Predictive Valve Integrity System
Your hydraulic valves already know they are failing. Nothing is listening.
CANARY installs inline between the plant and a hydraulic proportional or servo valve and runs a proprietary AI prognostic engine over the signals the valve has been emitting all along — current draw, spool behaviour, vibration, acoustic emission. In a 75-day pilot programme it forecast 17 of 17 predictable failures across seven degradation modes, with a minimum of 9.1 days’ warning, so the repair lands in a planned maintenance window instead of a stopped production line.
$799 deposit per unit secures your allocation · $2,946 all in · ships March 2027
At a glance
- Failure modes watched
- 7
- Typical warning lead
- 8–10 days
- Installation
- Inline, 12-pin
- Control loop impact
- None
- Valve types
- Proportional, servo
- Supply
- 24 VDC
How we report performance. The headline figures above come from a 75-day pilot programme on a ten-valve fleet, not from simulation. Our Monte-Carlo simulation programme produced closely comparable results, which is the correlation we were testing for. Every number on this site states where it came from. See the full pilot results.
The problem
Fixed intervals get it wrong in both directions
Without condition data, a maintenance schedule is a guess. Guess short and you strip serviceable valves. Guess long and the valve fails between service windows and takes the line with it. Both errors are expensive, and most plants are making both at once on different assets.
Over-maintenance
Serviceable valves pulled, stripped and rebuilt on a calendar. Parts, labour and planned downtime spent on components that had useful life remaining.
Under-maintenance
Degradation outruns the schedule. The valve fails between windows, converting a planned repair into an emergency callout with the line stopped behind it.
Service on condition
When the valve reports its own state continuously, the schedule stops being a guess. Work happens when the valve needs it, inside a window you chose.
What makes it different
Monitoring at the valve, not at the plant
It sits inline, and changes nothing
CANARY passes the supply and the full control signal straight through on a 12-pin input and a 12-pin output. It is a measurement device, not a controller: it never drives the valve, never intercepts a command, and leaves the existing control loop untouched. If the monitor loses power, the valve carries on.
It reads the signals that move first
Degradation begins as micro-changes in current draw, hysteresis, response timing and high-frequency acoustic energy — well below what a walk-round inspection or a handheld gauge can resolve. By the time a fault is visible to an operator, the valve is already failing.
A proprietary AI engine, not a threshold alarm
Anyone can tell you a valve has broken. CANARY runs a purpose-built prognostic model that fuses thirty engineering measurements, learns each valve’s own signature, and answers a harder question: how long until this reaches its limit. In the pilot it answered that question correctly seventeen times out of seventeen, and every time-to-failure estimate landed early rather than late. The output is a maintenance date, not a klaxon.
It tells you what it cannot see
A failure mode whose sensors are not fitted reports not monitored and names what it needs. It never shows a reassuring OK for something it is not actually watching. We think that is the minimum bar for a device people will plan around.
Coverage
Seven failure modes
Spool & sleeve wear
Rising friction, a weakening centring spring, growing hysteresis and response threshold.
Silting
Fine particles settling in radial clearances while the spool rests, producing silt lock.
Erosion & internal leakage
Metering edges rounding, internal seals bypassing. Requires pressure transmitters on ports A and B.
Cavitation
Bubble collapse at the metering edges, detected by high-frequency vibration and acoustic emission.
Coil degradation
Shorted turns and insulation ageing, visible as rising current per unit command and estimated coil temperature.
Valve electronics
Ageing capacitors, a drifting power stage, position-sensor noise, connector and solder fatigue.
Wiring & supply
Corroding or loosening pins, a weak plant supply, voltage sag under load, surges.
And what it cannot
External weeping, a cut cable, a sudden spring break or a single large particle jam. No precursor, no prediction — we say so.
The prognostic engine
Proprietary AI, built for one job
CANARY does not run a generic anomaly detector. Its prognostic engine was developed specifically for hydraulic proportional and servo valves, trained against the physics of how those valves actually degrade, and proven in a 75-day pilot against seven distinct failure modes.
Milliseconds and weeks, together
One branch reads high-frequency electrical transients; another reads degradation trend across 24-hour sequences. Fusing the two is what separates prognosis from detection.
It learns your valve, not a spec sheet
Every judgement is made against that specific valve’s own commissioning signature. In the pilot, used and remanufactured valves were detected as reliably as new ones.
Corroboration before escalation
Thirty engineering measurements are tracked hourly. The engine requires agreement across several before it raises a WARNING, which is what holds the false-alarm rate down.
No cloud in the loop
Inference runs on the monitor itself. No plant network round trip, no subscription, and no dependency on a service staying available to form a judgement.
Universal by design
Built for a mixed valve fleet
Plants rarely standardise on one valve. CANARY is specified to fit across a fleet: connectors are built to match the valve at order, and the control signal is set in configuration rather than by buying a different model.
Built to your valve
6+PE and 11+PE, DIN 43563, MIL-C-5015 7-pin and 12-pin, and the Form A, B and C solenoid connectors. Pin assignment matched from your data sheet.
18 configurations
Not a ±10 V-only device. Six voltage ranges from ±2 V to ±10 V, and twelve current ranges from ±5 mA to ±100 mA including 4 to 20 mA.
Four universal inputs
Each configured independently, so the command and the actual-value feedback can run on different signal types on the same valve.
Pre-order
1,700 units left — shipping March 2027
Pre-orders are open on the first 3,500 units. 1,800 are already accounted for in the initial production run. Allocation is strictly by deposit date.
$799
Per unit. Secures your allocation; the pre-order agreement follows.
$2,946
Against $3,995 retail — 20% off now, a further $250 off at invoicing.
1,700
Of the 3,500 opened. First come, first served.