Prognos™ Ecosystem
Predictive Maintenance Made Easy
The unified IIoT ecosystem seamlessly combining wireless vibration sensing, electrical signature analysis, autonomous smart lubrication, and cloud AI diagnostics to eliminate unplanned downtime across global industries.
Preventing Unscheduled Stoppages & Maximizing Plant Asset Reliability
Engineered by Zadeh.Tech, the Prognos™ ecosystem safeguards critical production lines, supports reliability and maintenance teams across machine lifecycles, and minimizes operational risk. Deploy continuous condition monitoring across hundreds or thousands of assets within days.
End-to-End Industrial IIoT Topology
A synchronized ecosystem uniting precision hardware, resilient RF mesh, autonomous edge computing, cloud analytics, and enterprise IT/OT integration.
Edge Sensing & Actuation
Prognos 3, 5 & 5 Ex vibration sensors, Prognos E-CM electrical monitors, and Prognos C1 / C4 autonomous smart lubricators.
Industrial Wirepas Mesh
Decentralized 2.4 GHz self-forming and self-healing RF mesh. Multi-hop architecture immune to harsh steel-plant RF noise.
Prognos Edge Gateway
Independent cellular (LTE/4G), Ethernet, and Wi-Fi uplink. Zero footprint or security conflict with plant internal OT/IT networks.
Zadeh Cloud Analytics
High-throughput time-series processing, Remaining Useful Life (RUL) estimation, and machine learning defect pattern recognition.
Enterprise REST API & SSO
Direct bi-directional data pipelines to SAP PM, IBM Maximo, and SCADA. Secure corporate login via Azure AD / OIDC with MFA.
Unified User Experience
Prognos Mobile App for field technicians, Web Dashboard for plant executives, and ExpertViewer for certified vibration analysts.
A Closed, Automated Loop for Manufacturing Resilience
The Prognos™ ecosystem is not an isolated point tool. It creates a self-reinforcing continuous feedback loop connecting physical factory assets directly with cloud intelligence and field action.
High-resolution tri-axial acceleration, velocity, and surface temperature capturing microscopic micro-fractures in rolling bearings.
Cabinet-level current, voltage, active/reactive power, and power factor analysis for submerged pumps and inaccessible motors.
Feedback-driven grease and oil delivery adjusting dispensing rates automatically based on real-time bearing friction and thermal load.
Automated spectral peak identification, envelope demodulation, Remaining Useful Life (RUL) projection, and trend extrapolation.
Four-tier color triage (Red Severe, Yellow Warning, Green Normal, Gray Suspect) with NFC machine tagging for maintenance technicians.
ISO 18436 Category III/IV vibration analysts providing secondary validation, threshold calibration, and root cause diagnosis.
Built for the World’s Most Demanding Environments
Certified enclosures, long-life lithium power cells, explosion-proof ratings, and precision electronics designed to withstand high heat, washdowns, and intense vibration.
Prognos 3
Optimized for standard rotating machinery across industrial plants. Continuously measures vibration and surface temperature to detect unbalance, misalignment, looseness, and bearing wear.
Prognos 5
Engineered for high-speed and complex machinery. Delivers broader high-frequency bandwidth for early identification of gear mesh impacts, compressor blade anomalies, and bearing defects.
Prognos 5 Ex
Certified intrinsically safe for explosive gas and dust environments. Provides the full diagnostic capability and high-speed bandwidth of Prognos 5 within certified explosion-hazard zones.
Prognos E-CM
Advanced 2-channel electrical condition monitor installed directly inside the motor control cabinet on standard 35mm DIN-rail. Evaluates stator and rotor health of low- and medium-voltage AC induction motors (DOL or VFD) using split-core current transformers or Rogowski coils. Ideal for submerged pumps, harsh slurry agitators, and furnace drives.
Prognos C1 Lubricator
Compact electromechanical lubricator operating at pressures up to 10 bar. Wirelessly connected to the Prognos Mesh, it reports remaining grease levels, battery charge, and back-pressure blockage alarms directly to the cloud. Guarantees precise, temperature-compensated lubricant dosing without grease bleeding.
Prognos C4 Heavy-Duty
Heavy-duty electromechanical piston pump generating an astounding 70 bar operating pressure. Features 4 independent output ports with 6mm push-in fittings, allowing long tubing runs to remote, hot, or inaccessible bearing positions. Accommodates standard grease cartridges up to 750 cm³ or an 850 cm³ oil reservoir.
Prognos Gateway & Gateway 2
The central industrial communication bridges of the ecosystem. Wirelessly aggregates telemetry from up to 50 field sensors and lubricators via the Wirepas Mesh protocol and uplinks encrypted payloads directly to Zadeh Cloud over integrated cellular LTE/4G, Ethernet, or Wi-Fi. Features internal hardware security modules (IEEE 802.1AR IDevID) and ATEX/IECEx Zone 2/21 hazardous area compliance.
