--- title: "SenseAi Embedded: Industrial IP67 Machine Health Monitoring | IoTFlows" description: "SenseAi Embedded is an IP67 vibration and temperature sensor that mounts on the motor or spindle itself, in coolant and washdown: machine health, downtime and OEE with no PLC. Customers see 35% less unplanned downtime in the first six months (median across IoTFlows customers, internal data)." source_url: "https://www.iotflows.com/products/senseai-embedded" --- SenseAi Embedded Industrial-Grade · IP67-Rated # Machine Health Monitoring for Harsh Environments SenseAi Embedded is sealed to IP67 and mounts on the motor or spindle itself, in coolant and washdown. It reads vibration and temperature at the source, so you see bearing and per-axis health and when the machine runs, stops and why. No PLC, no control wiring. [Buy Now](https://www.iotflows.com/shop/products/senseai-embedded) 45% higher OEE 24% less unplanned downtime Real-Time Visibility & Alerts Root-cause analysisknow why, not just what Mount at the source ## On the motor. In the coolant. The housing is sealed to IP67, so **the sensor goes where the vibration starts**: on the motor, the spindle or the pump, through coolant, cutting fluid and washdown. SenseAi Embedded attaches magnetically in seconds and calibrates in under five minutes. Set the magnet flat on clean steel or iron, plug in the M12 cable, and the machine reports. [Install and power up SenseAi Embedded](https://www.iotflows.com/docs/hardware/install-senseai-embedded) Machine health ## One score. Seven gauges. SenseAi Embedded turns the vibration it reads into **a health score from 0 to 100**, judged against a baseline for the machine: its ISO 10816 class, or a profile for pumps, compressors or gearboxes. Seven gauges sit beside it, from bearing health and alignment to imbalance and cavitation risk, each rated from Good to Unacceptable, so you see what is wearing, not only that something is. [Explore predictive maintenance](https://www.iotflows.com/solutions/predictive-maintenance) For engineers ## See the data behind the score Every health score opens onto the readings behind it, so your reliability engineer can check the call before anyone picks up a wrench. - FFT spectrum, spectrogram and 3D view - Harmonic markers from 1X to 6X, with RPM read from the vibration - RMS velocity (ISO 10816), peak acceleration and crest factor trends - Kurtosis and envelope kurtosis - X, Y and Z axes and the combined XYZ vector - Per-axis health scores and directional faults Loading FFT visualization... The platform ## One sensor. Everything your plant runs on. Every SenseAi Embedded feeds the same IoTFlows platform, from the live floor to the schedule and the work order. ### Every machine, live Each SenseAi Embedded puts its machine on the Assets page: running or down, for how long, and how the shift is going, with utilization, OEE and part counts by machine, shift and operator. - Live status for every machine - Utilization and OEE by machine and shift - Part counts and cycle times - Operator performance by shift [See machine monitoring](https://www.iotflows.com/platform/machine-monitoring) ### Fix the stop that costs the most Operators give each stop a reason in a few taps at the machine, and rules classify the routine ones. The Downtimes report ranks every reason by the hours it cost, by week and by machine. - Downtime reasons with notes - Rules that classify routine stops for you - Downtime ranked by reason - Trends by day, week and month [See downtime tracking](https://www.iotflows.com/solutions/downtime-tracking) ### From a health alert to a work order When a machine’s health score falls below 60, 40 or 20, the alert goes out by push, email, SMS or Slack, and a rule can open the work order in Maintain, assigned and with the machine on it. - Health alerts at scores of 60, 40 and 20 - A work order opened by the alert rule - Work orders from a classified stop - Preventive work orders from meters [See predictive maintenance](https://www.iotflows.com/solutions/predictive-maintenance) ### Schedule on real capacity The Production Scheduler plans jobs on the machines SenseAi Embedded already watches and shows each job’s progress from the live part count. - Gantt, table, list, Kanban and calendar views - An optimizer that proposes