Vibrational Condition Monitoring

Predict failures.
Before they happen.

SensIQ Realtime detects bearing defects, imbalance, and misalignment up to 14 days in advance — using 6-axis MEMS sensors (3 accel + 3 gyro) and AI-powered FFT analysis on any rotating machine.

Book a Demo →How It Works
6-axis MEMS: 3 accel + 3 gyro6-Axis
3A + 3G
32 kHz max sampling (6-axis)32 kHz
Sampling
Dustproof & waterproofIP67
Rated
Pilot-validated install time<1hr
Install
sensiq.app/realtime-view/machine-data/10003
SensiQ RealTime dashboard
⚠️
Caution Alert
Bearing · 3.45 mm/s Axial
LIVE · 86 samples
Trusted by maintenance & reliability teams across industries
Tapeline MotorIndustrial FabricsRO SystemsPump OEMsSteel MillsCement Plants
100k+
Data points / day per sensor
<1hr
Sensor install time
14d
Advance fault warning
2.7×
Pilot Y1 ROI
System Architecture

Precision hardware.
Intelligent software.

The SensIQ sensor mounts on any rotating machine in under an hour and streams 6-axis vibration data (3 accel + 3 gyro) to the cloud for continuous AI-powered analysis.

SensIQ Sensor
Sensor isometric
Isometric
Sensor mount face
Mount face
Sensor top view
Top view
01

Mount in minutes

Compact aluminum enclosure (IP67) with M8 connector. Stud-mount or magnetic base directly on machine surfaces — no complex wiring or PLC integration required.

02

Continuous 6-axis capture

Captures tri-axial acceleration and tri-axial gyroscope data simultaneously at up to 32 kHz — plus temperature and ambient sound via dedicated MEMS microphones.

03

Real-time FFT spectrum analysis

Fast Fourier Transform identifies bearing defect frequencies, imbalance, misalignment, and looseness signatures from the raw vibration signal automatically.

04

AI predictions & alerts

Baseline learning + ISO thresholds + anomaly detection flag degradation up to 14 days before failure — alerts via WhatsApp, SMS, and email to the right person instantly.

Seen In The Field

SensIQ on a live
motor — right now.

Watch the sensor mounted and running on a customer's tapeline motor at a manufacturing plant. Every vibration captured. Every axis streaming. No downtime, no disruption to production.

📍
Customer plant — tapeline motor
⏱️
5-minute install, immediate data stream
📡
Live FFT uploading to cloud dashboard
🔩
M8 stud-mount interface visible on housing
3.45
mm/s · Axial
CAUTION · 12.77 Hz
Bearing freq detected
Capabilities

Everything you need.
Nothing you don't.

Built for reliability engineers and plant managers who need answers — not raw data dumps.

📡
Plant Status Overview

At-a-glance view of every machine colour-coded green, amber, and red by ISO velocity thresholds. Know which machines need attention in real time.

ISO 10816 / 20816
〰️
FFT Frequency Spectrum

Live and historical frequency plots across all three axes with up to 32 kHz sampling — wideband FFT for early bearing and gear fault visibility. Auto-annotated dominant peaks with harmonic relationships for fast fault identification.

32 kHz sampling
🔔
Smart AI Alerts

Configurable caution and danger thresholds per axis, per machine. WhatsApp, SMS, and email routing to ensure the right person is always notified first.

WhatsApp native
📈
Trend & History Analysis

Track vibration levels over days, weeks, and months. Correlate spikes to maintenance events. Watch gradual degradation trends before they become failures.

Unlimited history
🌡️
Environmental Monitoring

Simultaneous RPM, temperature, and ambient sound capture alongside vibration — giving full operational context to every single data point collected.

RPM · Temp · Sound
📋
Reports & Service Orders

Automated shift, daily, and weekly reports. Raise, assign, and close maintenance tickets directly from the dashboard in one unified workflow.

PDF · Excel · API
Roadmap

Upcoming
modules.

