Gain real-time insights across your entire operation—machines, teams, and jobs. Our AI sensors capture every detail, from OEE and downtime patterns to job progress and root causes, helping you identify top performers and uncover training opportunities instantly.
Transform how you schedule and forecast production with AI-powered planning tools. Automatically prioritize jobs based on demand, monitor ongoing work, and dynamically adjust schedules to hit your targets—even when priorities shift.
Equip your workforce with intuitive tools that make hitting daily production goals effortless. Enable real-time collaboration between machines and people, streamline downtime tracking, and keep everyone aligned on job changes—so operators can focus on value-added work.
Discover exactly what production bottlenecks are costing you and prioritize improvements that deliver real impact. Pinpoint downtime drivers, quantify the financial impact of issues, and unlock hidden capacity to boost both throughput and profitability.
SenseAi Embedded is engineered for manufacturers who need industrial-grade monitoring in demanding conditions. With an IP67-rated aluminum alloy enclosure, M12 waterproof connectors, and industrial magnets for secure mounting, it thrives where standard sensors fail—from coolant spray and washdown areas to high-vibration and extreme temperature environments.
Industrial Features:
Transform your operations with complete visibility into efficiency, downtime, and production performance across all machines, shifts, and departments.
Step 1
Connect Power Supply
Step 2
Attach to Equipment
Step 3
Get Insights
Monitor every aspect of machine health with AI-powered analytics that detect issues before they become failures
Track actual runtime hours and trigger maintenance at the right time, not on an arbitrary calendar schedule.
Time to Service
~10 days
Current
548.26 hrs
Trigger Point
600 hrs
Work order created automatically when usage reaches 600 hours
Get real-time alerts for machine health degradation, temperature anomalies, and vibration patterns. Prevent equipment failures before they happen.
Track machine health scores and get alerted before failures occur
Detect overheating and thermal anomalies in real-time
Monitor shock and vibration levels to prevent equipment damage
Get notified immediately when machines go offline or idle
Overall health score has dropped below 45%
Motor temperature exceeding normal operating range
Shock levels indicate potential bearing failure
Machine is up and running
Machine has been idle for longer than scheduled
Gradual decrease in overall machine health detected
Bearing temperature trending upward
Unusual vibration pattern detected on X-axis
Machine stopped unexpectedly during production
Gradual decrease in overall machine health detected
Machine is up and running
Bearing signature indicates accelerated wear patterns
Multiple motor parameters outside acceptable range
Drive belt tension below optimal operating range
Automatic lubrication system level below threshold
Pneumatic system pressure showing instability
Seal integrity degraded - replacement urgently needed
Hydraulic system temperature critically high
Gearbox operating above normal temperature range
Cooling system not maintaining target temperature
Rapid temperature increase detected in control cabinet
Refrigeration unit temperature exceeded safe range
Process temperature below pasteurization minimum
Fermentation tank temperature drifting from setpoint
Unusual vibration signature indicates pump cavitation
Severe vibration indicates potential shaft misalignment
Intermittent vibration patterns suggest belt slippage
Vibration analysis indicates rotor imbalance condition
Production line successfully started and running
Scheduled maintenance completed, equipment operational
Equipment successfully recovered from fault condition
Planned maintenance window in progress
Safety system activated - machine stopped immediately
Production paused due to raw material depletion
Unexpected power interruption caused machine shutdown
Machine idle during scheduled operator break
Overall health score has dropped below 45%
Motor temperature exceeding normal operating range
Shock levels indicate potential bearing failure
Machine is up and running
Machine has been idle for longer than scheduled
Gradual decrease in overall machine health detected
Bearing temperature trending upward
Unusual vibration pattern detected on X-axis
Machine stopped unexpectedly during production
Gradual decrease in overall machine health detected
Machine is up and running
Bearing signature indicates accelerated wear patterns
Multiple motor parameters outside acceptable range
Drive belt tension below optimal operating range
Automatic lubrication system level below threshold
Pneumatic system pressure showing instability
Seal integrity degraded - replacement urgently needed
Hydraulic system temperature critically high
Gearbox operating above normal temperature range
Cooling system not maintaining target temperature
Rapid temperature increase detected in control cabinet
Refrigeration unit temperature exceeded safe range
Process temperature below pasteurization minimum
Fermentation tank temperature drifting from setpoint
Unusual vibration signature indicates pump cavitation
Severe vibration indicates potential shaft misalignment
Intermittent vibration patterns suggest belt slippage
Vibration analysis indicates rotor imbalance condition
Production line successfully started and running
