Plant-wide Coverage Built Around Your Infrastructure, Budget and Asset Value

It depends on three factors: whether cabling and power already reach the asset, the budget behind it, and what the asset is worth to the line. Wired sensors suit high-value assets where cabling exists and early detection matters most. Wireless sensors suit equipment where running cable isn’t practical or justified. Flex Reliability from Infinite Uptime’s PlantOS™ lets you mix both across one plant, with every reading feeding the same prescription engine.

Piezoelectric accelerometers capture a wider frequency band with a lower noise floor, which makes them the standard for critical and hard-to-monitor rotating equipment. MEMS sensors deliver broadband vibration data at a fraction of the cost and footprint, which suits the pumps, fans, motors and gearboxes that make up most of a plant. PlantOS™ offers both: vSense wired piezoelectric sensors, plus vEdge and FitMachine MEMS sensors in wired and wireless versions.

Continuous monitoring suits equipment where a stoppage halts production or where faults can develop quickly, such as main mill drives, large fans and critical gearboxes. Periodic health checks suit auxiliary and balance-of-plant equipment, where a scheduled reading is enough to catch a developing fault in good time. In Flex Reliability, wired sensors stream continuously and wireless sensors take periodic readings, so each asset gets the data rate its role justifies.

Use self-powered wireless sensors that need no cabling, batteries or gateways. InfiSense 3XT harvests energy from ambient light, connects over built-in cellular, and mounts by magnet without a specialist. That makes it practical to cover equipment that has never had a monitoring budget, while replacing more than 4 hours of manual inspection rounds per asset per year. Readings arrive as PlantOS™ prescriptions rather than raw data.

Low-speed machines produce weak, low-frequency vibration signals, so they need a sensor with high sensitivity and a low noise floor. The vSense 1XT wired piezoelectric sensor covers equipment running as slow as 2 RPM, and its sensing is rated for harsh operating envelopes. That makes it suitable for ball and SAG mill drives, heavy gearboxes and other slow, high-load assets.

Yes, with certified sensors. Flex Reliability includes ATEX-certified options at each level of coverage: vSense wired piezoelectric sensors for explosive-atmosphere zones, the FitMachine 3XT-Ex wireless MEMS sensor with a battery life of 5+ years, and an ATEX-certified version of InfiSense 3XT. This lets chemical, oil and gas, and pharma plants extend coverage into hazardous zones without running new cable.

Yes. Flex Reliability ingests data from existing third-party sensors as it is, and PlantOS™ works alongside your SCADA, historian and CMMS. There is no rip and replace. Coverage grows from what you already own, and new sensors are added only where there’s a gap.

A condition monitoring system shows vibration trends and raises alarms that an analyst still has to interpret. Flex Reliability delivers a prescription: the component at fault, the cause, the corrective action and its severity. Operators validate each prescription with a digital sign-off, and those validations retrain the models across 1,000 plants, so accuracy improves the longer the system runs.

Together they cover the plant’s full criticality spectrum on one platform. AI Shields protect flagship production equipment such as kilns, mills and cranes with equipment-specific AI. Flex Reliability covers the rest of the rotating fleet with wired and wireless sensing. Plant Fusion rolls both into one risk model that drives maintenance, spares and CAPEX decisions.