Machine condition monitoring
Machine condition monitoring that warns you weeks before a breakdown
Wireless vibration and temperature sensors on your critical machines, analysed around the clock. You get a health score, the reason behind it and the next action, without hiring a vibration analyst.
What every sensor measures
- RMS velocity (mm/s, in/s) on X, Y and Z
- RMS and peak-to-peak acceleration (g)
- High-frequency acceleration for bearing faults
- Displacement and surface temperature
- Sensor and communication health
Why monitor machines continuously?
Most rotating-equipment failures don't happen suddenly. Imbalance, misalignment, looseness and bearing wear develop over weeks, and they show up in vibration long before anyone hears noise or feels heat. Walk-around routes with a handheld analyser sample each machine once a month at best. Continuous monitoring watches every minute, including nights and weekends.
Fewer unplanned stops
Early warnings turn emergency repairs into planned jobs with parts on the shelf and a scheduled window.
Lower maintenance cost
Service machines when their condition calls for it, not on a fixed calendar that replaces healthy bearings too early.
Safer plant
Fewer people walking routes near hot, moving or hard-to-reach equipment, and fewer catastrophic failures.
From raw vibration to a clear decision
AnalytIQ combines several indicators so a single noisy reading doesn't trigger a false alarm, and a real developing fault isn't averaged away.
| Indicator | What it reveals |
|---|---|
| RMS velocity | Overall severity: imbalance, misalignment, looseness |
| RMS acceleration | Higher-frequency energy from gears and bearings |
| High-frequency peak | Early-stage bearing defects and lubrication problems |
| Crest factor & kurtosis | Impacts and spikiness typical of bearing damage |
| Axis comparison | Directional faults, e.g. strong axial vibration from misalignment |
| Temperature | Friction, overload and lubrication failure |
Health you can explain to anyone
- Machine profile. Set machine type, power class, foundation and speed. Limits follow the right ISO 10816-3 group automatically.
- Health score 0–100 with the indicator that drove it, e.g. "Raised to Warning by kurtosis and high-frequency vibration".
- Anomaly detection compares current behaviour against the machine's own learned baseline.
- Running status and runtime, so readings taken while the machine is stopped don't skew the picture.
- Predictive maintenance insight and a recommended action for the planner.
- Recent events timeline of every condition change.
Common faults AnalytIQ helps detect
Imbalance
High radial vibration at running speed, often after impeller build-up or a lost balance weight.
Misalignment
Elevated axial vibration and heat at the coupling, typically after maintenance or base movement.
Bearing wear
Rising high-frequency energy, crest factor and kurtosis weeks before temperature climbs.
Looseness
Erratic, multi-harmonic vibration from soft foot, cracked bases or worn fits.
Lubrication issues
High-frequency noise floor rises when grease degrades or is over- or under-applied.
Cavitation
Broadband high-frequency vibration on pumps running away from their best efficiency point.
Overheating
Temperature trend versus load and ambient flags cooling or overload problems.
Resonance
Sharp vibration changes at specific speeds on variable-speed drives.
Read our practical guide to vibration monitoring for the details behind each fault.
Machines with more than one measurement point
Large motors and pumps are best measured at both the drive end (DE) and non-drive end (NDE). AnalytIQ rolls machine health up from the worst point, never an average, so a failing bearing can't hide behind a healthy one. It also shows which end is driving the alert.
Read about predictive maintenancePairs well with
- Power monitoring: current and kW on the same machine timeline
- Environmental monitoring: ambient temperature and humidity in motor rooms and stores
- Raw data export to your CMMS, historian or BI tool
Frequently asked questions
What is machine condition monitoring?
Machine condition monitoring is the continuous measurement of signals such as vibration, temperature and current that reflect the mechanical health of equipment. Changes in those signals reveal developing faults like imbalance, misalignment, looseness and bearing wear long before the machine fails.
Which machines can AnalytIQ monitor?
Any rotating equipment where a sensor can be mounted on the bearing housing: electric motors, centrifugal and positive-displacement pumps, fans and blowers, compressors, gearboxes, agitators and conveyor drives.
Is wireless vibration monitoring accurate enough?
For trending and early fault detection, yes. Modern tri-axial MEMS sensors measure RMS velocity and acceleration reliably across the frequency bands that matter for most industrial faults. What matters most is consistent mounting and continuous trending, which wireless sensors make affordable at scale.
What happens when a sensor stops reporting?
AnalytIQ tracks data freshness for every sensor. A silent sensor is flagged as stale instead of leaving an old healthy reading on screen, and the last known assessment is clearly labelled with its age.
How is the vibration severity calculated?
RMS velocity is classified into zones aligned with ISO 10816-3 for the machine group and mounting you set in the machine profile. Additional indicators such as crest factor, kurtosis and high-frequency acceleration can raise the condition when they point to bearing or impact faults.
See your own machines on AnalytIQ in 30 minutes
Book a live demo. We'll walk through vibration, health scoring and energy dashboards on real plant data, then scope a pilot on one or two of your critical assets.