Scheduled maintenance completed, equipment operational
Equipment successfully recovered from fault condition
Planned maintenance window in progress
Safety system activated - machine stopped immediately
Production paused due to raw material depletion
Unexpected power interruption caused machine shutdown
Machine idle during scheduled operator break
Machine idle during scheduled operator break
Unexpected power interruption caused machine shutdown
Production paused due to raw material depletion
Safety system activated - machine stopped immediately
Planned maintenance window in progress
Equipment successfully recovered from fault condition
Scheduled maintenance completed, equipment operational
Production line successfully started and running
Vibration analysis indicates rotor imbalance condition
Intermittent vibration patterns suggest belt slippage
Severe vibration indicates potential shaft misalignment
Unusual vibration signature indicates pump cavitation
Fermentation tank temperature drifting from setpoint
Process temperature below pasteurization minimum
Refrigeration unit temperature exceeded safe range
Rapid temperature increase detected in control cabinet
Cooling system not maintaining target temperature
Gearbox operating above normal temperature range
Hydraulic system temperature critically high
Seal integrity degraded - replacement urgently needed
Pneumatic system pressure showing instability
Automatic lubrication system level below threshold
Drive belt tension below optimal operating range
Multiple motor parameters outside acceptable range
Bearing signature indicates accelerated wear patterns
Machine is up and running
Gradual decrease in overall machine health detected
Machine stopped unexpectedly during production
Unusual vibration pattern detected on X-axis
Bearing temperature trending upward
Gradual decrease in overall machine health detected
Machine has been idle for longer than scheduled
Machine is up and running
Shock levels indicate potential bearing failure
Motor temperature exceeding normal operating range
Overall health score has dropped below 45%
Machine idle during scheduled operator break
Unexpected power interruption caused machine shutdown
Production paused due to raw material depletion
Safety system activated - machine stopped immediately
Planned maintenance window in progress
Equipment successfully recovered from fault condition
Scheduled maintenance completed, equipment operational
Production line successfully started and running
Vibration analysis indicates rotor imbalance condition
Intermittent vibration patterns suggest belt slippage
Severe vibration indicates potential shaft misalignment
Unusual vibration signature indicates pump cavitation
Fermentation tank temperature drifting from setpoint
Process temperature below pasteurization minimum
Refrigeration unit temperature exceeded safe range
Rapid temperature increase detected in control cabinet
Cooling system not maintaining target temperature
Gearbox operating above normal temperature range
Hydraulic system temperature critically high
Seal integrity degraded - replacement urgently needed
Pneumatic system pressure showing instability
Automatic lubrication system level below threshold
Drive belt tension below optimal operating range
Multiple motor parameters outside acceptable range
Bearing signature indicates accelerated wear patterns
Machine is up and running
Gradual decrease in overall machine health detected
Machine stopped unexpectedly during production
Unusual vibration pattern detected on X-axis
Bearing temperature trending upward
Gradual decrease in overall machine health detected
Machine has been idle for longer than scheduled
Machine is up and running
Shock levels indicate potential bearing failure
Motor temperature exceeding normal operating range
Overall health score has dropped below 45%
Gearbox operating above normal temperature range
Cooling system not maintaining target temperature
Rapid temperature increase detected in control cabinet
Refrigeration unit temperature exceeded safe range
Process temperature below pasteurization minimum
Fermentation tank temperature drifting from setpoint
Unusual vibration signature indicates pump cavitation
Severe vibration indicates potential shaft misalignment
Intermittent vibration patterns suggest belt slippage
Vibration analysis indicates rotor imbalance condition
Production line successfully started and running
Scheduled maintenance completed, equipment operational
Equipment successfully recovered from fault condition
Planned maintenance window in progress
Safety system activated - machine stopped immediately
Production paused due to raw material depletion
Unexpected power interruption caused machine shutdown
Machine idle during scheduled operator break
Overall health score has dropped below 45%
Motor temperature exceeding normal operating range
Shock levels indicate potential bearing failure
Machine is up and running
Machine has been idle for longer than scheduled
Gradual decrease in overall machine health detected
Bearing temperature trending upward
Unusual vibration pattern detected on X-axis
Machine stopped unexpectedly during production
Gradual decrease in overall machine health detected
Machine is up and running
Bearing signature indicates accelerated wear patterns
Multiple motor parameters outside acceptable range
Drive belt tension below optimal operating range
Automatic lubrication system level below threshold
Pneumatic system pressure showing instability
Seal integrity degraded - replacement urgently needed