a better order - Conflicts flagged before they reach the floor - Job progress from live counts [See the Production Scheduler](https://www.iotflows.com/platform/production-scheduler) Real-Time Alerts ## Monitor Equipment Health & Conditions Get real-time alerts for machine health degradation, temperature anomalies, and vibration patterns. Prevent equipment failures before they happen. ### Health Monitoring Track machine health scores and get alerted before failures occur ### Temperature Tracking Get alerted when a machine runs past the warning or critical temperature you set ### Vibration Detection Monitor shock and vibration levels to prevent equipment damage ### Downtime & Uptime Tracking Get notified immediately when machines go offline or idle Usage-based meters ## Service on the hours it ran, not the calendar A meter counts a machine’s **runtime hours or parts** straight from SenseAi Embedded. Your team gets an email at 85%, the work order opens in [Maintain](https://www.iotflows.com/platform/maintain) at 100%, and a reset after the service starts the next cycle. Change a gearbox’s oil every 1,250 hours or grease a spindle every 2,000, when the machine has earned it. [How meters work](https://www.iotflows.com/docs/maintain/meters) ## Customer Testimonials [Zero silent failures > "Continuous vibration monitoring gave us eyes we never had before. We can see tool crashes that would have been invisible, identify the exact moment and severity, and pull historical data to understand what went wrong." Miguel Silva, Systems Engineer, RNPSA Read Story](https://www.iotflows.com/customers/rnpsa)[20%+ higher efficiency Every Epicor job tied to its machining and labor hours. > "The real-time visibility has been amazing for optimizing our operations. With the ERP integration, I see the numbers and where every job stands, without digging for them in our ERP." Dennis Moreno, Vice President of Manufacturing and Operations, MiRus Read Story](https://www.iotflows.com/customers/mirus)[50% less shift-changeover downtime > "Where was downtime actually coming from? We had no idea until we started using IoTFlows SenseAi. By tracking downtime categorization week to week and month to month, we could see exactly where our biggest problems were and track whether our fixes actually worked." Brien Stevenson, Site Director, Datwyler Read Story](https://www.iotflows.com/customers/datwyler)[< 1 week from the box to monitored machines 87% of downtime now has a root cause, and resolution is 60% faster. > "The speed of implementation was remarkable. We went from limited visibility to complete operational transparency in less than a week. We’re now identifying inefficiencies we didn’t even know existed. IoTFlows has fundamentally changed how we approach manufacturing optimization." Kyle Simpson, Operations Manager, Sorinex Read Story](https://www.iotflows.com/customers/sorinex-exercise-equipment) Customers see 35% less unplanned downtime in the first six months. [Read the customer stories](https://www.iotflows.com/customers). ## Built for the machines that can’t fail. Spindles, pumps, compressors. If you can reach the motor or the spindle, SenseAi Embedded reads it at the source. Each machine has a guide. - [### CNC spindles On the spindle housing, in the coolant. Every cycle counted, the bearings watched. Set up a CNC machine](https://www.iotflows.com/docs/production/cnc-machines) - [### Pumps On the pump or its motor, scored with a pump profile and a cavitation gauge. Choose a baseline profile](https://www.iotflows.com/docs/monitoring/baseline-profiles) - [### Compressors and gearboxes Profiles for screw and reciprocating compressors and gear drives know their normal. Monitor machine health](https://www.iotflows.com/docs/monitoring/machine-health) - [### Motors and fans On the motor housing, scored against its ISO 10816 class by power and foundation. Install SenseAi Embedded](https://www.iotflows.com/docs/hardware/install-senseai-embedded) Best mounting point dry and easy to reach? [SenseAi](https://www.iotflows.com/products/senseai) reports the same machine performance and reads sound too. Counting units on a conveyor? Use [BeamTracker](https://www.iotflows.com/products/beamtracker). Network ## Your Wi-Fi, or a network of its own SenseAi Embedded joins 