Request Gateway PilotOptimized Vibration Measurement Modes
Prognos sensors automatically adapt their acquisition algorithms to match machine duty cycles, optimizing data resolution while conserving multi-year battery reserves.
Standard Mode
Samples vibration parameters and temperature at regular, predetermined time intervals. Designed specifically for industrial machinery operating continuously for at least 4 hours per shift.
Dynamic Mode
The sensor actively monitors machine state and initiates precision sampling only when the asset is running and has reached thermal and mechanical stability (≥30 seconds continuous operation).
High Dynamic Mode
Ultra-fast event detection engineered for short-cycle machinery with active operational bursts lasting between 5 and 30 seconds. Captures peak transient shock loads and bearing impacts.
From Mobile Field Triage to Deep Vibration Analytics
A unified software hierarchy catering to plant technicians, reliability directors, and ISO-certified vibration analysts.
Prognos Mobile App
Available for iOS & Android, the mobile application provides hands-on technicians with instant machine diagnostics, NFC commissioning, and visual condition badges.
- Severe (Red): Critical damage requiring immediate shutdown or urgent intervention.
- Warning (Yellow): Developing defects flagged for planned turnaround maintenance.
- Normal (Green): Verified optimal vibration within ISO 10816 baseline thresholds.
- Suspect (Gray): Unverified or early-stage anomalies flagged for baseline trend tracking.
- Lubrication Triage: Cartridge days remaining & back-pressure line alerts.
- Connectivity Status: Instant notification for nodes missing mesh packets.
Prognos Web Dashboard
Centralized multi-plant overview giving corporate reliability teams total visibility across all global production lines, facilities, and rotating assets.
- Panoramic asset health hierarchy and plant tree navigation.
- Multi-variable correlation: Vibration vs Temperature vs Load.
- Automated severity scoring and fleet-wide KPI aggregation.
- Role-based user permissions (RBAC) with audit trail logs.
- Instant exportable executive reliability and compliance reports.
Prognos ExpertViewer
High-end desktop analytical suite built specifically for ISO 18436 Category II/III/IV certified vibration specialists requiring forensic diagnostics.
- High-resolution Fast Fourier Transform (FFT) frequency spectrum.
- Raw Time Waveform analysis with circular time-domain plotting.
- High-frequency Demodulation (DeMod) for micro bearing impacts.
- Sideband, harmonic markers, and gear mesh defect calculators.
- Multi-year historical trend overlay and waterfall plots.
Enterprise Interoperability & Zero-Trust Cybersecurity
Prognos integrates natively into SAP ERP, IBM Maximo, SCADA, and CMMS environments via bidirectional REST APIs while enforcing bank-grade industrial cybersecurity.
Zadeh Expert Services & 3-Phase Roadmap
We do not just ship hardware — our international reliability engineers partner with your plant through every step, from baseline establishment to full autonomy.
Installation & Deployment
Asset planning, mesh network configuration, technician onboarding and certification, and rapid plug-and-play sensor deployment across your facility within days.
Expert Co-Pilot
“We act as the guardians of your lines.” Continuous defect analysis by certified international vibration specialists, alarm threshold fine-tuning to eliminate false alerts, and documented ROI tracking.
Scaling & Site Autonomy
Seamless handover of routine system monitoring to your qualified internal site team, backed by on-demand specialist deep-dive analysis whenever critical plant anomalies arise.
Customer Experiences Across Global Heavy Industry
The strongest testament to the Prognos™ ecosystem is the proven satisfaction and documented financial savings of plant managers in tough operational settings.
“The Prognos ecosystem helped us permanently prevent unplanned production stoppages on our corrugator lines, generating over $920,000 in direct, documented financial savings. The simplicity of setup, clean user experience, and real-time visibility across all critical drives is extraordinary.”
“Installing hundreds of vibration sensors was vastly faster than anticipated and finished in just 14 hours! The commissioning was so completely seamless and trouble-free that we sent the deployment crew home well ahead of schedule.”
“The Prognos C1 smart lubricator alerted us long before any incident that the cartridge was empty. Opening the mobile app and seeing every critical bearing running smoothly in optimal green status delivers true peace of mind to our engineering staff.”
Unify Your Plant’s Reliability with Prognos™
Connect with Zadeh.Tech reliability engineering experts to evaluate your plant machinery, schedule an on-site pilot trial, or calculate your facility’s projected Return on Investment.
Contact Us
Email: sales@zadeh.tech
Phone: 09938724918
Phone: 09017378178
Address:
Azadi Innovation Factory, Tehran