Wired vs. Wireless: Choosing the Right Sensors for Your Condition Monitoring Strategy
As the condition monitoring landscape continues to evolve, the conversation around sensor selection is more important than ever. Whether you’re optimizing a wireless rollout or reinforcing your critical assets with rugged, high-fidelity tools, understanding the differences between IEPE and MEMS sensors can make or break your program. It behooves us to take a closer look at how each technology plays a role, why the most resilient strategies use both, and where the industry is heading as data ownership and flexibility become central to long-term success.
An observation from Mechanical of Rotating Equipment (Lei & Wu, 2020) captures this shift:
“The traditional wired monitoring technology faces problems such as high-frequency signal pickup and high-precision data collection…The emergence of wireless sensor networks has broken this wired connection model.”
MEMS vs. IEPE: Two Distinct Tools for Different Jobs
Two common sensor technologies used in vibration monitoring today are MEMS (Micro-Electro-Mechanical Systems) and IEPE (Integrated Electronics Piezoelectric). While they serve the same fundamental purpose, their performance and applications differ significantly.
MEMS Sensors
Best For: Long-term IIoT monitoring, data-rich environments, remote installations
Advantages:
- Low power requirements make MEMS ideal for wireless applications
- Can detect very low-frequency vibrations
- Compact and easy to deploy
- Enables remote data collection with high sampling flexibility
Limitations:
- Narrower frequency range
- Less suitable for high-temperature environments
- Cannot provide true continuous monitoring due to battery constraints
IEPE Sensors
Best for: Critical machines, diagnostic tasks, and harsh environments
Advantages:
- Wide frequency response, capable of detecting high-speed faults
- High sensitivity with minimal noise
- Reliable continuous monitoring
- Performs well in extreme environmental conditions (heat, caustics, submersion)
Limitations:
- Requires constant power supply
- Cable management challenges in permanent installations
- Slower to deploy and gather data compared to wireless alternatives
Why the Best Programs Use Both
Today’s most effective condition monitoring strategies leverage both wired and wireless sensors to cover the full range of application needs.
Wireless Solutions Offer:
- Facility-wide coverage with easy installation
- High-frequency data collection for trend analysis
- Integration with cloud platforms and other IIoT tools like WiSER Vibe®
- Time savings by eliminating the need for route-based collection
Wired Solutions Offer:
- True continuous monitoring with the ability to monitor more critical assets with an appropriate solutions like DEFIANT
- Durability in high-temperature or chemically aggressive environments
- Compatibility with portable analyzers like DigivibeMX for advanced diagnostics
By combining both, facilities can implement a layered approach: wireless sensors for widespread coverage and alerts, wired sensors for high-resolution insight on critical equipment.
The State of the Industry
The condition monitoring industry has undergone a significant shift. Not long ago, portable data collectors and permanently wired sensors were the norm. Data was gathered manually by reliability teams or third-party service providers–professionals who understood each asset’s function and unique failure modes.
The introduction of wireless sensors established a new norm for speed and accessibility–but also raised concerns. Many providers now offer closed WaaS or SaaS platforms where data is managed externally. While convenient, this model often lacks context–overlooking the critical value of asset-specific knowledge that only plant personnel or trusted partners possess.
This has led to a new challenge: automation without understanding. AI-powered diagnostics are only as effective as the knowledge behind them–and generic algorithms often fall short when evaluating machines with unique load conditions or specialized roles in production.
Erbessd's Approach
ERBESSD INSTRUMENTS takes a different route. The company offers open, hardware-based platforms, working directly with end users and third-party service providers to empower them–not replace them.
- No Saas/WaaS lock-in
- Full data ownership
- Flexible protocols like Modbus, MQTT, and OPC-UA
- Support for hybrid setups (wired + wireless)
The result is a vibration monitoring ecosystem that respects the role of skilled reliability professionals and ensures they maintain control over their machines–and their data.
Final Thought
In an industry increasingly focused on wireless solutions, the most effective outcomes stem from partnering with providers who value flexibility, transparency, and reliability. The right partner empowers your team, complements your in-house expertise, and invests in truly understanding the equipment and processes being monitored. It’s about more than just deploying sensors–it’s about building a monitoring strategy as adaptable and forward-thinking as your operation.
Brad Ferraro, BBA, ISO CAT-1 VA, is the Customer Success Leader at ERBESSD INSTRUMENTS, based in New York. In this role, hem manages customer relationships to ensure smooth program implementations and long-term customer satisfaction. Brad is actively engaged with clients year-round, representing ERBESSD at industry conferences and conducting on-site visits to support customer needs.
With over seven years of experience in the vibration and condition monitoring industry, Brad has worked with several leading sensor manufacturers across both wired and wireless technologies. He studied Business Administration and holds Category I Vibration Analyst certification.
ERBESSD INSTRUMENTS® is a global manufacturer of Vibration Analysis Equipment, Dynamic Balancing Machines, and Condition Monitoring solutions, with facilities in Mexico, United States, UK, Colombia, and India.
