Regal Rexnord
Predictive Maintenance & Condition Monitoring
Regal Rexnord predictive maintenance solutions — powered by the Perceptiv Intelligent Reliability and Maintenance platform — shift industrial maintenance from reactive crisis management to proactive, data-driven asset management that eliminates unplanned downtime, extends machine life, and reduces total maintenance cost. The Perceptiv ecosystem combines multi-modal wireless sensors (vibration, temperature, motor current, speed), a Universal Gateway with PLC and cloud connectivity, and a Microsoft Azure-based web platform where reliability engineers monitor machine health trends, receive AI-generated anomaly alerts, and schedule maintenance based on actual component condition rather than arbitrary calendar intervals. The platform is designed for scalability: a single conveyor or an entire plant with hundreds of rotating assets can be monitored through the same architecture, with flexible analysis options ranging from self-managed data interpretation to Regal Rexnord reliability engineer support. Deployment data shows Perceptiv reduces unexpected equipment failures by up to 55%, increases machine life by as much as 40%, and improves energy efficiency by 18%.
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Trusted by Industry Leaders
Multi-Modal Sensor Fusion
Simultaneous vibration, temperature, current, and speed sensing provides a comprehensive view of equipment health, detecting failure precursors that single-parameter monitoring would miss — from bearing spalling to winding insulation degradation.
Universal Gateway — Wired & Wireless
A single gateway connects to multiple sensor types via wired or wireless interfaces and communicates data to on-premises PLCs or cloud platforms, simplifying infrastructure without extensive IT involvement.
Scalable from Single Machine to Enterprise
Start with one critical asset or expand to hundreds of machines across multiple sites using the same platform architecture, with per-machine monitoring costs declining as deployment scales.
Choose Self-Managed or Expert-Monitored Service Models
Internal reliability teams access raw sensor data and analytical tools directly; alternatively, Regal Rexnord reliability engineers provide monthly health reports with prioritized maintenance recommendations.
Integrated with Existing Automation Infrastructure
Perceptiv connects to PLCs and third-party cloud platforms, feeding condition data into existing operational dashboards and preventing creation of isolated, orphaned data silos.
55% Fewer Unplanned Failures, 40% Longer Machine Life
Documented outcome metrics from deployed sites provide CFO-ready justification for condition monitoring investment, with payback typically realized within 6–12 months.
Why Perceptiv Changes the Maintenance Equation
The economic argument for predictive maintenance has been understood for decades — yet adoption has historically been limited by high sensor cost, complex integration, and the need for data science expertise that most industrial operations lack. Perceptiv directly removes these barriers. Sensor costs have been driven down to the point where instrumenting an entire conveyor or pump skid costs less than a single shift of emergency overtime. The dual-path analysis model means that organizations without internal condition-monitoring expertise can still deploy Perceptiv and receive actionable, engineer-vetted maintenance guidance every month.
Applications Across Asset Types
Perceptiv monitors a broad range of industrial rotating and reciprocating equipment. Conveyor systems track bearing vibration, motor current, and chain/belt elongation. Pumps and compressors monitor impeller condition, seal health, and bearing degradation. Gearboxes and gear drives receive vibration trend analysis that identifies developing tooth wear or bearing pitting months before audible noise. Fans and blowers track unbalance and misalignment that degrade efficiency and shorten bearing life. This asset-type breadth makes Perceptiv a universal condition monitoring solution for any industrial operation.