Condition Monitoring for Gearboxes
Frustrated with maintenance programs that drain time and budget without stopping failures? UpTime Solutions delivers advanced asset condition monitoring for gearboxes by combining industrial-grade 3-in-1 sensors, intelligent software, and expert-driven prescriptive analytics to detect issues early, protect critical gearbox assets, and eliminate unplanned downtime.
PROUDLY PARTNERING WITH
Trusted by Reliability & Maintenance Professionals
The Advantage of UpTime’s Gearbox Condition Monitoring
World’s First 3-in-1 Gearbox Sensors
VIEW DETAILS
In 2019, we launched the world’s first wireless sensor that combines ultrasonic, vibration, and temperature monitoring in a single device. Since then, we’ve continued to advance the technology, delivering actionable insights that help keep critical gearbox assets operating efficiently while minimizing downtime.
Industry-Specialized Expert Analysts
VIEW DETAILS
AI can recognize patterns and detect abnormal signatures, but UpTime goes further. Our expert analysts review alerts, identify the root cause, and recommend the right corrective action. With decades of experience across industries, our team has deep expertise working with gearboxes and other rotating equipment.
Prescriptive Work Orders in Your CMMS
VIEW DETAILS
UpCast connects seamlessly with your CMMS and EAM platforms through an MQ broker, helping improve asset visibility and streamline maintenance workflows. Alerts are prioritized and sent directly to your team, along with prescriptive work orders in your CMMS so you can plan repairs faster and allocate resources more effectively.
ISO 9001 & 27001 Certified
VIEW DETAILS
Quality and security are central to our approach. UpTime Solutions is ISO 9001 and ISO 27001 certified, demonstrating our commitment to strict quality management standards and strong information security practices. You can be confident that your operational data is protected and your systems remain secure.
A Complete Ecosystem for Monitoring Gearbox Health and Performance
MistEX & MistLX
Wireless sensors that monitor ultrasound, vibration, and temperature, built to support scalable deployments and large-scale rollouts
MistLX: Compact, rugged design with a small footprint for flexible mounting
MistEX: High-performance model with extended battery life of up to five years
Key features of both models:
- Bluetooth connectivity to UpCastCM, UpTime’s cloud platform
- IP69-rated for maximum durability and protection
- Optional stainless steel housing for wet, high-moisture, or washdown environments
Brick T1SX
Hybrid wireless sensor that brings existing wired inputs into the UpTime platform without requiring batteries or additional infrastructure
Key Features:
- Powers and reads up to 15 sensor inputs
- Transforms junction boxes or accelerometers into wireless data hubs
- Long-range 900 MHz wireless connectivity with no battery replacements required
- Wirelessly transmits data from up to seven accelerometers and seven process channels, plus tachometer input
UpCast
Cloud-based platform that connects all UpTime sensors to provide real-time insights into vibration, ultrasound, and temperature. Intelligent analytics transform data into actionable alerts, prescriptive work orders, and prioritized maintenance tasks
Key Features:
- Highly accurate diagnostics and alerting
- Prescriptive work orders prioritized by severity
- Seamless integration with third-party systems and Active Directory
- Scalable, enterprise-level platform built on Cassandra and MQTT
3-in-1 Gearbox Condition Monitoring Techniques
Featuring MistEX & MistLX – The Ultimate Asset Watchdogs
Ultrasound
By capturing high-frequency sound wave data, ultrasonic condition monitoring can detect developing gearbox faults weeks or even months before changes in temperature or vibration become noticeable. UpTime uses ultrasound as an early line of defense against gearbox failures, helping teams address issues sooner and reduce unnecessary downtime and maintenance effort.
Vibration
With vibration monitoring, each gearbox’s unique vibration signature provides a clear view of its condition and operating performance. While traditional preventive maintenance programs can lead to unnecessary service and still miss developing faults, UpTime gives your team the tools to identify gearbox issues early and prevent unplanned downtime.
Temperature
Relying only on an overload relay means gearbox issues are often detected only after excessive heat or stress has already occurred. UpTime’s Mist sensors monitor temperatures up to 250°F (121°C) and correlate them with vibration trends, while our software records and analyzes patterns over time, enabling earlier and more accurate detection of developing gearbox faults.
