Regal Rexnord
Condition Monitoring Systems
Regal Rexnord condition monitoring systems are integrated hardware and software solutions that continuously or periodically measure the vibration, temperature, lubrication condition, and electrical signature of rotating power - transmission equipment — motors, gearboxes, bearings, pumps, and fans — to detect the earliest signs of developing faults, enabling maintenance to be performed at the optimal time, before failure, without unnecessary intervention.Under the Perceptiv and ProTeg branded offerings, our condition monitoring portfolio spans wireless vibration and temperature sensors that install in minutes without wiring, multi - channel online protection systems for critical turbomachinery, oil - debris sensors that detect bearing - wear particles in circulating lube oil, and software platforms that apply machine - learning algorithms to turn raw sensor data into actionable maintenance recommendations.Plant reliability managers and maintenance directors select Regal Rexnord condition monitoring because it transforms maintenance from a cost center reacting to breakdowns into a strategic function that maximizes asset availability, extends equipment life, and eliminates the collateral damage, lost production, and safety risks of catastrophic rotating - equipment failures.With expertise that spans both the sensor technology and the mechanical equipment being monitored, Regal Rexnord provides the unique, integrated understanding necessary for a successful predictive - maintenance program.
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Trusted by Industry Leaders
Wireless Vibration & Temperature Sensors with Rapid Installation
Battery - powered, magnetically mounted sensors that communicate over wireless mesh or Wi - Fi — installed in minutes per machine, enabling facility - wide monitoring without costly sensor wiring.
Automated Fault Detection & Diagnostics Software
Machine - learning algorithms that learn each machine’s normal vibration signature and alert on developing faults(bearing defects, imbalance, misalignment, gear wear) without requiring a vibration analyst to interpret data.
Complete Asset Health Dashboards
Web - accessible, role - based dashboards showing real - time health status of all monitored equipment, with traffic - light(red / yellow / green) indicators that enable maintenance prioritization at a glance.
Oil - Debris & Wear - Particle Monitoring
In - line sensors that detect and classify metallic wear particles in gearbox and bearing - circulating - oil systems, providing the earliest possible indication of mechanical - component degradation.
Electrical Signature Analysis(ESA)
Motor - current and voltage analysis that detects rotor bar defects, stator winding issues, and air - gap eccentricity — all without sensors on the rotating equipment itself, using only the motor power leads.
Integration with CMMS & Plant Control Systems
Condition - monitoring alarms and work - order triggers that integrate directly with common CMMS platforms(SAP, Maximo) and plant control systems via OPC - UA, Modbus, and REST API.
Building an Effective Predictive Maintenance Program with Condition Monitoring
A successful predictive maintenance program starts with identifying the plant’s most critical and failure - prone rotating equipment — the assets whose unplanned failure causes the greatest production, cost, and safety impact.Regal Rexnord provides consulting services that conduct this criticality assessment, develop a monitoring - technology plan matched to each asset’s failure modes, and define the alarm thresholds and response procedures that translate sensor data into specific maintenance actions.The transition from reactive or time - based maintenance to a condition - based(predictive) program is phased — proving the technology and building organizational confidence on the most critical assets before expanding to the broader equipment population.Our reliability engineers partner with customer teams through this transformation, ensuring that the combination of technology, processes, and skills are in place to sustain the predictive program’s benefits over the long term.
The Return on Investment from Condition Monitoring
Industry studies consistently demonstrate that predictive maintenance programs reduce unplanned equipment downtime by 35 % to 45 %, reduce maintenance costs by 25 % to 30 %, and extend equipment life by 20 % to 25 % compared to run - to - failure or fixed - time - based maintenance.The avoided cost of a single catastrophic gearbox failure — including the gearbox rebuild, collateral equipment damage, lost production, and potential safety and environmental impact — can justify the investment in condition monitoring across an entire plant.Regal Rexnord helps customers quantify this ROI by modeling the cost of their specific failure history and projecting the reduction in failure frequency that condition monitoring will achieve.The result is a financially justified, phased implementation plan that delivers measurable results from the first monitoring installations.