Enterprise asset-management capabilities we are bringing into SensIQ—aligned with Aswartha Asset Management Services and Zolnoi’s Energy Efficiency, Factory Ops, and Asset Health products. Each row shows how the live dashboard experience could look for that module.

sensiq.app/modules/asset-health
SensIQ dashboard — Asset Health module (preview)
📡

Asset Health Monitoring

Real-time condition monitoring and health assessment using advanced IoT sensors and analytics.

IoT · Health scoring
Key features
  • Continuous vibration monitoring
  • Temperature and thermal imaging
  • Real-time alerting system
  • Predictive health scoring
sensiq.app/modules/lifecycle-cost
SensIQ dashboard — Lifecycle cost module (preview)
📈

Lifecycle Cost Analysis

Comprehensive TCO modeling and optimization to maximize asset value throughout its operational life.

TCO · CapEx planning
Key features
  • Total Cost of Ownership (TCO) modeling
  • Replacement vs. repair analysis
  • ROI and NPV calculations
  • Capital planning support
sensiq.app/modules/predictive-maintenance
SensIQ dashboard — Predictive maintenance module (preview)
🤖

Predictive Maintenance Strategy

AI-driven maintenance planning and scheduling to prevent failures before they occur.

ML · Scheduling
Key features
  • Machine learning algorithms
  • Failure prediction models
  • Maintenance scheduling optimization
  • Resource allocation planning
sensiq.app/modules/criticality-risk
SensIQ dashboard — Criticality & risk module (preview)
⚠️

Criticality & Risk Assessments

Strategic asset prioritization and risk mitigation to focus resources on what matters most.

Risk matrix
Key features
  • Asset criticality ranking
  • Risk probability analysis
  • Business impact assessment
  • Risk mitigation strategies
sensiq.app/modules/digital-twin
Digital Twin Module 1 Digital Twin Module 2 Digital Twin Module 3 Digital Twin Module 4 Digital Twin Module 5 Digital Twin Module 6 Digital Twin Module 7 Digital Twin Module 8
🧠

Digital Twin Development

Virtual asset modeling and simulation for enhanced decision-making and optimization.

Physics-based models
Key features
  • Physics-based modeling
  • Scenario simulation
  • Real-time data integration
  • Virtual testing capabilities
sensiq.app/modules/cmms
SensIQ dashboard — CMMS integration module (preview)
🔗

CMMS Integration

Seamless maintenance management system integration to enhance existing workflows.

API · Sync
Key features
  • Multi-platform compatibility
  • Data synchronization
  • Workflow automation
  • API development
sensiq.app/modules/rca-workshops
SensIQ dashboard — RCA workshops module (preview)
🎓

Failure Mode & RCA Workshops

Root cause analysis and failure prevention through structured problem-solving methodologies.

FMEA · Training
Key features
  • FMEA facilitation
  • Root cause analysis
  • Team training
  • Action plan development
sensiq.app/modules/audit-reporting
SensIQ dashboard — Audit & reporting module (preview)
📋

Audit & Optimization Reporting

Performance insights and improvement recommendations through comprehensive audits.

KPI · Roadmaps
Key features
  • Performance benchmarking
  • Gap analysis
  • Improvement roadmaps
  • KPI development
sensiq.app/partners/zolnoi/energy-efficiency
SensIQ dashboard — Energy Efficiency module (preview)
⚡

Energy Efficiency

Unify production, maintenance, and energy data for savings—not a standalone energy-only view. Product- and process-level energy with time-series AI to optimize under real plant load.

Plant load AI · KPIs
Key features
  • Energy KPIs from plant down to equipment (e.g. kWh per kg)
  • Baseline deviation alerts to catch overconsumption early
  • AI for optimal operating envelopes, batch runs, and peak load
  • Power quality alerts (power factor and related waste drivers)
sensiq.app/partners/zolnoi/factory-ops
SensIQ dashboard — Factory Ops module (preview)
🏭

Factory Ops

Derive productivity from electric current at each machine—plus optional control signals without heavy PLC integration. AI assistant and opportunity insights; install in minutes and go live in weeks.