Vibration Detects
Bearings & Gears
- Early-stage bearing wear before vibration changes appear
- Gear tooth friction, pitting, or micro-cracks
- Lubrication deficiencies causing increased friction
Lubrication & Oil Condition
- Oil film breakdown and dry-running conditions
- Contaminated or aerated lubricants
- Oil flow issues in critical gearbox components
Seal & Leak Detection
- Internal and external gearbox leaks
- Failing seals before catastrophic damage occurs
- Air or gas ingress affecting performance
Mechanical Friction & Contact
- Abnormal metal-to-metal contact
- Rubbing, misalignment, or loosened components
- Early-stage wear in shafts and couplings
Ultrasound Detects
Bearings & Gears
- Inner and outer race bearing defects
- Gear tooth wear, chipping, or cracking
- Bearing misalignment and lubrication issues
Shaft & Coupling Alignment
- Shaft imbalance and eccentricity
- Misaligned couplings causing vibration
- Torsional oscillations and resonance
Gear Mesh & Transmission
- Gear meshing faults, including pitting or scuffing
- Backlash changes and uneven load distribution
- Transmission harmonics for early wear detection
Housing & Structural Integrity
- Loose or cracked gearbox housings
- Mounting issues or foundation vibrations
- Resonance frequencies affecting overall performance
Temperature Detects
Bearings & Gears
- Bearing and gear temperatures to detect overheating
- Abnormal friction or misalignment
- Excessive heat from lubrication breakdown
Shafts & Couplings
- Overheating from misaligned or imbalanced shafts
- Torsional stress causing temperature spikes
- Hotspots in couplings under load
Lubrication & Oil Health
- Tracks lubricant temperature to prevent viscosity loss
- Detects hotspots that indicate oil starvation or contamination
- Thermal stress affecting critical gearbox components
Housing & Surrounding Components
- Gearbox casing for excessive heat buildup
- Thermal issues affecting seals and bearings
- Ambient vs. operational temperature to spot anomalies
How To Start a Pilot Trial for Our Gearbox Condition Monitoring System
Our customers typically see ROI within 2–12 months and experience over a 3x reduction in unplanned downtime. Ready to see the difference for yourself? Sign up for a pilot today.
Reliability Assessment
Collaborate with our sales team to determine if our gearbox condition monitoring system aligns with your facility's and maintenance goals.
Installation & Setup
We arrive on-site fully equipped to install and configure your gearbox condition monitoring system quickly and efficiently.
Expert Support & Review
Our analysts track your gearbox health, issue alerts for abnormal readings, and provide prescriptive work orders. They also provide monthly reviews to optimize your maintenance program.
Benefits of Motor Condition Monitoring
Prolonged Equipment Lifespan
By identifying maintenance issues before they escalate into failures, motor condition monitoring helps reduce or eliminate catastrophic breakdowns, which may drive excessive, unplanned wear and costly damage to critical equipment. Acting early extends asset service life, avoids emergency replacements, and significantly lowers repair and parts costs. For many UpTime customers, these avoided failures and efficiency gains translate into a measurable return on investment within just 3 to 12 months, while ensuring the long-term protection of capital investments.
Improved Maintenance Efficiency
Condition-based monitoring strengthens maintenance programs by eliminating the inefficiency of waiting for issues to appear on a fixed schedule. With UpTime, motor condition monitoring data is reviewed by expert reliability analysts who offer ongoing consultation to help facilities prioritize the right maintenance at the right time. Rather than reacting to raw alerts, teams can restructure their maintenance programs around validated insights, which helps reduce unnecessary work and avoids the over-maintenance of healthy assets.
Optimized Spare Parts Planning
Sensor-based motor condition monitoring generates high-value data that delivers deeper insight into true maintenance demands over time. UpTime’s 3-in-1 sensors combine ultrasonic, vibration, and temperature monitoring to detect developing issues well before they escalate into parts-consuming breakdowns. With this early visibility, maintenance teams can plan interventions proactively, forecast inventory needs with greater accuracy, reduce excess “just-in-case” stock, and ensure critical spare parts are available precisely when they’re needed.
Enhanced Operational Consistency & Quality
Motor condition monitoring sensors detect subtle changes in equipment performance that may not immediately trigger maintenance events but can impact product consistency and quality. With UpTime, real-time and historical data are continuously reviewed by expert reliability analysts who provide ongoing maintenance consultation and translate insights into actionable maintenance work orders directly within the platform.
Industries We Support With Gearbox Condition Monitoring Solutions
Gain the clarity you deserve
Protect your line’s bottom line by maximizing the ROI on your capital equipment.
Ready to get every ounce of value from your assets? Let’s talk.
