Gearbox Health Monitoring
Gearboxes are the most expensive rotating components in your plant. Fizix detects gear-tooth defects, bearing faults and lubrication loss before a $10K repair becomes a $500K replacement.
Your Most Expensive Machine Needs the Best Protection
Industrial gearboxes are among the costliest components in manufacturing — and their failures are among the most devastating. A failed gearbox on a cement mill, wind turbine or rolling mill can mean weeks of downtime and a replacement bill in the hundreds of thousands.
Gearbox failures are progressive. They start as microscopic tooth pitting or a bearing defect that generates specific high-frequency vibration. Without the right bandwidth and analysis, these early indicators stay invisible until failure is imminent.
Fizix's 16g dynamic range and wide bandwidth (up to 26.6 kHz) are built for the high-amplitude shock inside industrial gearboxes. Mate includes dedicated gear-mesh frequency analysis, cepstrum tooling and gear-specific diagnostic guides.
GEARBOXES MONITORED
What Fizix Detects on Your Gearboxs
Each fault leaves a distinct signature across vibration, acoustic emission, magnetic flux or temperature. Fizix catches them weeks before failure — and tells you which smart multi-sensor device saw it.
Gear-Tooth Defects
Pitting, spalling and tooth breakage identified through gear-mesh frequency and sideband analysis.
Gear Transmission Error
Worn gear profiles causing transmission error and rising mesh-frequency vibration.
Bearing Failures
Input, output and intermediate-shaft bearing defects detected at the earliest stage.
Inadequate Lubrication
Oil starvation and early metal-to-metal contact detected by acoustic emission before wear damage.
Shaft Misalignment
Input/output shaft misalignment causing uneven load distribution and localized tooth wear.
Looseness
Gear-mesh backlash and housing looseness detected through vibration signatures.
Thermal Anomalies
Friction, overload or cooling failure verified through on-device temperature trending.
The $10K → $500K Escalation
A gearbox fault is cheap to fix and ruinous to ignore. It starts as microscopic tooth pitting — a few thousand euros to refurbish. Left unseen, it cascades to tooth breakage that shreds the gearset, wrecks bearings and can mean weeks of downtime. Fizix's 16g dynamic range and gear-mesh/cepstrum analytics catch it at the cheap end of that curve.
One Platform, Value For Every Role
From the boardroom to the shop floor, gearbox monitoring delivers something different — and useful — to everyone who keeps production running.
Plant & Reliability Leaders
Turn unplanned gearbox failures into planned, budgeted work
A clear ROI and payback you can take to finance and the board
Fleet-wide visibility across every gearbox — one plant or many
Lower safety exposure and fewer emergency interventions
Predictable spend, less capital tied up in spares
Operations & Production Teams
Keep the line running — no process interruption to install
A simple health score per gearbox, readable without expertise
Alerts before a trip, so you shut down on your terms
Know which asset actually needs attention first
Web & mobile dashboards for the whole shift team
Maintenance & Reliability Engineers
Pinpoint the fault type and location on each gearbox
Plan repairs into routine stops, not emergencies
Order the right spare at the right time — no over-stocking
Guided diagnostics without deep vibration expertise
Remote checks — fewer trips into hot, hazardous zones
Reactive Maintenance vs Fizix
Most plants still run gearboxes on calendar schedules and walk-around checks. Here's what changes when your gearboxes talk to you.
See What Fizix Could Save You
Move the sliders to match your gearbox fleet. This is an indicative estimate — book a free consultation for a validated, site-specific business case.
Defaults reflect a typical gearbox-heavy plant. Adjust to your own figures.
Based on Fizix reference outcomes: up to 50% less downtime, 35% lower maintenance cost, ~134 kg CO₂/day per 200 kWh motor. Indicative only.
From Smart Multi-Sensor Device to Insight
An end-to-end solution connecting your gearboxes to actionable intelligence in real time — installed in minutes, with no process interruption.
