Real-Time Machine Monitoring for Maximizing Machine Performance

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

$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.

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.