Factory installed or field added. Every sensor you add generates data that strengthens your RigidVault archive, builds your RigidFlow capability certificate, and earns RigidRoyalty credits when you opt in. The hardware pays for itself in platform value. Most monitoring systems observe and alert. RigidSense feeds live data into RigidPulse, which observes and acts — adjusting feed rates, detecting chatter, protecting tooling, and logging everything to your sovereign vault in real time.
“The sensor is the truth. Everything downstream is interpretation.”
The cheapest hardware does the sensing. The AI in RigidPulse does the interpretation. Every sensor you add is not just a monitoring upgrade — it generates data that flows into RigidVault, earns a RigidFlow capability rating, or creates RigidTrust worker safety documentation.
ADXL357 accelerometer. Chatter, resonance, bearing wear.
Piezoelectric, spindle-mount. Micro-tool wear, carbide breakage — physics of the cut.
Hall clamps, per-axis. Motor load, tool engagement, binding detection.
High-res true power on spindle motor. Enables adaptive feedrate control and tool life curves.
IR + thermistors. Spindle thermal, motor overheat, coolant temp.
Bus voltage + quality sensor. Brownout, power events, supply health.
Temp + humidity. Thermal expansion compensation, environment logging.
PM2.5 + multi-gas. Worker safety — MDF dust, carbon fiber, aluminum fog environments.
MEMS mic, audible band. Acoustic chatter, bit breakage detection.
Global shutter camera, IP-rated. Cut zone monitoring, timestamped job archive.
Flow switch + pressure transducer. Pump failure, blocked lines, dry-run prevention.
Ultrasonic or float sensor. Coolant tank + oil mist reservoir monitoring.
Eddy-current probe, non-contact. Geometric drift, thermal growth, ballscrew wear.
On composite beam members. Structural load, cutting force, real deflection data.
Reader + per-tool tags. Tool provenance, life curves, wear history — stored in RigidVault.
Derived from existing signals. Uptime %, parts/hr, cycle time — powers RigidFlow certificates.
| Tier | Models | Sensors Included | Mode |
|---|---|---|---|
| Maker | RC-PRO3636 | Vibration, Audio, OEE Counters | Advisory |
| SE | RC-PRO4824 / 4848 | Maker sensors + Acoustic Emission, Current ×4, Spindle Power, Temperature, Power Bus, Coolant Flow/Pressure, Fluid Level | Active |
| Pro | RC-PRO4896 / 6060 | All SE sensors + Air, Particulate/VOC, Vision, Displacement, RFID Tool Tracking | Active Full |
| Industrial | RC-PRO60120+ | All 16 sensors including Strain Gauge on structural beam members | Active Full Stack |
Machine Health
Keep the machine running. Know what it's doing. Prove it.
Vibration + Acoustic Emission + Spindle Power. The trio that enables adaptive feedrate AI. Recommended field upgrade for all Node-tier customers.
Pulse Pack + Coolant Flow/Pressure + Fluid Level + Vision. Full unattended-shift confidence — the machine stops itself before a pump failure or broken tool becomes a catastrophic loss.
Guardian + Particulate/VOC + Air + OEE Counters. Predictive maintenance, worker safety documentation, and real productivity metrics. Prove capability — don't just claim it.
Geometry & Quality
Scan it. Verify it. Archive it. Cut it.
Structured light scanner + Displacement sensor. Monitors geometric drift live during a run, then verifies the finished part against the original model. No CMM needed.
Scanner + RigidVault license + scan-to-toolpath pipeline. Scan → model → toolpath on-machine. No Autodesk. No third-party cloud.
Scan Pack + photogrammetry module + RigidForge license. Hand the scanner a worn or one-of-a-kind part — get a validated toolpath on the machine with no external software touchpoint.
Ecosystem-Native
These packages only exist because of the KI ecosystem. No competitor can offer them.
Einstar VEGA scanner (geometry + integrated RGB color/texture) + Heritage RigidVault license. A grandfather's tool archived with accurate rust bloom, worn grain, and patinated metal — not just a gray mesh. Assets exempt from deletion on cancellation. Yours forever.
Every active sensor streams to RigidVault continuously, auto-building your machine's Digital Twin over time. Opt in to RigidAI training and earn quarterly RigidRoyalty credits. Your operational data has value — this is how KI pays it back.
OEE counters + Spindle Power history + Vision logs → immutable RigidFlow machine capability certificate. Verifiable proof of what your machine can hold — backed by sensor data, not self-reported claims. Higher-rated shops win better-priced work.
Particulate/VOC + Gas + worker exposure time logging → RigidVault, timestamped and immutable. RigidTrust Bill VIII compliance documentation for OSHA, defense prime audits, and aerospace supplier certification. The machine proves the shop cares about its workers.
The key distinction: Node observes and advises. SE and above observe and act. But RigidSense has a second dimension independent of motion control tier: ecosystem integration depth. A Node-tier customer with a full sensor array still generates vault data, still builds their Digital Twin, still earns a capability rating. Sensing and control are separate upgrade paths that reinforce each other — grow either one without replacing the other.
The Safety Pack data feeds directly into the RigidHealth shop floor wellness module — OSHA exposure tracking, noise dose logging, and particulate monitoring per worker per shift. The same sensors that protect the machine also protect the person running it. Worker exposure data is stored in the worker’s own RigidVault — not the employer’s. The employer sees aggregate OSHA compliance dashboards. The worker sees their full personal exposure history.
See RigidHealth →The Certification Pack converts your RigidSense performance data into a machine capability certificate that is posted to the RigidFlow marketplace. Shops with certified machines — verified tolerance achieved, verified material capability, verified cycle time, verified OEE — receive priority in job matching. The AI matching algorithm weights verified capability over self-reported specs. A certified machine is not just more competitive. It is the standard other shops are measured against.
See RigidFlow →Most OEE and machine monitoring platforms bolt sensors to your equipment and send you a dashboard. They tell you a machine stopped, a cycle was slow, a micro-stop added up to lost time. That’s useful. It’s also where they stop.
RigidSense is the sensing layer of a closed-loop system. When the vibration sensor detects chatter, RigidPulse doesn’t send you an alert and wait. It adjusts feed rate, flags the anomaly, and logs the event to RigidVault — all before the next tool pass. When the current sensor detects rising motor load, the system responds in milliseconds, not after you read an email.
The nervous system. Without sensor data, every other pillar is guessing.
Every pillar in the KI ecosystem is interconnected. No product works alone.
View Full Ecosystem Map →Kavanagh Industries · Always on