Sensor output synchronization with alignment reference points

A non-transitory computer storage in communication with a maintenance infrastructure, the maintenance infrastructure comprising a plurality of remote monitors, each monitor comprising:

• a wireless communication module, a microcontroller, an accelerometer, and a battery module, each monitor configured to collect machine samples from a machine or a subcomponent of the machine in a plant, the monitor in wireless communication with a receiver, the receiver configured to transmit the samples to one or more upstream servers in the maintenance infrastructure, wherein the non-transitory computer storage is configured to store executable program instructions that, when executed by one or more computing devices, configure the one or more computing devices to perform operations comprising:
• a first monitor, collecting samples from a first component of a machine, generating a first monitor output sample waveform;
• a second monitor, collecting samples from a second component of the machine, generating a second monitor output sample waveform;
• providing the monitors with synchronization instructions;
• the first monitor, sending a synchronization beacon comprising sample identifier of a first monitor sample, the first monitor sample corresponding to a sample collected by the first monitor when sending the synchronization beacon;
• a second monitor, receiving the synchronization beacon;
• the second monitor, recording a second monitor sample corresponding to a sample collected by the second monitor when the second monitor received the synchronization beacon;
• generating an alignment reference point comprising a pair of samples, the pair comprising the first monitor sample and the second monitor sample;
• an upstream server in the maintenance and monitoring infrastructure, receiving the alignment reference point;
• the upstream server aligning the first and second monitors output sample waveforms to superimpose the pair of samples in the alignment reference point;
• the upstream server, identifying a failure type and/or a failure source from the aligned output sample waveform between the first component and the second component of the machine;
• and
• troubleshooting the failure source, based on the aligned first and second monitors output sample waveforms.

A system comprising one or more processors in communication with a maintenance infrastructure, the maintenance infrastructure comprising a plurality of remote monitors, each monitor comprising:

• a wireless communication module, a microcontroller, an accelerometer, and a battery module, each monitor configured to collect machine samples from a machine or a subcomponent of the machine in a plant, the monitor in wireless communication with a receiver, the receiver configured to transmit the samples to one or more upstream servers in the maintenance infrastructure, wherein the one or more processors are configured to perform operations comprising:
• a first monitor, collecting samples from a first component of a machine, generating a first monitor output sample waveform;
• a second monitor, collecting samples from a second component of the machine, generating a second monitor output sample waveform;
• providing the monitors with synchronization instructions;
• the first monitor, sending a synchronization beacon comprising sample identifier of a first monitor sample, the first monitor sample corresponding to a sample collected by the first monitor when sending the synchronization beacon;
• a second monitor, receiving the synchronization beacon;
• the second monitor, recording a second monitor sample corresponding to a sample collected by the second monitor when the second monitor received the synchronization beacon;
• generating an alignment reference point comprising a pair of samples, the pair comprising the first monitor sample and the second monitor sample;
• an upstream server in the maintenance and monitoring infrastructure, receiving the alignment reference point;
• the upstream server aligning the first and second monitors output sample waveforms to superimpose the pair of samples in the alignment reference point;
• the upstream server, identifying a failure type and/or a failure source from the aligned output sample waveform between the first component and the second component of the machine;
• and
• troubleshooting the failure source, based on the aligned first and second monitors output sample waveforms.