Industrial Robot Health Monitoring
Robots deliver the speed, precision and repeatability that modern automation depends on. Fizix detects reducer gear-surface degradation and joint bearing wear — from motor current and vibration — before a worn axis costs you quality or halts the line.
When a Robot Drifts, the Whole Cell Stops
Industrial robots are the backbone of automation — welding, assembly, palletizing, painting and pick-and-place — prized for speed, precision and repeatability. When a precision robot degrades, scrap and rework rise long before it fails outright, and a single stopped robot can idle an entire automated cell or line.
Robot failures are overwhelmingly wear-related: gear-surface degradation and bearing damage in the joint reducers, driven by mechanical wear and the accumulation of metallic debris. Because robots operate in tightly sequenced cells, an unplanned failure means long, expensive downtime — exactly the risk condition monitoring exists to remove.
Fizix fuses the two most informative signals for robots — motor current and vibration — and computes statistical-moment health indicators (mean, variance, skewness, kurtosis) on-device. AI algorithms trained on gear-surface and bearing wear turn those signals into an early, actionable warning per joint.
ROBOTS & CELLS MONITORED
What Fizix Detects on Your Robots?
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.
Reducer Gear-Surface Degradation
Surface wear and pitting in RV / harmonic-drive reducers, detected from current and vibration statistical moments.
Joint Bearing Wear
Bearing degradation in the axis joints caught early through vibration envelope and rising kurtosis.
Metallic Debris Accumulation
Wear-particle buildup in reducer grease flagged by AI before it accelerates gear and bearing damage.
Repeatability / Backlash Drift
Growing lost motion and positioning error at the tool center point, before it shows up as scrap.
Servo & Winding Faults
Servo-motor electrical faults exposed through motor-current signature analysis.
Timing-Belt Wear
Belt slack and wear on belt-driven axes detected via vibration signatures.
Mechanical Looseness
Loose mounts, bolts and end-effector couplings amplifying vibration across the arm.
Joint Overheating
Reducer or servo overheating from friction, overload or lubrication loss verified by temperature.
Guarding Repeatability , Joint by Joint
A robot rarely fails all at once. Its reducers wear, metallic debris accumulates in the grease, and repeatability quietly drifts — so the first thing you notice is scrap, not a stopped machine. Fizix reads the wear directly in the shape of the motor-current and vibration signals.
σ Statistical-moment health indicators — mean, variance, skewness and kurtosis — rise as gear-surface wear and debris change the signal's shape, well before positioning fails.
AI Gear-surface & debris models translate current and vibration into a clear per-joint wear signal, trained on real robot failure modes.
🎯 Repeatability protected — you catch the drift at ±0.02 mm, not after it has widened into rework and scrap.
One Platform, Value For Every Role
From the boardroom to the shop floor, robot monitoring delivers something different — and useful — to everyone who keeps production running.
Plant & Reliability Leaders
Turn unplanned robot failures into planned, budgeted work
A clear ROI and payback you can take to finance and the board
Fleet-wide visibility across every robot — 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 robot, 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 robot
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 robots on calendar schedules and walk-around checks. Here's what changes when your robots talk to you.
See What Fizix Could Save You
Move the sliders to match your robot fleet. This is an indicative estimate — book a free consultation for a validated, site-specific business case.
Defaults reflect a typical robot-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 robots to actionable intelligence in real time — installed in minutes, with no process interruption.
Mount per joint in <15 min
The smart multi-sensor device attaches to the target axis/reducer housing — no cell rewiring, no line stop.
Fuse current + vibration
Motor current and vibration captured through the work cycle and processed at the edge.
Statistical moments + AI
Mate computes skewness/kurtosis and runs gear-surface and debris-wear models per joint.
Alert before quality drifts
You're warned as a reducer degrades — plan the swap before scrap or a cell stop.
How Fizix Protects Your Robots?
Smart multi-sensor devices in the field capture four signals — analyzed on the cloud-based Fizix Mate platform.
Protect Repeatability & Quality
Reducer and bearing wear erode positioning accuracy long before failure. Fizix catches the drift early, protecting part quality and cutting scrap and rework.
Catch Gear-Surface Degradation
Statistical-moment analysis of current and vibration exposes reducer gear-surface wear and metallic-debris buildup — the dominant robot failure modes.
Avoid Cell-Wide Downtime
A single failed robot can idle a whole automated line. Early warning turns a multi-day emergency into planned maintenance in a scheduled window.
AI Wear Models
Fizix hardware and AI algorithms are trained specifically on gear-surface and bearing wear, translating raw current and vibration into a clear per-joint health signal.
Monitor Inside Fenced Cells
Robots inside safety fencing are monitored continuously and remotely — no cell entry, no line stop, no manual route checks.
Fleet-Wide Robot Visibility
Every joint of every robot across a cell, line or plant visible from one Mate dashboard — on web and mobile.
What We Detect & Measure?
Fizix combines multiple measurement technologies to give complete robot health visibility.
Motor Current (MCSA)
Current-signature analysis for reducer load, servo and winding faults.
Vibration Analysis
Waveform, spectrum and envelope for gear and bearing wear up to 26.6 kHz.
Statistical Moments
Mean, variance, skewness and kurtosis computed on-device as health indicators.
AI Wear Detection
Gear-surface degradation and metallic-debris models per joint.
Temperature
Reducer and servo overheating detection.
Axis-Speed Tracking
Per-axis speed for load-normalized trending across the work cycle.
Fizix Smart Multi-Sensor Devices for Robot Monitoring
Choose the right smart multi-sensor device for each robot'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 Robot 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.
A robot's health is written in its current.
For robots, the two most informative signals are motor current and vibration. A single Fizix sensor captures both — plus acoustic emission and temperature — and computes statistical-moment health indicators (mean, variance, skewness, kurtosis) on-device, joint by joint.
Those signals stream to the AI-powered Mate platform, where models trained on gear-surface and bearing wear classify what's degrading in each reducer, how severe it is, and what to do next.
Real Diagnostics From Real Plants
Request a Free Expert Consultation
Tell us about your robots 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 robots
Tailored sensor & Mate platform recommendation
Optional pilot to prove ROI before scaling
Keep Every Robot — and Every Cell — Running
Detect reducer gear-surface wear, bearing degradation and repeatability drift in any robot, from motor current and vibration, before they stop your line.
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