Mount in <15 min
The smart multi-sensor device attaches to the gearbox housing near the target bearing or mesh — no shutdown.
Capture the shock
16g vibration and 80 kHz acoustic captured 24/7; enter tooth counts once.
Mesh + cepstrum + twin
Mate overlays gear-fault frequencies and separates sidebands from noise automatically.
Plan on the cheap end
Alerts catch pitting weeks early — refurbish before it becomes a replacement.
How Fizix Protects Your Gearboxs
Smart multi-sensor devices in the field capture four signals — analyzed on the cloud-based Fizix Mate platform.
Early Gear-Tooth Detection
Gear-mesh frequency analysis detects pitting and spalling weeks before catastrophic tooth breakage — giving teams time to plan.
Lubrication Monitoring
Acoustic emission at 80 kHz detects inadequate lubrication before it causes metal wear — the most common gearbox failure mode.
Avoid Catastrophic Replacement
Large gearboxes cost $50K–$500K+ and weeks to source. Fizix turns a potential catastrophe into a planned, budgeted swap.
Remote Monitoring
Wind-turbine nacelle boxes, buried conveyor drives and hot kiln drives are all monitored continuously without physical access.
Multi-Stage Support
Fizix handles complex multi-stage gearboxes — multiple mesh frequencies, shaft speeds and bearing sets tracked simultaneously.
Load-Normalized Trending
RPM tracking keeps vibration trending meaningful even as the gearbox operates across variable speed and load.
What We Detect & Measure?
Fizix combines multiple measurement technologies to give complete gearbox health visibility.
Gear-Mesh Analysis
Mesh harmonics and sidebands that reveal tooth wear and damage.
Cepstrum Analysis
Separates families of sidebands from noisy gearbox spectra.
Acoustic Emission
Lubrication failure and early contact up to 80 kHz.
High Dynamic Range (16g)
Captures high-amplitude shock from damaged teeth and bearings.
3D Waterfall / Cascade
Visualizes how the spectrum evolves as faults develop.
Gear-Property Guides
Enter tooth counts; Mate overlays fault frequencies automatically.
Fizix Smart Multi-Sensor Devices for Gearbox Monitoring
Choose the right smart multi-sensor device for each gearbox's criticality and environment.
Best for Critical Assets
Wired power for 24/7 continuous streaming. For high-criticality assets where any downtime is unacceptable.
Best for Important Assets
Battery-powered with up to 5-year life. ATEX-certified for hazardous areas. Wireless and quick to install.
Best for Balance-of-Plant
Bluetooth, compact and economical. Ideal for monitoring many assets across a facility cost-effectively.
Impact on Gearbox Reliability
Typical outcomes reported across Fizix deployments. Actual results vary by asset condition and baseline.
Figures reflect "up to" improvements observed across Fizix installations and the 200 kWh reference calculation for CO₂. Company-wide figures (150M+ monitoring hours, 40,000+ connected machines, 18+ sectors) are as of 2025. Asset-specific results should be validated during a pilot.
Gearboxes speak in sidebands.
A single Fizix smart multi-sensor device captures 3-axis vibration, acoustic emission, magnetic flux and temperature — with a 16g dynamic range built for gearbox shock. Gear-mesh and cepstrum analysis pull fault frequencies out of the noise a gearbox generates.
Data streams to the AI-powered Mate platform, where a digital twin and fault library classify tooth, bearing and lubrication faults, their severity, and the recommended action.
Request a Free Expert Consultation
Tell us about your gearboxes and what you want to protect. A Fizix specialist will get back to you within one business day to discuss your goals and outline a tailored path forward — with no obligation.
Free 1:1 consultation with a reliability expert
Assessment of your critical gearboxes
Tailored sensor & Mate platform recommendation
Optional pilot to prove ROI before scaling
Don't Wait for Your Gearbox to Fail
Get the early warning you need to plan gearbox maintenance — before a $10K repair becomes a $500K replacement.
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