Verified hardware resource consumption, execution latencies, and MISRA-C/C++ compliant firmware architecture for mission-critical industrial drives.
Engineered for mission-critical industrial applications where memory corruption, watch-dog timer timeouts, and unhandled floating-point exceptions are unacceptable.
| Parameter | Value | Design Basis & Verification Method |
|---|---|---|
| SRAM Consumption | 375 Bytes Total | 296 Bytes static .bss state machine + ~79 Bytes active stack frame. Zero heap growth. |
| Flash / ROM Consumption | 1,712 Bytes | Stripped static library object (.a). Compiles directly into your application firmware image. |
| Worst-Case Execution Time (WCET) | 101.6 µs @ 240 MHz | 24,396 hardware clock cycles. Consumes <0.2% CPU when evaluated at 15.6 Hz. |
| Arithmetic Unit | 100% Fixed-Point Integer | Zero FPU required. Pure 32/64-bit integer bit-shift and Newton-Raphson square root. |
| Dynamic Memory Allocation | 0 Bytes (malloc = 0) | MISRA Rule 21.3 compliant. Prevents runtime memory fragmentation and memory leaks. |
| Continuous Endurance Qualification | 0.00000% False Alarm Rate | Validated across 320,000,000 physical sensor samples (10M windows / 7.4 continuous days). |
| Defect Trip Latency | 1.28 Seconds (20 windows) | Decisive health decay latch upon real bearing raceway micro-spalling inception. |
| Sensor Ingestion Agility | Sensor-Agnostic SPI / I2C | Ingests standard 16/20/24-bit tri-axial integer counts directly from FIFO (Analog Devices, STMicro, Bosch, TDK). |
| Drive & Speed Compatibility | VFD & Fixed Speed | Dynamic baseline tracking supports inverter-driven variable speed motors (300 to 6,000+ RPM) with startup transient lockout. |
Eliminates false alarms caused by plant floor noise, dropped tools, and motor startup speed ramping without compromising sub-second defect detection.
Monitors rotor acceleration during startup (0 to rated RPM). Discards startup inrush current shocks and torque transient spikes during the initial 1.28s window before establishing steady-state baseline tracking.
Distinguishes between continuous structural bearing degradation and isolated mechanical shocks (e.g. dropped wrenches, pipe fluid hammer, or forklift base bumps). Single-sample outliers are filtered prior to health decay.
Prevents model poisoning. When mechanical defect energy rises above nominal baseline thresholds, the adaptation gates instantly clamp to prevent the engine from learning anomalous vibration as "new normal."
Integrates into existing FreeRTOS, Zephyr, or bare-metal motor control firmware in fewer than 10 lines of code. No hardware timers or peripherals are hijacked.
/* 1. Include the clean public header: */
#include "ac_engine.h"
void sensor_task_process_vibration(const int32_t *x_fifo, const int32_t *y_fifo, const int32_t *z_fifo) {
/* 2. Feed 32 accelerometer counts into engine (execution: 101.6 µs): */
ac_result_t result = ac_engine_feed_and_evaluate(x_fifo, y_fifo, z_fifo, 32);
/* 3. Output to local HMI keypad screen or visual status LED: */
lcd_set_health_display(result.health_index); /* Continuous: 100% -> 0% */
/* 4. Map directly to Modbus Holding Registers or safety trip relay: */
if (result.condition == AC_STATE_CRITICAL_FAULT) {
plc_trigger_bearing_alarm_relay(); /* Autonomous machine protection */
}
}