Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Conveyor Belt Vibration & Bearing Temperature Monitoring (Failure Prevention & Production Continuity)
Prevents belt failure, avoids production stoppages costing +50k€/h
Vibration
Temperature
Quick Overview
| Problem | Conveyor belts are mission-critical assets in mining operations. Bearing wear, misalignment, or overheating can escalate rapidly into belt failure, material spillage, or full production stoppage—often costing tens of thousands of euros per hour. Manual inspections are infrequent and reactive. |
| Solution | Sensa.io’s wireless vibration and temperature sensors continuously monitor conveyor bearings, rollers, and drive components to detect early mechanical degradation and overheating. |
| Value | Prevents belt failure • Avoids unplanned shutdowns • Protects production continuity • Predictable maintenance |
| ATEX | Generally non-ATEX; ATEX-certified vibration & temperature variants available for dusty or explosive zones |
The Operational Challenge
Conveyor belts transport ore, coal, aggregates, or overburden across long distances and harsh environments.
They operate under extreme conditions:
- Continuous duty cycles
- Heavy loads and abrasive materials
- Misalignment due to ground movement
- Dust, moisture, and vibration
Common failure modes include:
- Bearing wear and seizure
- Roller misalignment or imbalance
- Overheating due to friction or lubrication loss
- Belt mistracking leading to spillage or tearing
Traditional monitoring relies on:
- Periodic visual inspection
- Manual infrared temperature checks
- Operator experience and audible cues
These methods often detect issues after damage has already begun.
Why Vibration & Temperature Monitoring Matter
Vibration and temperature are the earliest indicators of conveyor degradation.
Continuous monitoring enables operators to:
- Detect bearing defects weeks before failure
- Identify misalignment or imbalance early
- Detect overheating before seizure or fire risk
- Schedule maintenance outside production peaks
In mining, a single unexpected conveyor failure can halt downstream crushing, milling, or loading operations.
Sensa.io Solution
Sensa.io delivers a wireless predictive maintenance solution for conveyor systems in mining environments.
Core Components
Vibration Sensor
Measures acceleration, RMS velocity, and frequency patterns to detect bearing wear, imbalance, misalignment, and structural resonance.
Temperature Sensor
Monitors bearing and roller temperature to detect friction, lubrication loss, or overload conditions.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, suitable for long conveyors and remote mine sites.
Installation & Power
Battery-powered clamp-on installation — no wiring, no shutdown, install in minutes.
Operational Benefits
- Early fault detection
- Reduced catastrophic belt failures
- Lower emergency maintenance cost
- Improved production availability
Results and ROI
ATEX Compliance and Safety
Where required, Sensa.io sensors support:
- ATEX Directive 2014/34/EU
- Ex ia IIIC T135°C Db (Dust Zones 20–22)
- IECEx certification
This enables safe monitoring near crushers, transfer points, or dust-laden conveyor galleries.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Mine SCADA, maintenance platforms, CMMS |
| Deployment | Pit, plant, or central control room |
| Cybersecurity | AES-128 encrypted communication |
FAQ - Common Questions
Are Sensa.io sensors compatible with any gateway or network?
What ATEX certifications apply to Sensa.io devices?
All hazardous-area models are certified Ex II 2 G Ex ia IIC T4 Gb and IECEx approved for Zones 0–2.
What is the typical battery life?
Up to 10 years at 15-minute intervals, depending on signal strength and environment.
How are the sensors integrated into existing systems?
Through standard protocols — LoRaWAN, Modbus, MQTT, REST API — no proprietary middleware needed.
How does predictive maintenance reduce OPEX?
Early anomaly detection reduces emergency interventions by 30–40 %, extends equipment life and lowers energy costs.
What does the Sensa.io Valve Position Sensor actually measure?
The device detects real-time valve position states—open, closed, or intermediate—with high accuracy. It continuously sends this information wirelessly to your monitoring dashboard.
Can this sensor detect partial valve movement or stuck valves?
Yes. The sensor identifies irregular patterns such as partial movement, delayed response, or stuck valves, enabling early maintenance before failure occurs.
Is this sensor suitable for manual, motorized, and actuated valves?
Yes. It supports a wide range of valve types including ball, gate, butterfly, actuator-driven, and manual valves.
How fast does it update the valve position?
You can configure the reporting interval—from seconds to minutes—depending on your operational and battery needs.
How long does installation take?
Most installations take under 10 minutes. The sensor mounts using brackets or clamps without modifying existing valves.
Explore Our Sensors
Valve position
The Sensa iO Valve Position Sensor provides real-time open/close feedback for manual and automated valves in oil & gas, chemical, and hydrogen operations.
Pressure
A rugged, industrial-grade pressure sensor designed for high-demand oil & gas applications. Provides continuous gas and liquid pressure monitoring, with ATEX intrinsic safety, IP67 housing, and LoRaWAN® connectivity.
Temperature
Sensa iO’s temperature sensor delivers precise temperature data for process lines, steam systems, heat exchangers, and storage assets.
Differential Pressure (ΔP)
A compact DP solution using dual synchronized pressure inputs to deliver accurate differential pressure data for filters, heat exchangers, separators, and manifolds.
Vibration
A high-resolution vibration sensor built for predictive maintenance of pumps, motors, compressors, and rotating equipment.
Acoustic
The Sensa iO acoustic sensor identifies ultrasonic leak signatures, gas escape, steam trap failures, and flare noise anomalies.
Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
