SSMDE – Industrial / Hardware Health (3.3)

From raw vibration and temperature to policy-grade maintenance and shutdown decisions

Problem → Fit

Problem. Machines do tell the truth — but only as numbers.
What humans need is:
• Is this safe?
• Is this drifting?
• Does this require slowdown, inspection, or shutdown right now?

Without shared meaning and timestamped policy, maintenance becomes guesswork and post-failure blame.

Fit. SSMDE turns each measurement into a policy-bearing safety state with:
• value (the raw reading),
• align (bounded stability / risk dial in (-1,+1)),
• band (actionable human status),
• manifest_id (declared safety rulebook),
• stamp (tamper-evident time and order proof).

The invariant dial (align)

Hardware telemetry can be noisy. But align is always bounded, fusable, and order-invariant:

a_c   := clamp(a_raw, -1+eps_a, +1-eps_a)
u     := atanh(a_c)
U     += w * u
W     += w
align := tanh( U / max(W, eps_w) )
  • a_raw is how far this reading is from safe baseline, declared in the manifest.
  • w may depend on load, runtime hours, strain, or other declared weighting.
  • Output is always -1 < align < +1.

No spike overwhelms the history. No “rolling average magic.” No silent reinterpretation.

Collapse parity stays intact: phi((m,a)) = m
Meaning: the value stays exactly the measured value, always.

Mapping to policy bands

Declare band cutpoints and actions in the manifest:

bands := [
  { name:"GREEN",  range:"[+0.35, +1.00)", action:"normal operation" },
  { name:"AMBER",  range:"[-0.20, +0.35)", action:"slowdown + schedule inspection" },
  { name:"RED",    range:"(-1.00, -0.20)", action:"controlled shutdown + notify maintenance <= 15m" }
]

band is not UI color.
band is an operational instruction.

What a hardware-state SSMDE record looks like

Minimal (dashboard-friendly)

{
  value: { bearing_vibration_rms: 0.037 },
  band: "AMBER",
  manifest_id: "PLANT_A_BEARING_SAFETY_v7"
}

Full (safety, insurance, audit, and warranty-grade)

{
  value: { bearing_vibration_rms: 0.037, rpm: 3400 },
  align: -0.28,
  band:  "AMBER",
  manifest_id: "PLANT_A_BEARING_SAFETY_v7",
  stamp: "SSMCLOCK1|2025-11-05T10:14:55Z|sha256=8fe3...|prev=71bc..."
}

Reading this record:

  • The vibration measurement is exact.
  • align = -0.28 means drifting, risk emerging.
  • band = AMBER means slowdown + inspection required.
  • manifest_id tells you which safety policy defined AMBER.
  • stamp proves this statement existed at that time in that order.

No dashboard interpretation.
No dispute.
No blame post-failure.

Where a_raw comes from (declared per asset)

Choose one, declare in the manifest, and do not change mid-run:

a_raw := stability_score_from_baseline(vibration_fft, baseline_fft)
a_raw := -strain_ratio(actual_strain / max_safe_strain)
a_raw := -delta_temp_over_allowed((T_now - T_nominal) / margin)
a_raw := health_signal_from_model(soh_battery_pct)

Semantics MUST be declared:

positive = stable / predictable
negative = unstable / approaching failure mode

Producer workflow (sensor or gateway)

[ ] Measure raw value(s) exactly
[ ] Compute a_raw using declared baseline/logic
[ ] Run clamp → atanh → fuse → tanh to compute align
[ ] Determine band via manifest cutpoints
[ ] Emit SSMDE record with manifest_id and stamp

Consumer workflow (maintenance / control system)

IF band == "GREEN" → normal operation
IF band == "AMBER" → slowdown + inspection window
IF band == "RED"   → trigger controlled shutdown + notify human

No hidden heuristics.
No “interpretation layer.”
The data itself gives instructions.

Fleet and vendor interoperability

Two plants, two vendors, two sensor OEMs — no problem.
The manifest makes the rulebook public and stable:

manifest_id: "PLANT_A_BEARING_SAFETY_v7"

Anyone can replay it later.

This is what makes insurance, warranty, maintenance contracts, and regulator audits finally operate on shared, provable truth.

Copy-ready real-world example

{
  value: { pump_temperature_K: 341.7, load_pct: 82.1 },
  align: -0.61,
  band:  "RED",
  manifest_id: "PLANT_B_PUMP_HEAT_v11",
  stamp: "SSMCLOCK1|2025-11-05T11:02:09Z|sha256=b73c...|prev=e221..."
}

Interpretation:

  • This pump was already in failure approach territory at 11:02:09Z.
  • The threshold was not guessed — it is declared in manifest v11.
  • No one can later say “we didn’t know.”

One-line takeaway

SSMDE makes machine telemetry actionable, explainable, and replayable — turning raw sensor values into safety-grade operational decisions with proof.

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