--- title: "SenseAi: Plug-and-Play AI Machine Monitoring Sensor | IoTFlows" description: "SenseAi is a magnetic-mount AI machine monitoring sensor: real-time OEE, downtime and root-cause analysis 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" --- SenseAi # Real-Time Machine Monitoring for Maximizing Machine Performance Snap SenseAi onto any machine with a motor. It reads vibration and sound, and your dashboard shows when the machine runs, when it stops and why. No PLC, no wiring. [Buy Now](https://www.iotflows.com/shop/products/senseai) Install ## On the machine in seconds. Calibrated in minutes. SenseAi attaches magnetically in seconds and calibrates in under five minutes. Screw on the antenna, plug in the power and set the magnet flat near the spindle or main motor. Paint makes no difference. Run the machine, let it idle, and **running and stopped are set for that machine**, so its uptime matches what it actually did. [Install and power up SenseAi](https://www.iotflows.com/docs/hardware/install-senseai) Parts ## Part counts without a counter The same trace that says running also marks every cycle. Pick how the machine counts, and **each stroke or cycle becomes a part**, with its cycle time. Counting units as they pass a point on a line? That is [BeamTracker](https://www.iotflows.com/products/beamtracker). [Choose a counting algorithm](https://www.iotflows.com/docs/production/choose-an-algorithm) Network ## Your Wi-Fi, or a network of its own SenseAi 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) The platform ## One sensor. Everything your plant runs on. Every SenseAi feeds the same IoTFlows platform, from the live floor to the schedule and the work order. ### Every machine, live Each SenseAi 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 stop to a work order When a stop needs a repair, the operator opens the work order from the same dialog, with the reason, the note and the machine already filled in. Maintenance sees it in Maintain right away. - A work order from a classified stop - The reason, note and machine filled in - Work orders from alerts and meters too - Operator View on a tablet at the machine [See Maintain](https://www.iotflows.com/platform/maintain) ### Schedule on real capacity The Production Scheduler plans jobs on the machines SenseAi 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, shocks and vibration patterns. Prevent equipment failures before they happen. ### Health Monitoring Track machine health scores and get alerted before failures occur ### 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. 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. Grease a spindle every 2,000 hours or inspect a press every 100,000 parts, when the machine has earned it. [How meters work](https://www.iotflows.com/docs/maintain/meters) ## Customer Testimonials [< 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)[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)[2x machine utilization Chemical bath timing errors went to zero. > "SenseAi gave us eyes we never had before. Our team leaders can instantly see which machines are running, which are down, and identify issues immediately instead of discovering them hours later. That visibility transformed our ability to manage production." Ben Huskey, Quoting Manager, Storm Power Components Read Story](https://www.iotflows.com/customers/storm-power-components)[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) Customers see 35% less unplanned downtime in the first six months. [Read the customer stories](https://www.iotflows.com/customers). ## Fits the machines you already run. Old or new. If it has a motor and a steel frame, SenseAi can read it. Each machine type has a set-up guide. - [### CNC mills and lathes On the frame near the spindle. Cycle times that change with the part are no problem. Set up a CNC machine](https://www.iotflows.com/docs/production/cnc-machines) - [### Injection molding On the injection unit or near the hydraulic power unit, every cycle counted. Set up a molding machine](https://www.iotflows.com/docs/production/injection-molding) - [### Presses and press brakes On the frame near the ram, counting 10 to 120 strokes a minute. Set up a press](https://www.iotflows.com/docs/production/stamping-presses) - [### Robots, lasers and waterjets On the frame or the base, reading every cycle the cell runs. Install SenseAi](https://www.iotflows.com/docs/hardware/install-senseai) Coolant or washdown at the motor? Use [SenseAi Embedded](https://www.iotflows.com/products/senseai-embedded), sealed to IP67. Counting units on a conveyor? Use [BeamTracker](https://www.iotflows.com/products/beamtracker). Buy SenseAi ## One sensor per machine. Bought once. $149 per SenseAi, once $119 per device per month