5 Best Wireless Condition Monitoring Sensors

Industrial plants are reaching the limit of what manual vibration routes, handheld tools, and wired systems can support. Once you are monitoring dozens, or even hundreds, of machines per site, the wireless network becomes just as important as the sensor itself.

This guide explains how wireless condition monitoring sensors work, what sets them apart from wired approaches, and how leading vendors compare on range, reliability, battery life, and integration.

What Are Wireless Condition Monitoring Sensors?

Wireless condition-monitoring sensors capture physical signals from rotating equipment, such as vibration, temperature, and RPM, then transmit the data through a low-power wireless network to gateways and cloud platforms. These devices eliminate the need for cables or manual data routes and allow real-time monitoring across wide areas, hazardous zones, and hard-to-reach machine locations.

Unlike wired systems, wireless sensors must balance four technical priorities simultaneously:

1. Long-range communication through obstacles

2. Low power draw to extend battery life

3. Robust data integrity for diagnostics

4. High-volume scalability without network interference

In an industrial environment full of machinery, thick walls, and electromagnetic noise, achieving all four requires more than a generic wireless chip. The most advanced vibration sensors use proprietary sub-GHz radios with encrypted communication to maintain long-distance signal stability and multi-year battery performance.

Wireless condition-monitoring sensors help teams detect early failure modes like bearing wear, imbalance, misalignment, looseness, lubrication degradation, and thermal changes that typically evade manual inspection.

Benefits of Wireless Condition Monitoring

Modern industrial operations need uninterrupted machine health visibility across shifting workloads, day and night shifts, and complex physical layouts. Wireless sensors provide several advantages that make condition-based maintenance easier to scale:

Faster Deployment and Lower Installation Cost: No conduit runs, no junction boxes, no cabling. Technicians can install a wireless sensor in minutes instead of hours or days.

Wider and Safer Monitoring Coverage: Wireless links allow data collection from overhead cranes, elevated motors, enclosed spaces, high-heat areas, and hazardous zones that are difficult or unsafe for manual routes.

Real-Time Monitoring Instead of Periodic Snapshots: Wireless sensors deliver continuous trend data across entire fleets, capturing failure progression that handheld vibration analyzers often miss.

Scalable Predictive Maintenance Across Multiple Sites: A strong wireless backbone allows a single platform to monitor hundreds of machines per facility and thousands across global operations.

Reduced Dependence on Route-Based Data Collection: Technicians spend less time walking routes and more time acting on high-quality insights.

The Top 3 Priorities When Evaluating Wireless Sensors

Industrial buyers evaluating wireless sensor systems should focus on these three capabilities above all others.

1. Wireless Range and Network Stability: How much of the plant can you cover with each gateway, and how reliably does data get through in your real environment.
2. Multi-Year Battery Life at Real Sampling Rates: How long batteries last with your actual sampling strategy, not just spec-sheet scenarios.
3. Integration Into Diagnostics, CMMS, and Maintenance Execution: How easily wireless insights turn into technician-ready actions instead of sitting in a separate dashboard.

Wireless Condition Monitoring Sensors at a Glance

Top 5 Wireless Condition Monitoring Sensors

Tractian Smart Trac Ultra

Best for: Industrial operations that need secure long-range wireless vibration monitoring, rugged hardware, built-in AI diagnostics, and integrated maintenance execution.

Tractian Smart Trac Ultra is engineered for industrial-scale wireless monitoring. The sensor combines encrypted sub-GHz wireless, triaxial vibration, temperature, runtime, and automatic RPM detection, covering more than 100 machine types, including variable-speed and intermittent equipment.

Where many platforms rely on dashboards or external analysts, Tractian closes the loop. The system detects anomalies, diagnoses the failure mode, and automatically generates inspections, tasks, and procedures through its AI-powered CMMS.

Smart Trac Ultra is built for harsh industrial environments and is ATEX certified for hazardous locations, making it suitable for chemicals, mining, food production, oil and gas, and heavy manufacturing.