Current signature · OEE
Key features
  • Machine status: who is in production and who needs attention
  • Downtime reasons when idle or stopped—lost time made visible
  • Hourly progress tracker for the current shift
  • Real-time AI alerts for downtime, speed, energy waste, repeat failures
sensiq.app/partners/zolnoi/asset-health
SensIQ dashboard — Asset Health (ESA) module (preview)
🔌

Asset Health (ESA)

Non-invasive electric current signature analysis (ESA) for motors and transmissions—meter at the supply panel instead of sensors on the equipment. Extend models for industry-specific faults; continuous learning for accuracy.

ESA · Non-invasive
Key features
  • Equipment health score for which assets need attention soon
  • Alert workflow from detection through investigation to closure
  • Models that refine with more data and maintenance history
  • Strong fit for harsh, submerged, or hazardous environments
Interactive demo

Simulated ML pipeline

A gentle, slowed-down walkthrough: raw vibration → spectrum (FFT) → “is this normal?” (anomaly) → how much life might be left (RUL) and overall health. All numbers are illustrative — your production system would use real sensor data and your own models.

How to use this — Start with Pause if you want to read without things moving. Scenario sets how “sick” the simulated machine is at the start. Wear rate controls how fast the fault develops while Play is on (higher = faster). Reset snaps back to the scenario defaults.

  • 1 · Capture — The sensor streams samples; you see one axis in the waveform below.
  • 2 · FFT — We turn that wiggle into frequency peaks (Hz on the horizontal axis). Bearing faults add energy at characteristic frequencies.
  • 3 · Anomaly — A simple score (0–100) for “how unusual is today’s spectrum vs quiet running?” Higher usually means more defect energy in the fault bands.
  • 4 · RUL / Health — Health is an easy 0–100 asset grade; RUL is a rough “days left” estimate from the same simulated wear (not a warranty).
1 · Capture 2 · FFT 3 · Anomaly 4 · RUL / Health

Tip: the blue highlight above shows which step is “running” in the story; it moves slowly so it’s readable.

Time domain (Axial)

Each point is vibration amplitude vs time. As wear increases, the pattern gets busier — more shock from a degrading bearing.

FFT magnitude (0–1.2 kHz)

FFT shows how strong vibration is at each frequency (Hz). The demo adds peaks near 59 Hz (BPFI-style) when wear grows — typical of a rolling-element bearing fault on the inner race.

— Health
Anomaly score
— / 100
Within baseline

0 ≈ looks like normal history; high ≈ more energy in fault-frequency bands. Here it’s computed from the spectrum (demo heuristic), not a trained model.

Est. remaining useful life
— days

RUL = rough “days before wear reaches failure region” in this toy simulation. Real RUL needs history, loads, and validated models — treat this as a narrative number.

The Health ring is the same story in one glance: 100 = good; it falls as simulated wear rises.

Demo uses synthetic bearings-related peaks (~59 Hz BPFI, harmonics) plus process noise. Anomaly and RUL are heuristic transforms of defect energy — replace with your Isolation Forest / LSTM+Kaplan–Meier stack as needed.

The Platform

The dashboard your team
will actually use.

sensiq.app/realtime-view
SensIQ FFT Dashboard
🎨

Three-zone severity bands

Green, amber, and red zones configurable per machine and axis — aligned to ISO standards or your own thresholds.

🔍

Click-to-FFT investigation

Click any point on the velocity trend to instantly see the FFT spectrum at that exact moment. Trace peaks to bearing BPFI, BPFO, BSF fault frequencies.

📊

Multi-axis simultaneous view

X, Y, and Z channels overlaid on a single spectrum with colour-coded traces and interactive tooltips showing exact frequency, amplitude, and timestamp.

🔧

Integrated service orders

Raise, assign, and close maintenance tickets directly from the alert view — one platform for monitoring and maintenance.

Industries

Built for every
rotating machine.

If it spins, we monitor it — across heavy industry, manufacturing, oil & gas, and utilities.

Manufacturing Plants

Keep production lines running. Monitor CNC spindles, cooling fans, conveyor drives, and compressors before they cause unplanned stoppages that erode OEE.