on Pro, billed monthly; less on longer plans and with more devices ### In the box - SenseAi sensor - External antenna - USB-C cable (10 ft) - USB-C power adapter ### At a glance Reads Vibration and sound Mounts Magnetic base, no tools Network 2.4 GHz Wi-Fi or the IoTFlows 4G/LTE router Power USB-C, 5 V Install Seconds to mount, under five minutes to calibrate [Buy Now](https://www.iotflows.com/shop/products/senseai)[See SenseAi pricing](https://www.iotflows.com/products/senseai/pricing)[All specifications](https://www.iotflows.com/products/senseai/specs) ## Questions people ask ### What is SenseAi and how does it work? SenseAi is a magnetic-mount sensor that reads a machine’s vibration and sound and reports, with no PLC connection, when the machine runs, when it stops and why. It attaches magnetically in seconds and calibrates in under five minutes. The sensor decides running or stopped against thresholds calibrated for that machine, and the IoTFlows cloud turns the stream into uptime, utilization, downtime, part counts and cycle times, and vibration health, on the web dashboard, the iOS and Android apps and the screens on your floor. ### What machines can SenseAi monitor? Any machine with a motor and a flat steel or iron surface near it: CNC mills, lathes and grinders, presses and press brakes, injection molding machines, robot cells, lasers, waterjets and EDM machines. For washdown or coolant positions use SenseAi Embedded, sealed to IP67; to count units as they pass a point on a line, use BeamTracker. ### What does SenseAi measure? Vibration and sound. From that one stream 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 own cycle, operator performance by shift, and vibration health: a health score against a baseline, vibration trends and shock events. ### 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. ### How long does installation take? SenseAi attaches magnetically in seconds and calibrates in under five minutes. Screw on the antenna, power it from the supplied adapter or a machine USB port that supplies at least 500 mA, set the magnetic base flat near the spindle or main motor, and bring it online from the IoTFlows mobile app over Bluetooth, or let it join the IoTFlows 4G/LTE router on its own. IoTFlows registers each sensor to its machine before it ships, and nothing is wired into the controls. ### How does SenseAi connect to the internet? Over a 2.4 GHz Wi-Fi network secured with WPA2-PSK or WPA3, 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. ### Do I need IT, a PLC or protocol knowledge to install SenseAi? No. There is no PLC, protocol or wiring to set up, and with the 4G/LTE router there is nothing for IT to configure. IoTFlows helps you calibrate each sensor for its machine and mounting spot during onboarding. ### Does SenseAi send alerts? Yes. Event rules alert when a machine goes down or stays down past the minutes you set, on a shock, or when the health score falls, by email, push, SMS, Slack, Microsoft Teams, Discord or a webhook, and a rule can open a work order in Maintain. ### Can I show SenseAi data on TVs on the floor? Yes. Pair any Google TV running the IoTFlows app with its six-digit screen code and it shows a live view of the floor, and comes back on its own after a restart. The same data is on the web dashboard and the iOS and Android apps. ### Does SenseAi 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? 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 cost? $149 per SenseAi, 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 SenseAi 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 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. ## Documentation Want the detail? These guides walk through each feature step by step. - [SenseAiWhat it measures, what ships in the box and what it needs.](https://www.iotflows.com/docs/hardware/senseai) - [Install and power up SenseAiThe antenna, a flat metal spot near the spindle, power.](https://www.iotflows.com/docs/hardware/install-senseai) - [Calibrate SenseAi and SenseAi EmbeddedRunning and stopped thresholds against what the machine does.](https://www.iotflows.com/docs/hardware/calibrate-senseai) - [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) - [Choose a counting algorithmTurn each cycle or stroke into a part count.](https://www.iotflows.com/docs/production/choose-an-algorithm) - [Monitor machine healthThe health score, the spectrum and the trend charts.](https://www.iotflows.com/docs/monitoring/machine-health) - [LED and status codesWhat each light on the device means.](https://www.iotflows.com/docs/hardware/led-and-status-codes) ## Put SenseAi on your first machines Start with 10 to 25 machines for four weeks, with no commitment to buy. The SenseAi sensors in a pilot are free.