Wireless Capabilities

• Sub-GHz wireless radio with long-range stability
• Up to roughly 100 meters indoors and up to 1 km line of sight
• Encrypted communication for secure data transport
• Battery design that supports continuous monitoring without frequent sensor maintenance
• Exceptional performance through walls, tanks, and high-interference zones

Notable Features

• Asset GPT provides plain-language explanations for each insight so teams understand what triggered it and can make faster, informed decisions.
• Engineered for reliability, Smart Trac Ultra is built for harsh industrial areas with IP69K protection and ATEX-certified hazardous-location readiness for washdown, dusty, high-heat, and flammable environments.
• Temperature Seasonality automatically filters out normal environmental temperature shifts to prevent false interpretations.
• Always Listening captures data whenever intermittent equipment runs, ensuring accurate vibration snapshots during actual operation.
• RPM Encoder estimates rotational speed directly from vibration signatures, including on assets that change speeds.
• Bearings Library supports automatic fault frequency matching across a wide range of equipment types.
• Machine health scoring and benchmarking tools help teams compare performance across assets, production lines, and multiple sites.

Why real customers choose Tractian’s Wireless Condition Monitoring Sensors

• “We observed many recurring lubrication failure insights. We revised our maintenance plan, and today we no longer have this type of failure. We were able to train the sensor by providing feedback on the insights related to material changeovers.” says William C., Maintenance Coordinator
• “I'm really impressed by the reliability metrics that Tractian is able to calculate in real time, and the level of detail when it comes to the failure modes and the insight generation. Tractian has really improved our asset availability.” says Gautam Sane, Senior Reliability Engineer
• “For the first time, we can clearly see what’s happening on the floor before a failure hits. That kind of visibility is a game-changer.” says Trevor Baker, Sr. Manager, Manufacturing Strategic Initiatives

What Industries are using Tractian’s Wireless Condition Monitoring Sensors?

Smart Trac Ultra is deployed across a wide range of industrial sectors where equipment reliability, safety, and uptime directly influence output and operating costs. These sensors are chosen by teams that manage a large range of critical assets and need accurate insight into machine health without adding complexity to daily operations.

• Mining and Metals teams use Smart Trac Ultra on crushers, conveyors, pumps, and mobile equipment operating in harsh or remote areas. Continuous monitoring helps reduce unplanned stoppages and maintain safe, steady production.
• Chemical plants deploy Tractian on pumps, mixers, compressors, and other rotating assets that run under strict process conditions. Early insights support safer operation and help teams stay ahead of issues in regulated or hazardous zones.
• Mills and Agriculture operations monitor critical machines that run heavily during seasonal peaks. Early detection of bearing wear or alignment issues helps maintain throughput and protect high-value processing equipment.
• Manufacturing facilities use Tractian to support line uptime across motors, gearboxes, conveyors, and robotics. Wireless diagnostics help maintenance teams reduce unexpected stoppages and support continuous improvement goals.
• Oil & Gas operators apply Smart Trac Ultra in upstream, midstream, and downstream environments where equipment may be exposed to hazardous conditions. Wireless monitoring helps teams maintain reliability and support safety requirements.
• Heavy Equipment fleets use Tractian to track machine health across active job sites. Continuous monitoring supports equipment availability and helps reduce the risk of costly breakdowns during time-sensitive projects.
• Food & Beverage producers monitor assets tied to temperature control, hygienic processes, and product consistency. Wireless condition data helps avoid unplanned downtime and supports cleanliness and regulatory standards.
• Automotive and Parts manufacturers deploy Tractian on high-precision machinery and automated systems to keep assembly lines moving and support just-in-time production.

Tractian is trusted across industries by companies such as DHL, Ingredion, CP Kelco, and CZM, who use the platform to support equipment reliability, meet compliance requirements, and scale consistent maintenance practices across their operations.

AssetWatch

Best for: Plants that want external analysts to interpret wireless data.

AssetWatch provides wireless vibration and temperature sensors connected to a cloud platform supported by remote analysts. This approach is often selected by facilities that are new to condition monitoring programs or that prefer having external reliability specialists review sensor data and provide recommendations.

The model can help teams that do not have internal vibration expertise. It also reduces the learning curve for organizations building their first predictive maintenance framework. However, relying on a service-centered model may limit how much diagnostic knowledge is developed inside the plant. When alerts and recommendations flow through a separate system, plants may need additional steps to incorporate these insights into their own workflows. Multi-site facilities may also experience increased coordination requirements as their program grows.

Notable Features

• Wireless vibration and temperature sensors suitable for many rotating assets
• Remote analysts who interpret wireless data and send recommended actions
• Straightforward deployment model for teams new to predictive maintenance

Potential Downsides

• Heavy reliance on external analysts slows internal capability building
• Diagnostics may lack transparency, making it harder for reliability teams to validate recommendations
• Multi-site scaling increases service fees and may introduce reviewer bottlenecks

What real customers say about AssetWatch

• “Cannot access trend charts on mobile app. Basically can’t select any filter.” says joseph smith
• “This team is an absolute joy to work with. Could not be happier with them!” says Charmaine Berry

Waites

Best for: Cost-conscious plants beginning wireless condition monitoring with optional analyst help.

