Flux Master

Process Automation for Maintenance & Operations

Comprehensive automation solution that abstracts sensors and actuators, integrating them into a variety of processes - primarily deployed in maintenance halls and depots.

Intelligent Sensor & Actuator Integration

Flux Master is a hardware-independent automation platform that abstracts sensors and actuators, seamlessly integrating them into diverse industrial processes. Designed primarily for maintenance halls and operational depots, our solution provides flexible process control with browser-based visualization.

Whether in vehicle maintenance, equipment servicing, or depot operations, Flux Master adapts to your specific workflow requirements. Hardware independence, high availability, and predictive maintenance capabilities ensure reliable operations and minimal downtime.

Sensor & Actuator Abstraction

Universal abstraction layer for sensors and actuators that eliminates vendor lock-in and technology dependencies. Connect proximity sensors, pressure sensors, temperature sensors, and any actuator type through a unified interface. Whether you work with Siemens, Beckhoff, WAGO, or other vendors - Flux Master provides a consistent API. Replace hardware components without changing your application logic. Migrate between fieldbus systems without rewriting control code. The abstraction layer handles protocol conversions and hardware specifics, so your process logic remains clean and maintainable.

Browser-Based Process Visualization

Monitor and control your entire operation from any modern web browser - no thick clients or special software installations required. Access real-time process visualization from Windows control panels, Linux workstations, tablets, or smartphones. Maintenance technicians can monitor critical parameters from anywhere in the facility. Operations managers get instant status overview on their office computers. The responsive interface adapts to screen sizes while maintaining full functionality. WebSocket connections ensure low-latency updates even with dozens of concurrent users.

Maintenance & Automatic Mode

Switch seamlessly between automatic operation and maintenance mode without system restart. In automatic mode, the system executes programmed sequences reliably and efficiently. Switch to maintenance mode to manually control individual sensors and actuators for troubleshooting, commissioning, or process optimization. Test valve sequences step-by-step before running full production. Manually position equipment during setup and calibration. Operators can fine-tune process parameters based on real-world observations. The intuitive interface shows clear mode indicators and provides safe manual controls with configurable permission levels.

Hardware-Independent. IO-System Agnostic.

We deliver the control software - you choose your preferred IO systems and field components. No proprietary hardware that ties you to expensive single-source suppliers. Works with standard industrial fieldbus systems including EtherCAT, Profinet, Modbus TCP, and others. Select components based on your criteria: availability, price, delivery time, or existing supplier relationships. Use proven industrial components with guaranteed long-term availability and spare part supply. Retrofit existing installations by connecting to legacy IO systems. The software adapts to your hardware choices, not the other way around.

High Availability & Redundancy

Mission-critical reliability through comprehensive redundancy architecture. Duplicate critical system components with automatic failover in milliseconds. Network redundancy ensures connectivity even if primary communication paths fail. Hot standby servers maintain synchronized state and take over seamlessly when the primary system experiences issues. Redundant IO connections prevent single points of failure in field communication. Software-level synchronization keeps backup systems constantly ready. Automatic health monitoring detects degraded components before complete failure. Operations continue uninterrupted even during component replacement or maintenance.

Flexible Process Integration

Integrate sensors and actuators into diverse operational workflows across maintenance halls, depots, and facility operations. Model complex multi-step processes involving equipment positioning, safety checks, and coordinated actions. Define process sequences graphically or through configuration files. Coordinate multiple processes running simultaneously without conflicts. Handle interdependencies between equipment and resources intelligently. The flexible architecture adapts to vehicle maintenance workflows, equipment servicing procedures, cleaning operations, or custom facility-specific processes. Process definitions remain readable and maintainable even for complex automation scenarios.

Sensor & Switching Monitoring

Comprehensive monitoring and logging of all sensor readings and switching operations for predictive maintenance and fault analysis. Track how often valves actuate, monitor sensor reading trends, and detect unusual patterns. Historical data reveals equipment degradation before failures occur - catch valve seats wearing out, sensors drifting, or actuators slowing down. Automated alerting notifies maintenance teams when thresholds are exceeded. Detailed event logs support troubleshooting with millisecond-resolution timestamps. Export data for compliance reporting or detailed analysis. The monitoring system helps optimize maintenance schedules based on actual equipment usage rather than fixed time intervals.

Continuously Evolving Product

Permanent development program with new features and improvements included in your service contract. This is not an isolated custom project that becomes obsolete - it is a mature product platform continuously refined through multiple customer installations since its inception. When one customer needs a new feature, all installations benefit after thorough testing. Security patches, protocol updates, and browser compatibility improvements roll out to all systems. Bug fixes discovered in one installation protect all others. Your investment grows more valuable over time as the product matures and expands. Long-term product lifecycle ensures support availability for decades, not just years.

Real-Time Monitoring & Control

Instant visibility into all process states, sensor values, and actuator positions with sub-second update rates. Monitor pressure sensors, position switches, motor states, and any other connected IO in real-time. Color-coded status indicators provide immediate overview of system health. Live charts show trending data for critical parameters. React immediately to changing conditions - stop processes, override controls, or adjust parameters on-the-fly when needed. Responsive control interfaces acknowledge commands instantly and show execution feedback. Audit logs capture every operator interaction with precise timestamps for accountability and troubleshooting.

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