Top 5 Condition Monitoring Sensors in 2026

Industrial plants are under pressure to keep production running, eliminate unplanned downtime, and achieve more with lean maintenance teams. Most facilities now run 50 to 500 critical machines per site, many operating 24 hours a day, where a single unexpected failure can cost hundreds of thousands in lost output.

Condition-monitoring sensors have become essential because they provide early detection of equipment problems, especially in continuous process industries like chemicals, oil and gas, pulp and paper, mining, and food processing, where availability is the top metric. For large discrete manufacturers focused on Overall Equipment Effectiveness (OEE), they help maintain performance and quality while reducing micro-stops and preventing scrap.

This guide compares the top condition monitoring sensors that industrial reliability teams, plant managers, and predictive engineers are evaluating.

What Are Condition Monitoring Sensors?

Condition monitoring sensors continuously capture vibration, temperature, and performance indicators from rotating equipment. They provide early warnings for failure modes like bearing defects, imbalance, misalignment, looseness, lubrication issues, and mechanical looseness.

The best systems do more than detect anomalies. They diagnose the issue, guide the technician with step-by-step actions, and help teams prove the impact through avoided downtime and improved reliability KPIs.

This matters because most industrial maintenance organizations have in-house technicians and reliability roles who want to build internal capability, not outsource their diagnostics entirely. These teams demand clarity, accuracy, rugged hardware, and platforms that integrate with their Computerized Maintenance Management System (CMMS) and workflows.

Benefits of Investing in Condition Monitoring Sensors

Industrial teams deploy predictive maintenance sensors to eliminate surprises, catch failures earlier, and make better decisions about where to spend time and budget. Key benefits include:

• Reduced unplanned downtime: Sensors catch early vibration and temperature anomalies so technicians can intervene before failures cause line stoppages or expensive emergency repairs.
• Improved technician productivity: Automated data collection eliminates manual routes, allowing maintenance teams to focus only on assets that need attention.
• Safer maintenance operations: Remote monitoring reduces the need for technicians to enter hazardous areas or perform risky manual inspections.
• Smarter maintenance planning: Trend data and clear diagnostics support better scheduling, fewer surprises, and more efficient use of labor and spare parts.
• Stronger reliability practices: Consistent machine health insights help standardize processes, reduce variability between shifts, and support a disciplined CBM program.

A successful condition monitoring program pays off in higher output, fewer breakdowns, and more predictable operations.

Top 3 Priorities When Selecting Condition Monitoring Sensors

When evaluating solutions, industrial buyers prioritize three core requirements. They focus on tools that prevent downtime, reduce maintenance costs, and deliver measurable ROI across lines, shifts, and sites.

Industrial-Grade Sensing and Hardware: Reliability teams need sensors built to survive harsh environments such as washdown, chemical exposure, heat, vibration, and hazardous locations. Triaxial vibration measurement, wide frequency ranges, long battery life, shock resistance, hazardous certifications, and strong wireless connectivity are essential.

Built-In Diagnostics that Reduce Noise: Maintenance teams want fewer but clearer alerts. The best platforms combine AI insights, failure-mode identification, severity scoring, RPM detection, bearing fault frequencies, and historical trend learning so technicians can act without manual double-checks.

Integration and Execution: Insights only create value if they convert into action. Leading systems integrate directly into CMMS platforms, generate work orders automatically, and provide machine-specific procedures. This ties detection, diagnosis, and corrective action into one loop that technicians and planners can execute with confidence.

Condition Monitoring Sensors at a Glance

Top 5 Condition Monitoring Sensors for Industrial Teams

Tractian Smart Trac Ultra

Best for: Industrial plants with in-house maintenance that want rugged hardware, built-in diagnostics, and a complete closed-loop reliability workflow.

Smart Trac Ultra is a wireless vibration sensor designed for heavy industrial environments. It monitors vibration, temperature, runtime, and RPM across more than 100 asset categories, including variable-speed and intermittent machines.

What sets Tractian apart is the closed-loop condition-based maintenance system. The sensor detects problems early, the platform diagnoses the failure mode, then automatically generates structured inspections and step-by-step SOPs with AI. 

For plants that prioritize availability, want predictable execution, and operate critical assets 24 hours a day, Smart Trac Ultra provides the most complete end-to-end solution.

Notable Features

• Asset GPT strengthens reliability programs by explaining anomalies in simple terms, showing why an issue was detected, and helping teams make faster, more confident maintenance decisions.
• Engineered for reliability, the sensor is IP69K-rated and certified for hazardous locations, allowing it to operate reliably in washdown zones, high-heat areas, dusty spaces, and explosive atmospheres.
• Temperature Seasonality detects natural seasonal temperature shifts and filters them out, helping teams avoid misreading normal environmental changes as signs of equipment failure
• Always Listening for intermittent operations, capturing vibration precisely when machines move.
• RPM Encoder that infers rotational speed directly from vibration signals, even on variable-speed assets.
• Bearings Library with more than 75,000+ fault models for automatic fault frequency detection.
• Machine health indicators and benchmarking across assets, sites, and historical timelines..

