts were replaced within minutes. The defect was validated as belt-related imbalance.
RESULTS
Early detection enabled immediate intervention and significantly reduced maintenance time. Instead of prolonged troubleshooting, the issue was identified and resolved in approximately 15 minutes, compared to an estimated one hour without prior indication. Sonora helped streamline maintenance actions and minimize operational disruption.
FURNITURECUTTER BEARING WEAR
CLIENT
SBA Innoline
COMPANY OPERATIONS
Industrial furniture manufacturing
EQUIPMENT TYPE
Edge processing cutter
SBA Innoline
COMPANY OPERATIONS
Industrial furniture manufacturing
EQUIPMENT TYPE
Edge processing cutter
DIAGNOSED ISSUE
In February 2026, Sonora detected increasing vibration levels on a motor in the Hymmen UV processing line, with rising RMS values and growing noise across the frequency spectrum. The data indicated developing tool wear or early-stage bearing deterioration.
Initial inspection suggested that elevated vibration could be partially influenced by a mechanical interference, where the drive belt was contacting a nearby structural element. However, continued monitoring showed a steady increase in RMS values, reaching levels close to critical thresholds, along with clear harmonic activity at shaft frequency – indicating progressing bearing wear.
Based on the observed trend and increasing vibration levels, the motor was replaced. The defect was validated as bearing-related deterioration.
RESULTS
Continuous monitoring enabled early identification and tracking of increasing vibration levels, allowing maintenance teams to act before reaching critical thresholds. By distinguishing between temporary mechanical interference and actual bearing degradation, Sonora supported accurate diagnosis and timely motor replacement, preventing further equipment damage.
METAL CONVERTINGFAN IMBALANCE
CLIENT
CIE LT Forge
COMPANY OPERATIONS
Metal-working facility for the automotive industry
EQUIPMENT TYPE
Industrial fan
CIE LT Forge
COMPANY OPERATIONS
Metal-working facility for the automotive industry
EQUIPMENT TYPE
Industrial fan
DIAGNOSED ISSUE
In January 2026, Sonora detected vibration patterns indicating shaft imbalance on a fan operating in the oil tank ventilation system. The data showed characteristic behavior associated with imbalance, prompting a recommendation to inspect the fan impeller and shaft.
During inspection, CIE LT Forge identified significant contamination on the fan impeller, while no bearing defects were found. The accumulated debris caused an imbalance in the rotating assembly, leading to increased vibration levels. The issue was validated as contamination-induced imbalance.
RESULTS
Early detection of imbalance enabled quick identification of the root cause and prevented further mechanical stress on the fan and its components. By distinguishing between bearing faults and imbalance, Sonora supported targeted maintenance actions and helped avoid potential equipment damage and operational disruption.
FURNITURECUTTER WEAR ON EDGE PROCESSING LINE
CLIENT
SBA Innoline
COMPANY OPERATIONS
Industrial furniture manufacturing
EQUIPMENT TYPE
Edge processing cutter
SBA Innoline
COMPANY OPERATIONS
Industrial furniture manufacturing
EQUIPMENT TYPE
Edge processing cutter
DIAGNOSED ISSUE
In February 2026, Sonora detected increasing vibration levels on a motor in the Hymmen UV processing line, with rising RMS values and growing noise across the frequency spectrum. The data indicated developing tool wear or early-stage bearing deterioration.
Initial inspection suggested that elevated vibration could be partially influenced by a mechanical interference, where the drive belt was contacting a nearby structural element. However, continued monitoring showed a steady increase in RMS values, reaching levels close to critical thresholds, along with clear harmonic activity at shaft frequency – indicating progressing bearing wear.
Based on the observed trend and increasing vibration levels, the motor was replaced. The defect was validated as bearing-related deterioration.
RESULTS
Continuous monitoring enabled early identification and tracking of increasing vibration levels, allowing maintenance teams to act before reaching critical thresholds. By distinguishing between temporary mechanical interference and actual bearing degradation, Sonora supported accurate diagnosis and timely motor replacement, preventing further equipment damage.
PROVISION OF SERVICES
Operated by Kartonika Ltd. (European Union) and its affiliate companies.
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