Machine digital twin
See every machine. Live, in 3D and 2D.
ASTR connects to your PLCs, SCADA and shop-floor hardware and builds a live digital twin of every machine and line. Walk the plant from your screen, compare each machine with its OEM limits and act before a breakdown stops production.
Plant 1 · Fabrication hallLive · OPC UA
MACHINES
- CNC-04CNC machining centreAlarm
- PRS-01Hydraulic press 250 tWarning
- WLD-03Robotic welding cellRunning
- OVN-02Powder-coating ovenIdle
- Running
- Warning
- Alarm
- Idle
CNC machining centre
CNC-04
Alarm
- OEE
- 61%
- Spindle
- 7,850 rpm
- Temp
- 68 °C
PLC tags
| Spindle speed | DB10.DBD4 | 7,850 rpm |
| Vibration | DB10.DBD12 | 6.8 mm/s |
| Coolant temp | DB10.DBD20 | 31 °C |
| Part count | DB12.DBW0 | 1,206 |
ASTR: Vibration is above the OEM limit of 4.5 mm/s. Likely spindle bearing wear — maintenance ticket MT-219 opened.
From sensor to decision.
ASTR reads data where it already lives — on the PLC, in SCADA, or straight from a sensor — and turns it into context your team can act on.
Field
Machines & sensors
Motors, drives, temperature, vibration, energy, counters.
Control
PLC
Logic and tags on your existing controllers.
Supervisory
SCADA / HMI
Alarms, events and operator screens.
Edge
Edge gateway
Protocol conversion, buffering and security.
Intelligence
ASTR AI
OEE, OEM limits, breakdown prediction.
Action
Twin · Alerts · Work orders
In Anvaya, on any device.
PLC & SCADA integration
Speaks the protocols your plant already runs.
Read-only by default. Write-back to setpoints only where you approve it, with every change logged.
- OPC UA
- OPC DA
- Modbus TCP
- Modbus RTU
- MQTT
- Profinet
- EtherNet/IP
- S7 protocol
- REST / Webhooks
- Tag mapping from PLC addresses to named machine signals
- Alarms and events pulled from existing SCADA and HMIs
- Buffering at the edge when the network drops
- Data history for trends, playback and audits
Hardware integration
No PLC? We add the sensors.
Vibration & temperature sensors
Condition monitoring on motors, spindles and bearings.
Energy meters
Power per machine, per shift and per unit produced.
Weighbridges & scales
Weights captured straight into orders and batches.
Barcode, QR & RFID
Track material, WIP and finished goods by scan.
Cameras & vision QC
Visual inspection and defect capture at the line.
Counters & proximity sensors
Cycle counts and part counts on older machines.
Edge gateways
Secure bridge from the shop floor to ASTR.
Andon & floor displays
Live status and alerts where operators work.
What the twin tells you.
Live OEE per machine
Availability, performance and quality as they happen, not at month end.
OEM limit comparison
Every signal checked against the manufacturer’s operating range.
Breakdown prediction
Drift in vibration, temperature or cycle time flagged early.
Alarm history & playback
Replay what a machine did before a stoppage.
Energy per unit
Know which machines and shifts cost the most to run.
Work orders from alerts
Maintenance tickets raised in Anvaya automatically.