Why real customers choose Tractian’s 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 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 operators use Tractian to monitor crushers, conveyors, and mobile assets running in extreme environments. Continuous monitoring helps prevent unplanned stoppages, protect workers, and keep high-value equipment running across remote or rugged locations.
• Chemical plants rely on Tractian to keep pumps, mixers, and compressors stable within tightly controlled process conditions. The platform supports strict safety requirements and provides early warnings that help avoid failures in hazardous production areas.
• Mills and Agriculture processors use Smart Trac Ultra to ensure machines stay operational during peak seasons. Early detection of bearing wear or misalignment helps prevent disruptions during high-demand harvest windows and safeguards expensive processing equipment.
• Manufacturing and industrial production depend on Tractian to maintain line uptime, reduce unexpected stoppages, and support continuous improvement programs. Real-time diagnostics help teams protect motors, gearboxes, and robotics used across mixing, forming, packaging, and assembly operations.
• Oil & Gas refineries, midstream facilities, and upstream operations use Tractian to monitor equipment in remote and hazardous environments. The system helps keep rotating assets running safely while supporting compliance with industry safety and reliability standards.
• Heavy Equipment operators depend on Tractian to track maintenance across job sites, prevent expensive failures on high-value mobile assets, and maintain equipment availability for time-sensitive projects.
• Food & Beverage producers leverage Tractian to avoid contamination risks and prevent unplanned downtime on equipment that impacts temperature control, hygienic processes, and product quality. Continuous monitoring supports regulatory compliance and plant cleanliness standards.
• Automotive and Parts plants rely on Tractian to keep high-precision machinery, robotics, and assembly lines running smoothly. Real-time insights help support just-in-time production schedules and reduce the risk of costly delays.

Tractian is trusted by companies like DHL, Ingredion, CP Kelco, and CZM, who require robust asset reliability, regulatory compliance, and the ability to scale maintenance excellence across global operations.

AssetWatch

Best for: Teams that want a managed monitoring service where external analysts interpret sensor data.

AssetWatch provides wireless sensors and a cloud platform supported by remote condition-monitoring analysts. This model is useful for facilities without internal vibration expertise.

However, relying heavily on external analysts can limit how much internal capability teams develop. Alerts may also sit in a separate portal unless integrations are built, which can delay action for plants that require fast, technician-first execution. Scaling across multi-site operations may introduce bottlenecks because everything funnels through the vendor’s service layer.

Notable Features

• Wireless vibration and temperature sensors built for continuous equipment monitoring
• Straightforward deployment model designed for plants without in-house vibration expertise
• Remote condition monitoring analysts who interpret sensor data and issue recommendations

Potential Downsides

• Heavy reliance on vendor analysts can slow internal capability-building and limit transparency into diagnostic reasoning
• Alerts and recommendations may require an additional portal unless integrations are manually configured
• Scaling across multi-site portfolios can increase service dependency and long-term operating costs

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: Plants looking for an economical condition monitoring starter package with optional expert review.

Waites provides affordable wireless sensors and a cloud portal for vibration and temperature data. It works well for facilities transitioning from handheld data collection to continuous monitoring.

The trade-off is that alert tuning and sampling must be managed carefully, or teams may receive excessive notifications. Integrations with CMMS and enterprise tools are limited, which adds manual steps that slow execution. For large plants running hundreds of critical machines, this can overwhelm lean maintenance teams.

Notable Features

• Wireless triax vibration and temperature sensors for motors, gearboxes, pumps, and conveyors
• Cloud portal with spectra views, historical trend charts, and configurable alarms
• Affordable hardware suited for large fleets of mid-criticality equipment

Potential Downsides

• Alert tuning often requires close attention, and noisy notifications can overwhelm teams if not properly configured
• Integrations with CMMS and plant systems are limited and may require extra work or middleware
• Less suitable for large enterprises that need deep diagnostics, standardized workflows, or corporate-wide reliability structure

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: Organizations that want AI-driven anomaly detection combined with a managed expert service.

Augury uses vibration, temperature, and magnetic data analyzed through proprietary AI models. Their offering includes recommended corrective actions driven by a combination of machine learning and Augury experts.

The downside is the black-box nature of diagnostics. Reliability specialists often want transparent fault frequencies and clear reasoning behind alerts. Deployments typically require IT, OT, and network support, which can slow rollout. Service-heavy models are harder to justify long-term for plants that prefer in-house ownership of reliability practices.

Notable Features

• Multi-signal sensing with vibration, temperature, magnetic signatures, and process context
• Portfolio-wide risk dashboards designed for multi-site reliability leaders
• Managed monitoring service focused on high-criticality industrial assets

Potential Downsides

• Diagnostic logic is heavily tied to proprietary AI models, reducing transparency for vibration specialists
• Implementations often require substantial IT and OT coordination, extending rollout timelines
• Managed-service pricing can be difficult to justify for lean teams that want more control or lower recurring costs

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: Teams looking for lightweight, compact sensors with basic anomaly detection.