2.4 GHz plant Wi-Fi from the IoTFlows phone app and connects out over HTTPS on port 443. Rather keep it off the plant network? The [IoTFlows 4G/LTE router](https://www.iotflows.com/shop/products/4g-lte-router-ifcr-150) ships configured, and **every device within 100 ft joins on its own**. [Connect through the 4G/LTE router](https://www.iotflows.com/docs/hardware/use-the-lte-router) Power ## One adapter. A whole cell. SenseAi Embedded runs on 4.5 to 28 V DC over an industrial M12 connector that locks against vibration. Plug one into an outlet with the M12 power adapter, or **daisy-chain units mounted close together with T-splitters**, so one outlet powers the cell. [Connect power over M12](https://www.iotflows.com/docs/hardware/install-senseai-embedded#power) Buy SenseAi Embedded ## One sensor per machine. Bought once. $199 per SenseAi Embedded, once $119 per device per month on Pro, billed monthly; less on longer plans and with more devices ### In the box - SenseAi Embedded, sealed to IP67 - External antenna ### Added to your order - M12 power adapter ### At a glance Reads Vibration and temperature Housing IP67, sealed Mounts Magnetic base, no tools Network 2.4 GHz Wi-Fi or the IoTFlows 4G/LTE router Power 4.5 to 28 V DC over M12 [Buy Now](https://www.iotflows.com/shop/products/senseai-embedded)[See pricing](https://www.iotflows.com/products/senseai-embedded/pricing)[All specifications](https://www.iotflows.com/products/senseai-embedded/specs) ## Questions people ask ### What is SenseAi Embedded and how does it work? SenseAi Embedded is a vibration and temperature sensor in a sealed IP67 housing that mounts on the motor or spindle itself, in coolant, cutting fluid and washdown. It runs the same application as SenseAi and reports, with no PLC connection, when the machine runs, when it stops and why, plus machine health read at the source: a health score against a baseline, seven operations metrics such as bearing health and imbalance, the vibration spectrum, per-axis trends and the temperature. ### What’s the difference between SenseAi and SenseAi Embedded? Both run the same application. SenseAi reads vibration and sound through a magnetic base and powers over USB-C; it suits most machines. SenseAi Embedded reads vibration and temperature from an IP67-sealed housing with M12 power, so it mounts on the motor or spindle itself, in coolant and washdown, and reading at the source adds advanced health analytics and temperature alerts. ### What does SenseAi Embedded measure? Vibration and temperature, at the motor or spindle. From those readings IoTFlows reports machine status in real time, uptime and utilization, downtime with the reason for each stop, part counts and cycle times derived from the machine’s cycle, and machine health: a health score against a baseline profile, operations metrics such as bearing health, imbalance, alignment, lubrication, structural looseness and cavitation risk, the vibration spectrum with harmonic markers, X, Y and Z trends and shock events, and the temperature, with a warning and a critical alert at thresholds you set. ### Which machines is SenseAi Embedded for? Any machine where you can mount on the motor or spindle itself, or where the mounting point sees coolant, washdown or dust: CNC spindles and machining centers, pumps, compressors, gearboxes, motors and fans. Baseline profiles cover ISO 10816 classes and machine types such as centrifugal pumps, screw compressors and gearboxes. Where the best mounting point is dry and reachable, a standard SenseAi reports the same machine performance and reads sound as well. ### What does IP67 mean for SenseAi Embedded? The housing is dustproof and protected against immersion to 1 m (3 ft) for 30 minutes, so coolant, cutting fluid and washdown reach it without harm. It is sealed and pre-configured, with nothing to open or wire inside, and runs from -20 °C to 60 °C (-4 °F to 140 °F). ### How is SenseAi Embedded powered? Over an industrial M12 connector, at 4.5 to 28 V DC. Plug an M12 power adapter into a standard 100 to 240 V AC outlet, or daisy-chain units mounted close together with M12 T-splitters, with an M12 extension cable of 1 to 3 m (3 to 10 ft) where the adapter will not reach. The box holds the device and its external antenna; the M12 power parts