  • Motor & pump vibration monitoring
  • Cooling fan and blower health
  • Conveyor drive bearing condition
  • Compressor and hydraulic unit monitoring
  • Integration with existing CMMS/ERP
Explore Manufacturing →
Manufacturing plant
Industrial motors
Factory machinery
Manufacturing equipment

Heavy Industry

Crushers, mills, kilns, and steel process equipment operate under extreme loads. Detect early bearing degradation, structural looseness, and drive-train wear before catastrophic failure.

  • Crusher & mill drive monitoring
  • Steel process rotating asset health
  • Mining conveyor & motor condition
  • Kiln, rotary dryer & support roller monitoring
  • Structural vibration & looseness detection
Explore Heavy Industry →
Heavy industry
Steel plant
Mining
Industrial machinery

Oil, Gas & Petrochemicals

Refineries, pipelines, and processing plants rely on pumps, compressors, and turbines operating 24/7. SensIQ keeps them running with continuous wideband vibration monitoring.

  • Pump & compressor vibration analysis
  • Pipeline pumping station monitoring
  • Gas turbine & generator health
  • Petrochemical process asset condition
  • API 670 & ISO 20816 compliance support
Explore Oil & Gas →
Oil refinery
Gas plant
Pipeline pump
Oil infrastructure

Utilities & Infrastructure

Power plants, water treatment, HVAC systems, and critical infrastructure depend on reliable rotating assets. SensIQ enables proactive maintenance to prevent service disruptions.

  • Power generation turbine & generator monitoring
  • Water pump & treatment plant assets
  • Remote infrastructure condition monitoring
  • HVAC chiller & fan motor health
  • Smart grid & distributed asset management
Explore Utilities →
Power plant
Water treatment
Utility infra
HVAC systems
For Your Team

One platform,
every role.

From the maintenance floor to the boardroom — SensIQ gives every stakeholder the view they need.

01

Reliability Engineer

Vibration analysis & fault diagnosis

  • ✓ Full-spectrum FFT with harmonic cursors
  • ✓ Bearing defect frequency identification
  • ✓ Trend overlay & baseline comparison
  • ✓ ISO 10816 / 20816 threshold management
See ML demo →
02

Maintenance Manager

Work planning & team coordination

  • ✓ Priority-ranked alert queue
  • ✓ WhatsApp & SMS escalation
  • ✓ In-app service orders with photo evidence
  • ✓ Maintenance calendar & scheduling
See features →
03

Plant Head

Operational visibility & KPIs

  • ✓ Plant-wide health score dashboard
  • ✓ Downtime reduction tracking
  • ✓ Predictive maintenance ROI reports
  • ✓ Multi-site portfolio overview
See dashboard →
04

Operations Director

Strategic asset management

  • ✓ Fleet-level reliability benchmarks
  • ✓ Capital planning support data
  • ✓ Compliance & audit trail
  • ✓ Executive summary exports
Compare plans →
Wall of Love

Trusted by
reliability teams.

Hear from the engineers and managers who rely on SensIQ every day.

★★★★★

"We went from reactive firefighting to predicting failures two weeks out. SensIQ paid for itself within the first quarter."

RK
Rajesh Kumar
Reliability Manager — Tata Steel
Manufacturing
★★★★★

"The FFT analysis quality rivals systems costing 5× more. 32 kHz sampling on a wireless sensor is a game-changer for our rotating equipment."

SM
Sarah Mitchell
Vibration Analyst — Shell
Oil & Gas
★★★★★

"Installation took 2 hours for 40 machines. The WhatsApp alerts mean our team never misses a critical threshold breach — even on night shifts."

AP
Amit Patel
Maintenance Lead — Adani Power
Utilities
★★★★★

"Finally, a condition monitoring platform our whole team actually uses — from the technician on the floor to the plant head reviewing KPIs."

LW
Li Wei
Plant Engineer — BaoSteel
Heavy Industry
★★★★★

"The ML anomaly detection caught a bearing inner-race defect that our route-based program missed. Saved us a $180K compressor rebuild."