Hydraulic system temperature critically high
Gearbox operating above normal temperature range
Cooling system not maintaining target temperature
Rapid temperature increase detected in control cabinet
Refrigeration unit temperature exceeded safe range
Process temperature below pasteurization minimum
Fermentation tank temperature drifting from setpoint
Unusual vibration signature indicates pump cavitation
Severe vibration indicates potential shaft misalignment
Intermittent vibration patterns suggest belt slippage
Vibration analysis indicates rotor imbalance condition
Production line successfully started and running
Scheduled maintenance completed, equipment operational
Equipment successfully recovered from fault condition
Planned maintenance window in progress
Safety system activated - machine stopped immediately
Production paused due to raw material depletion
Unexpected power interruption caused machine shutdown
Machine idle during scheduled operator break
Overall health score has dropped below 45%
Motor temperature exceeding normal operating range
Shock levels indicate potential bearing failure
Machine is up and running
Machine has been idle for longer than scheduled
Gradual decrease in overall machine health detected
Bearing temperature trending upward
Unusual vibration pattern detected on X-axis
Machine stopped unexpectedly during production
Gradual decrease in overall machine health detected
Machine is up and running
Bearing signature indicates accelerated wear patterns
Multiple motor parameters outside acceptable range
Drive belt tension below optimal operating range
Automatic lubrication system level below threshold
Pneumatic system pressure showing instability
Seal integrity degraded - replacement urgently needed
Hydraulic system temperature critically high
Overall health score has dropped below 45%
Motor temperature exceeding normal operating range
Shock levels indicate potential bearing failure
Machine is up and running
Machine has been idle for longer than scheduled
Gradual decrease in overall machine health detected
Bearing temperature trending upward
Unusual vibration pattern detected on X-axis
Machine stopped unexpectedly during production
Gradual decrease in overall machine health detected
Machine is up and running
Bearing signature indicates accelerated wear patterns
Multiple motor parameters outside acceptable range
Drive belt tension below optimal operating range
Automatic lubrication system level below threshold
Pneumatic system pressure showing instability
Seal integrity degraded - replacement urgently needed
Hydraulic system temperature critically high
Gearbox operating above normal temperature range
Cooling system not maintaining target temperature
Rapid temperature increase detected in control cabinet
Refrigeration unit temperature exceeded safe range
Process temperature below pasteurization minimum
Fermentation tank temperature drifting from setpoint
Unusual vibration signature indicates pump cavitation
Severe vibration indicates potential shaft misalignment
Intermittent vibration patterns suggest belt slippage
Vibration analysis indicates rotor imbalance condition
Production line successfully started and running
Scheduled maintenance completed, equipment operational
Equipment successfully recovered from fault condition
Planned maintenance window in progress
Safety system activated - machine stopped immediately
Production paused due to raw material depletion
Unexpected power interruption caused machine shutdown
Machine idle during scheduled operator break
Overall health score has dropped below 45%
Motor temperature exceeding normal operating range
Shock levels indicate potential bearing failure
Machine is up and running
Machine has been idle for longer than scheduled
Gradual decrease in overall machine health detected
Bearing temperature trending upward
Unusual vibration pattern detected on X-axis
Machine stopped unexpectedly during production
Gradual decrease in overall machine health detected
Machine is up and running
Bearing signature indicates accelerated wear patterns
Multiple motor parameters outside acceptable range
Drive belt tension below optimal operating range
Automatic lubrication system level below threshold
Pneumatic system pressure showing instability
Seal integrity degraded - replacement urgently needed
Hydraulic system temperature critically high
Gearbox operating above normal temperature range
Cooling system not maintaining target temperature
Rapid temperature increase detected in control cabinet
Refrigeration unit temperature exceeded safe range
Process temperature below pasteurization minimum
Fermentation tank temperature drifting from setpoint
Unusual vibration signature indicates pump cavitation
Severe vibration indicates potential shaft misalignment
Intermittent vibration patterns suggest belt slippage
Vibration analysis indicates rotor imbalance condition
Production line successfully started and running
Scheduled maintenance completed, equipment operational
Equipment successfully recovered from fault condition
Planned maintenance window in progress
Safety system activated - machine stopped immediately
Production paused due to raw material depletion
Unexpected power interruption caused machine shutdown
Machine idle during scheduled operator break
SenseAi Embedded delivers industrial-grade health monitoring with advanced vibration analytics and temperature sensing. Get instant visibility into machine condition with comprehensive metrics designed for predictive maintenance and reliability engineering.
