Machine Health Monitoring for Harsh Environments

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.

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.

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.

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.

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).

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.

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.

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.

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.

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.

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.

$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.

ROI typically comes in under three months. Customers see 35% less unplanned downtime in the first six months.

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.