JD
James Davidson
Asset Integrity Lead — Chevron
Petrochemical
★★★★★

"We evaluated five vendors. SensIQ was the only one with real-time FFT, in-app service orders, AND WhatsApp alerts — at a fraction of the price."

NK
Nisha Krishnan
VP Engineering — UltraTech Cement
Heavy Industry
Product Comparison

SensIQ Pro vs
IntellyVibe Ultra.

See how SensIQ Pro stacks up. All SensIQ Pro specs are verified — please confirm IntellyVibe Ultra specs on the vendor datasheet.

SpecificationSensIQ ProIntellyVibe Ultra
Max Sampling Rate32 kHz 6-axis25.6 kHz (single-axis)
Triaxial Vibration✓ Simultaneous 6-axis (3A+3G)✓ Sequential
FFT Resolution6400 lines3200 lines
Temperature Sensor✓ Built-in✓ Built-in
Auxiliary Channels✓ Speed / process inputs—
Analytics StackML anomaly + RUL + health scoreThreshold alerts only
ISO Threshold Engine✓ 10816 / 20816 autoManual config only
WhatsApp / SMS Alerts✓ Built-in— Email only
In-App Service Orders✓ Photo + notes—
Deployment TimeSame day (cloud-ready)2–4 weeks (on-prem setup)
Wireless ProtocolBLE 5.0 + Wi-FiBLE 5.0
Battery LifeUp to 3 yearsUp to 2 years
IP RatingIP68IP67

Comparison based on published specifications. Please verify IntellyVibe Ultra details on the vendor datasheet.

FAQ

Common
questions.

Can't find what you're looking for? Our team is happy to help.
Ph: +65 8210 0288 · Email: contact@sensiq.pro · Address: River Valley Rd, Sg


Contact Us →
SensIQ monitors vibration (acceleration, velocity, displacement) across 3 axes at up to 32 kHz, plus surface temperature. It performs real-time FFT analysis, anomaly detection, remaining useful life (RUL) estimation, and health scoring — covering bearing faults, imbalance, misalignment, looseness, and gear defects on any rotating machinery.
Most sites go from unboxing to live dashboard within the same day. Our wireless sensors mount magnetically or with studs, connect via BLE 5.0 to a gateway, and stream to the cloud. No complex on-prem infrastructure is needed.
If it rotates, we monitor it — motors, pumps, compressors, fans, turbines, gearboxes, crushers, conveyors, centrifuges, and more. Our customers span manufacturing, heavy industry, oil & gas, petrochemicals, power generation, water treatment, and utilities.
SensIQ Pro offers 32 kHz simultaneous triaxial sampling, 6400-line FFT, built-in ML anomaly detection with RUL estimates, WhatsApp/SMS alerting, in-app service orders, and same-day cloud deployment — a combination no competitor matches at this price point.
Yes. SensIQ provides REST API endpoints, webhook event triggers, and scheduled CSV/JSON exports. We support integration with SAP PM, IBM Maximo, Fiix, UpKeep, and custom systems. Our upcoming CMMS module will offer deeper bi-directional sync.
Sensors store data locally and auto-sync when connectivity resumes. No measurement windows are lost. The gateway buffers events for up to 72 hours, and the cloud dashboard flags any gaps in the data timeline so you always know the status.
SensIQ automatically applies ISO 10816 / ISO 20816 baseline thresholds on first connect. You can customize alarm and danger bands per machine, per axis. The ML engine also learns your equipment's normal signature and flags deviations, even if they're within ISO limits.
Full waveform data, FFT spectra, trend history, alert logs, service order records, and health score timelines — all exportable as CSV, JSON, or PDF reports. We provide configurable retention periods and audit trail support for compliance.
Get Started

Ready to predict failures
before they happen?

Join reliability teams worldwide who trust SensIQ to protect their rotating assets. Setup takes hours, not weeks.

Request a Demo →

No commitment required · Response within 1 business day
Ph: +65 8210 0288 · Email: contact@sensiq.pro · Address: River Valley Rd, Sg