Unlike black-box solutions, SenseAi gives you full access to the raw data and advanced visualizations that power our AI diagnostics.
Monitor the equipment where failure is most costly
Monitoring
Bearing health, runout, balance
Monitoring
Imbalance, bearing, looseness
Monitoring
Cavitation, bearing, seal wear
Monitoring
Gear mesh, bearing, lubrication
Monitoring
All 7 health scores
Monitoring
Pump health, valve operation
See the potential savings from preventing just 35% of critical asset failures.
Potential Annual Savings
$
Based on 35% reduction in unplanned failures
Maximize efficiency with real-time cycle time analysis, automated downtime tracking, and actionable insights that pinpoint exactly where production is being lost. Whether managing a single line or multiple facilities, SenseAi helps you identify bottlenecks, eliminate waste, and make data-driven decisions that directly improve throughput and profitability.
Empower your operators with real-time machine status, instant downtime alerts, and simple tools to classify issues and create work orders on the spot. With automated notifications for unclassified downtimes and performance drops, your team can respond immediately—reducing mean time to resolution and keeping production flowing smoothly.
Unplanned stops don't have to stay a mystery. SenseAi automatically detects, classifies, and tracks every downtime event across all your machines—capturing when, where, why, and how often issues occur. With powerful root cause analysis and downtime trending, you can identify recurring patterns, quantify their impact on efficiency, and prioritize fixes that deliver the biggest gains in uptime and throughput.
Get the full story behind your operations with comprehensive reports that track efficiency, downtime root causes, OEE trends, and shift-by-shift performance. View daily snapshots or analyze long-term patterns across weeks, months, or years. Every report includes downtime classifications, root cause breakdowns, and actionable insights—empowering your team to make data-driven decisions that boost productivity and profitability.
CNC Spindles
Monitor spindle vibration, temperature, and health in real-time. Detect bearing wear, imbalance, and misalignment before catastrophic failure occurs.
Precision Machining Centers
Track machine health metrics alongside production data. Optimize preventive maintenance schedules and maximize uptime on critical equipment.
Injection Molding
Automatically capture runtime, downtimes, and root causes for every molding cycle. Receive instant alerts for extended downtimes, track efficiency trends, and optimize scheduling to maximize production runs.
Robot Arm
Track pick-and-place cycles, movement patterns, and downtime events with intelligent alerting. Identify efficiency drops, classify stoppages, and ensure your automation consistently delivers peak performance.
Press Brake
Monitor bending cycles, setup times, and operator efficiency with automated downtime tracking. Classify delays, analyze root causes, and eliminate hidden losses to boost throughput on your forming operations.
SenseAi Embedded is an industrial-grade vibration and temperature monitoring sensor designed for harsh manufacturing environments. With its IP67-rated aluminum alloy enclosure and M12 waterproof connector, it provides advanced machine health insights including anomaly detection, health scores, vibration trends, crest factor, peak vibration, RMS, and more—alongside complete production monitoring capabilities.
SenseAi Embedded features an IP67-rated aluminum alloy enclosure for harsh industrial environments, M12 waterproof connections instead of USB-C, and includes advanced health monitoring metrics like temperature sensing, crest factor, kurtosis, FFT analysis, and velocity trends. It focuses on vibration and temperature monitoring without acoustic sensors, making it ideal for condition-based maintenance and predictive analytics in demanding applications like CNC spindles and critical rotating equipment.