Waites offers wireless vibration and temperature sensors built for straightforward deployment. Their platform is designed to help teams move from handheld data collection into a continuous monitoring workflow. Plants often choose Waites for its approachable pricing and simple setup, particularly when monitoring a large number of mid-criticality machines.

The system provides basic vibration and temperature data along with cloud-based trend views. Because its alerting tools are configurable, teams may need to tune thresholds to avoid unnecessary notifications. Limited integration options may lead to extra manual steps when moving alerts into work orders or internal systems. Larger plants monitoring many assets may find that these manual processes require additional oversight.

Notable Features

• Cloud portal with spectra, trend charts, and configurable alarm settings
• Lower-cost hardware suitable for broad early-stage deployments
• Optional access to Waites reliability specialists

Potential Downsides

• Alarm thresholds may require tuning to avoid excessive notifications
• Integrations with CMMS platforms may require additional setup or manual steps
• Large-scale deployments may require careful network planning

What real customers say about Waites

• “They monitor 24/7 and record to an online database. Its still early in the data collection to establish a base line.” says MySavageAncestors
• “Waites came and trained us at our site. Although they can be a pain in the ass, they also help letting us know when there is a potential for catastrophic failure on conveyor beds and motors.” says PalpitationFar6923
• “Holy crap it's such a pain in the ass. Those things alert for almost anything. Idk if you have been signed into the Waites Wireless website to check alerts. Simplest ones to do are obviously when repeaters are not repeating and when sensors become detached.” says AndyPlaysBadly

Augury

Best for: Plants seeking AI-supported anomaly detection paired with expert review.

Augury provides wireless sensors that capture machine signals such as vibration, temperature, and magnetic signatures. Data is analyzed using a combination of automated models and Augury specialists who provide recommended actions. Companies often choose Augury to supplement internal reliability teams with additional analytical support.

The platform can help organizations that want AI-driven anomaly detection, although some users prefer more visibility into the underlying diagnostic reasoning when reviewing machine health findings. Implementations in industrial environments may involve IT or OT coordination to ensure stable connectivity and data flow. Plants evaluating a service-based monitoring model should consider long-term cost structure and internal ownership of diagnostics as their program matures.

Notable Features

• Multi-signal sensing capabilities
• AI-assisted anomaly detection and recommended actions
• Portfolio-level dashboards for reliability leaders

Potential Downsides

• Diagnostic reasoning is primarily algorithm-driven, which may limit visibility for specialists
• Deployments require coordination with internal IT or OT teams
• Ongoing service-based models can increase long-term operating costs for large fleets

What real customers say about Augury

• “Augury provides a range of industrial settings, from small factories to large manufacturing plants, and can be customized to meet the specific needs of each business.” says Prashant S., Small-Business
• “Consistency is a concern for me. Even though they provide me with the best possible service, but at times notification reaches to me a bit late. They can improve in that sector.” says Kartik A., Trainee Engineer

Relay (formerly Sensemore)

Best for: Facilities piloting small-scale wireless monitoring or monitoring low to mid-criticality equipment.

Relay offers compact IIoT sensors designed for quick installation and early-stage condition monitoring programs. Their wireless sensors and cloud dashboard provide basic condition information such as vibration and temperature trends. Plants often select Relay when they want a cost-effective, smaller-scale solution with simple visualization tools.

Relay’s wireless range and diagnostic depth are designed for lighter industrial use and may not meet the needs of heavy manufacturing, hazardous locations, or large multi-building facilities. Teams that need advanced fault identification, hazardous certifications, or enterprise-level workflow standardization typically layer in more robust systems as their program grows.

Notable Features

• Compact wireless IIoT sensors for vibration and temperature
• Quick setup suitable for small facilities or pilot programs
• Lower-cost entry point for digital condition monitoring

Potential Downsides

• Wireless range may not support large industrial footprints
• Not hazardous-location certified, limiting use in regulated environments
• Diagnostic depth designed for lighter industrial needs

Why Tractian Leads in Wireless Condition Monitoring

Most wireless monitoring platforms can collect vibration and temperature data. The difference comes from how reliably they deliver continuous signals, how clearly they help teams interpret machine health, and how seamlessly insights connect to maintenance execution. Tractian is designed around those priorities, which is why many industrial teams choose it for plant-wide wireless condition monitoring.