are ordered with it in the shop. ### How long does installation take? SenseAi Embedded attaches magnetically in seconds and calibrates in under five minutes. Connect the antenna, set the magnetic base flat on a clean steel or iron surface on the motor or spindle, connect the M12 cable and lock its collar, and power it. It joins the IoTFlows 4G/LTE router on its own, or 2.4 GHz Wi-Fi from the IoTFlows mobile app over Bluetooth. IoTFlows registers each sensor to its machine before it ships, and nothing is wired into the controls. ### How does SenseAi Embedded connect to the internet? Over a 2.4 GHz Wi-Fi network, or through the IoTFlows 4G/LTE router (IFCR-150), which gives the sensors their own network and reaches the cloud over cellular, off the plant network. Either way the sensor connects out over HTTPS on port 443. ### Does SenseAi Embedded send alerts and open work orders? Yes. Event rules alert when the health score falls below 60, 40 or 20, when the temperature passes the warning or critical threshold you set (70 °C and 80 °C by default), on a shock past the threshold you set, or when a machine goes down or stays down, by email, push, SMS, Slack, Microsoft Teams, Discord or a webhook, and a rule can open a work order in Maintain. ### Does SenseAi Embedded integrate with my existing systems? Yes. Alerts post to Slack, Microsoft Teams and Discord, hosted webhooks send events to your own endpoint, and a REST API works with a key IoTFlows issues to your organization; MQTT is set up by IoTFlows with you. Schedules import from any ERP export. For Enterprise customers IoTFlows builds two-way ERP connectors and connects PLCs and robots through the IoTFlows edge device. ### Is my data secure with SenseAi Embedded? Yes. Data is encrypted at every step: from the device at the edge, in transit over TLS with SHA-256 certificates, and at rest in the IoTFlows cloud. The 4G/LTE router can keep the sensors off the plant network entirely. Access is by organization, role and machine list, with two-step authentication on every account. ### How much does SenseAi Embedded cost? $199 per SenseAi Embedded, once, then a subscription per device per month. Pro is $119 billed monthly, $99 on an annual plan paid upfront and $59.50 on a three-year plan paid upfront, for 1 to 9 devices, with lower prices from 10 and from 25 devices. 50 or more devices are quoted. The M12 power parts are ordered with it. The SenseAi Embedded pricing page has every option. ### How quickly will I see a return? ROI typically comes in under three months. Customers see 35% less unplanned downtime in the first six months. ### Can we pilot SenseAi Embedded before we commit? Yes. A pilot puts IoTFlows on 10 to 25 machines for four weeks with no commitment to buy, on the same sensors and dashboard you would keep afterwards. The SenseAi sensors in a pilot are free. SenseAi Embedded units are $199 each, and your first one is free. ## Documentation Want the detail? These guides walk through each feature step by step. - [SenseAi EmbeddedWhat it measures, what ships in the box and what it needs.](https://www.iotflows.com/docs/hardware/senseai-embedded) - [Install and power up SenseAi EmbeddedThe mounting spot, the antenna and M12 power.](https://www.iotflows.com/docs/hardware/install-senseai-embedded) - [Calibrate SenseAi and SenseAi EmbeddedRunning and stopped thresholds against what the machine does.](https://www.iotflows.com/docs/hardware/calibrate-senseai) - [Monitor machine healthThe health score, the gauges, the spectrum and the trends.](https://www.iotflows.com/docs/monitoring/machine-health) - [Baseline profilesISO 10816 classes and machine-type profiles.](https://www.iotflows.com/docs/monitoring/baseline-profiles) - [Connect a device to Wi-FiPut a sensor on 2.4 GHz plant Wi-Fi from the mobile app.](https://www.iotflows.com/docs/hardware/connect-to-wifi) - [Connect through the 4G/LTE routerBring sensors online without the facility network.](https://www.iotflows.com/docs/hardware/use-the-lte-router) - [LED and status codesWhat each light on the device means.](https://www.iotflows.com/docs/hardware/led-and-status-codes) ## Put SenseAi Embedded on your critical machines Start with 10 to 25 machines for four weeks, with no commitment to buy. Your first SenseAi Embedded is free.