Relay offers compact IIoT sensors with temperature and vibration monitoring. The solution is simple and quick to roll out, appealing to plants exploring monitoring for the first time.

For large industrial facilities, the platform may not offer the depth of diagnostics, hazardous certifications, or maintenance workflow integration needed for plant-wide deployment. Scaling across multi-line or multi-site operations often requires more advanced capabilities than Relay currently supports.

Notable Features

• Lightweight cloud platform for basic anomaly alerts and trend visualization
• Cost-effective pathway for plants looking to digitize early-stage CBM efforts
• Integrates easily with smaller edge gateways and IoT networks

Potential Downsides

• Limited diagnostic depth compared with enterprise-grade vibration systems used in heavy industry
• Not certified for hazardous environments, restricting use in oil and gas, chemical, or explosive areas
• More suitable for small equipment groups, may not scale well for plants monitoring hundreds of critical machines

Why Tractian Leads in Industrial Condition Monitoring

Most condition monitoring systems can collect vibration and temperature data. The difference comes from how quickly those signals turn into clear diagnostics, prioritized actions, and measurable improvements that technicians and planners can execute on the floor.

Smart Trac Ultra is built for industrial teams that want a complete reliability workflow instead of a basic alerting tool. It brings together several components that are often split across multiple vendors.

Native integration with an AI-powered CMMS 

• Smart Trac Ultra feeds directly into the same platform that manages work orders, PMs, procedures, labor, and inventory. When the system detects abnormal behavior, Tractian automatically generates structured inspections and technician-ready tasks instead of leaving insights trapped in a separate dashboard.

Rugged hardware engineered for real industrial environments

• The sensor’s IP69K rating and hazardous-location certifications allow it to operate safely on assets in washdown areas, explosive zones, and heavy-duty process environments. This level of durability makes it suitable for industries like chemicals, food production, oil and gas, and mining, where many competing devices cannot be installed.

Built-in intelligence that strengthens in-house reliability teams

• The platform includes advanced tools such as Fault-Finding Auto Diagnosis, RPM Encoder, and a large bearings library. These capabilities help internal teams diagnose root causes without relying entirely on vendor analysts. Support is always available, but the system is designed to grow internal expertise rather than outsource it.

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

Tractian vs AssetWatch and Waites: These providers emphasize external analyst services to interpret data. Tractian focuses on empowering in-house teams with clear automated diagnostics, while still offering expert support when needed. This keeps knowledge inside the plant and reduces long-term dependence on a service model.

Tractian vs Augury: Tractian prioritizes operational execution by tying sensor insights directly to work orders, procedures, parts, and planning. This is often more practical for maintenance crews who need fast action paths rather than multi-step handoffs.

Traction vs Relay: Relay offers lightweight sensing and basic anomaly detection. Tractian provides deep diagnostics, hazardous-environment readiness, and an integrated CMMS built for industrial-scale operations. This makes Tractian more suitable for plants managing large asset counts and uptime-critical environments.

If your goal is to unify condition monitoring, diagnostics, and maintenance execution in one technician-first system, Smart Trac Ultra, paired with Tractian’s CMMS, delivers a single environment where asset health data and daily maintenance work operate together.

Ready to see how Tractian predictive maintenance sensors can 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.

Condition Monitoring Sensor FAQs

1. How do condition monitoring sensors improve availability on critical assets?

Continuous vibration and temperature monitoring detects early signs of bearing wear, imbalance, and lubrication issues that typically go unnoticed during manual inspections. By catching these problems early, teams can schedule repairs before failures occur, protecting uptime and keeping production targets stable across continuous or multi-shift operations.

2. Do I need vibration expertise to use condition monitoring sensors effectively? 

Not necessarily. Modern platforms include automated diagnostics, fault-type identification, severity scoring, and clear recommended actions. These tools help technicians and reliability engineers understand what is happening without needing to interpret raw spectra. Plants with vibration specialists can still drill into the data when needed, but day-to-day teams benefit from simplified guidance.

3. How does condition monitoring data connect to work orders and maintenance workflows? 

Most sensors send data to a cloud platform that interprets anomalies and forwards alerts to your CMMS through integrations or connectors. Systems like Tractian simplify this by housing sensor data and maintenance execution in the same platform so that fault detection automatically generates inspections, updates asset records, and informs planning without switching tools.

4. Can these sensors monitor intermittent or variable-speed machines? 

Some sensor platforms are capable of monitoring equipment that starts and stops frequently or runs at changing speeds. Advanced features like motion-triggered sampling and automatic RPM detection help capture accurate data whenever the machine is active. This allows teams to monitor assets that traditional route-based vibration programs often struggle to assess.

5. What certifications or ratings should I look for in harsh or hazardous environments?

Industrial plants should look for IP69K or similar ingress protection, along with ATEX, IECEx, or NFPA hazardous-location certifications when deploying sensors in washdown zones, chemical areas, refineries, or dust-prone environments. Sensors lacking these ratings may not perform reliably or be permitted by safety teams in regulated areas.