SenseAi Embedded is optimized for critical rotating equipment and high-precision machines: CNC spindles, precision machining centers, industrial pumps, motors, compressors, gearboxes, bearings, and any equipment where vibration and temperature analysis are essential for preventing failures and maximizing uptime.
SenseAi Embedded requires a 12-24VDC power supply via its M12 waterproof connector. The M12 power supply can be purchased directly from our online store and ensures reliable operation in industrial environments.
SenseAi Embedded delivers comprehensive machine health metrics including: anomaly detection, health scores, trending analysis, crest factor, peak vibration, RMS (Root Mean Square), kurtosis, FFT (Fast Fourier Transform) analysis, velocity trends, and mounting surface temperature monitoring. These insights enable predictive maintenance, early fault detection, and condition-based monitoring.
SenseAi Embedded includes a precision temperature sensor that measures the temperature of the mounting surface, providing critical thermal data about your equipment. Temperature changes can indicate bearing failures, lubrication issues, misalignment, or excessive friction—giving you early warning of potential problems.
Yes. SenseAi Embedded can generate instant alerts based on vibration thresholds, temperature anomalies, health score changes, or trend deviations. These alerts can automatically trigger work orders in your CMMS or maintenance management system, ensuring rapid response to potential equipment failures.
IP67 rating means SenseAi Embedded is fully protected against dust ingress and can withstand immersion in water up to 1 meter for 30 minutes. This makes it ideal for harsh environments with coolant spray, washdown procedures, high humidity, dust, and extreme conditions where standard sensors would fail.
Installation takes less than 5 minutes. SenseAi Embedded features two strong industrial magnets for secure mounting to any metal surface. Simply attach to your equipment, connect the M12 power supply, and the sensor automatically begins collecting vibration and temperature data. IoTFlows experts will help calibrate the sensor for your specific equipment and mounting location.
Yes. SenseAi Embedded includes all the production monitoring features of standard SenseAi: utilization monitoring, production tracking, downtime root cause analysis, OEE calculation, shift reporting, and operator performance analytics. You get both machine health insights and production visibility in one industrial-grade device.
SenseAi Embedded offers the same connectivity options as standard SenseAi: connect directly to your existing Wi-Fi network, or use our secure 4G/LTE router for a completely air-gapped setup with no connection to your facility network. The 4G/LTE option is perfect for isolated environments or facilities with strict network security policies.
SenseAi Embedded is ideal for precision manufacturing, aerospace, automotive, oil & gas, pharmaceutical production, food & beverage processing, chemical processing, and any industry with critical rotating equipment where unplanned downtime is extremely costly and equipment health monitoring is essential.
Yes. SenseAi Embedded features a modern tech stack with multiple integration options: REST API, MQTT API, webhooks, and ready-to-go integrations. Pull or push data—whether raw sensor data, processed health metrics, or production insights—to your ERP, MES, CMMS, or other systems. Check our documentation or contact support@iotflows.com for integration assistance.
SenseAi Embedded includes the IP67-rated aluminum alloy sensor with industrial vibration accelerometer and temperature sensor, two strong magnets for mounting, M12 waterproof cable, and a 1-year warranty. The M12 12-24VDC power supply is available separately in our online store. Choose Wi-Fi connectivity or add our 4G/LTE router for network isolation.
By preventing even a single unplanned failure on critical equipment, SenseAi Embedded typically pays for itself immediately. Manufacturers see measurable improvements through reduced downtime, extended equipment life, optimized maintenance schedules, and the ability to plan repairs during scheduled maintenance windows rather than emergency shutdowns.
All data is protected with SHA-256 encryption during transmission and storage. Every account includes optional two-factor authentication (2FA) for enhanced security and compliance. Plus, our 4G/LTE router option provides complete network isolation for maximum security in sensitive environments.
We provide comprehensive onboarding calls, sensor calibration assistance, vibration analysis training, technical support, and ongoing guidance to ensure you get maximum value from day one. Our team helps you configure the system for your specific equipment, set appropriate thresholds, and interpret health metrics. Contact support@iotflows.com anytime for help.