Tractian Smart Trac Ultra combines long-range wireless connectivity, rugged hardware, built-in diagnostics, and integrated work execution inside one ecosystem. This helps maintenance teams detect issues early, understand what is happening, act with confidence, and prove the impact through reliability reporting.

Industrial-Grade Wireless Designed for Real Plant Conditions

• Smart Trac Ultra uses a long-range wireless architecture built for industrial environments, maintaining stable communication through metal structures, equipment, and busy production areas. Its ability to reach strategically placed receivers helps reduce network components and keeps deployments simple across wide plant floors.

Multi-Year Battery Performance Built for Continuous Monitoring

• Battery longevity is a key factor in any wireless monitoring program. Smart Trac Ultra is designed for multi-year operation under typical sampling settings, allowing teams to choose intervals that fit their assets without frequent sensor maintenance. With built-in battery health visibility, technicians can plan replacements efficiently and stay focused on equipment conditions rather than device upkeep.

Rugged Hardware for Harsh, Wet, Hot, and Hazardous Environments

• Smart Trac Ultra carries IP69K and ATEX certifications, making it suitable for washdown, dusty, and hazardous areas where many wireless sensors cannot operate. This ruggedness lets teams install the device directly at the point of failure across demanding industries such as chemicals, oil and gas, food production, and mining.

Built-In Diagnostics That Reduce Noise Instead of Creating It

• Tractian emphasizes clear and actionable insights rather than noise. The platform identifies likely fault types, rates severity, detects RPM, uses a large bearings library, and tracks condition changes over time. Technicians can see why an alert was generated, which helps minimize false alarms and supports faster, more confident decisions.

Closed-Loop Execution Inside an Integrated CMMS

• Tractian connects condition data directly to inspections and work orders in its AI-powered CMMS. When Smart Trac Ultra finds an issue, the system identifies the likely failure mode, generates tasks, captures evidence, and updates reliability reports so teams can act quickly without manual transfers.

Several distinctions emerge when comparing Tractian with the other vendors in this guide:

Tractian vs AssetWatch and Waites: AssetWatch and Waites pair wireless sensors with external analyst services, which can help teams without internal vibration expertise. Tractian focuses on giving in-house teams clear, automated diagnostics so they can act quickly without relying on a service layer. Plants that want to build internal capability often find this approach more efficient.

Tractian vs Augury: Augury’s wireless system is supported by AI models and expert recommendations, but the workflow often moves through a managed service process. Tractian connects wireless insights directly to inspections and work orders inside its CMMS, which helps maintenance teams move from detection to action without extra steps.

Tractian vs Relay: Relay offers compact wireless sensors suited for small deployments and basic monitoring. Tractian is built for larger industrial environments that need long-range wireless performance, hazardous-area readiness, and integrated execution. This makes Tractian a stronger fit for plants monitoring many assets or operating in demanding conditions.

If your goal is to bring wireless condition monitoring, diagnostic clarity, and maintenance execution into one technician-first platform, Smart Trac Ultra and Tractian’s CMMS create a single system where asset health data and daily work operate together. 

Ready to see how Tractian condition monitoring sensors help your operations?

Request a demo and discover what your team can achieve when equipment health insights, AI diagnostics, and maintenance execution operate as one unified system.

Wireless Condition Monitoring Sensor FAQs

1. How far can wireless sensors reach in an industrial environment?

Sub-GHz sensors often achieve around 100 meters indoors and up to 1 km line-of-sight. BLE and Wi-Fi typically have shorter ranges and are more affected by interference.

2. Do wireless sensors work in hazardous or washdown environments?

Only sensors with proper certifications (ATEX, IECEx, IP69K) can be installed in hazardous or high-moisture areas.

3. Will wireless interference cause missed alerts?

Advanced radios with strong error correction and long-range frequencies significantly reduce packet loss. Systems designed specifically for industrial use offer much stronger reliability than generic off-the-shelf wireless chips.

4. Do I need IT involvement?

Some vendors require IT to approve network access or BLE mesh routing. Tractian’s system communicates through dedicated receivers without tying into corporate Wi-Fi, simplifying installation.

5. How many sensors can a single gateway support?

This depends on the protocol. Sub-GHz networks can support dense deployments with many sensors per receiver, while BLE and Wi-Fi often support fewer devices due to interference and bandwidth constraints.