Industrial Edge AI
XyloZero
XyloZero is an edge AI solution that analyzes condition signals with operating data to detect equipment anomalies early, on site.
Operators use the selected anomaly events to set inspection priorities and judge maintenance timing.
Field challenges
Equipment faults often surface only after a stop. A louder sound or a new vibration is not an anomaly by itself; start, stop and load changes have to be read alongside the signal.
How it works
Sensor nodes mount on equipment with magnets or bolts, collect condition signals, and connect to PLC and drive data. XyloZero picks the valid intervals by operating state, selects anomaly events at the edge, and sends results to dashboards, alerts and inspection priorities.
Equipment
- Motors
- Bearings
- Gearboxes
- Conveyors
- Pumps
- Fans
- Compressors
- Cranes
- Turbines
- Generators
Device
One sensor node carries microphones, motion and environmental sensors, a processor and a battery.
- Top cover
- Sealing gasket
- MEMS microphones
- ESP32-S3 module
- Main board
- Battery
- Housing
- Mounting magnets
01
Multimodal sensing
MEMS microphones, a 6-axis IMU, a magnetometer and temperature, humidity, pressure, light, CO2, VOC and NOx sensors share one board, so sound, vibration, rotation and environmental change land on the same timeline.
- Sound: 4 MEMS microphones
- Vibration and motion: 6-axis IMU
- Rotation and magnetic field: 3-axis magnetometer
- Environment: temperature, humidity, pressure, light, CO2, VOC, NOx
- Top cover
- Sealing gasket
- MEMS microphones
- ESP32-S3 module
- Main board
- Battery
- Housing
- Mounting magnets
- Screws
02
Context Gating
PLC and drive data separate running, stopped, loaded and transitional states, and XyloZero judges only the intervals worth analyzing. Signals from transients such as start-up and shutdown are less likely to be read as anomalies.
- Running, stop, load and transition states
- Valid intervals selected for analysis
- Less noise and fewer false alarms
03
XAP and XMBP data path
Sound is compressed with XAP (Xylolabs Audio Protocol), an LC3-based audio codec, and sensor readings are packed with their timestamps into XMBP (Xylolabs Metadata Binary Protocol) batches. Both travel to the server in one HTTPS session; compression and batching keep uploads small on narrow site links.
- XAP: LC3-based audio compression
- XMBP: batched sensor readings
- HTTPS session uploads and OTA updates
Collect, context, select, act
Collect
Condition signals and PLC and drive data are collected on site.
Context
Operating state and site conditions are analyzed on the same timeline.
Select
Edge AI selects the anomaly events that matter.
Act
Events reach the control room, alerts, inspection priorities and follow-up.
Key capabilities
- Multimodal sensing: sound, vibration, temperature and humidity, magnetic field
- PLC and drive data integration
- Context Gating by operating state
- Edge AI inference
- Anomaly event selection
- Dashboard, alert and maintenance system integration
Deployment goals
- Early anomaly detection
- Inspection priorities
- Maintenance timing support
- Fewer unplanned stops and safety risks
Key specifications
| Sound | 4 MEMS microphones, 48 kHz 4-channel capture |
|---|---|
| Vibration and motion | 6-axis IMU (accelerometer, gyroscope) |
| Magnetic field | 3-axis magnetometer |
| Environment | Temperature, humidity, pressure, light, CO2, VOC and NOx |
| Power status | Voltage and current monitoring |
| Processor | ESP32-S3 dual-core 240 MHz, 16 MB flash, 8 MB PSRAM |
|---|---|
| Audio codec | XAP (LC3-based) |
| Data format | XMBP binary batches |
| Connectivity | Wi-Fi 2.4 GHz, HTTPS (TLS 1.3), LTE through an external router |
| Equipment integration | Industrial protocols such as CAN and EtherCAT |
| Storage | microSD local archive |
| Updates | Over-the-air updates |
| Power | USB-C, 1-cell lithium-ion battery charging |
|---|---|
| Battery | 10,000 mAh |
| Battery life | 1 year (varies with operating conditions) |
| Mounting | Magnets or bolts |
| Explosion-proof certification | Optional |
Frequently asked questions
- Which signals does XyloZero use?
- Condition signals such as sound, vibration, temperature and humidity and the magnetic field, together with PLC and drive data.
- Which equipment comes first?
- Equipment whose condition signals can be collected: motors, bearings, gearboxes, conveyors, cranes, pumps, fans and compressors.
- Do we need to replace our PLC or control system?
- No. We check the site interfaces and connect to existing PLC and drive data and to control, alert and maintenance systems.