Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Crusher & Mill Vibration Analysis (Predictive Maintenance & Catastrophic Failure Prevention)
Early detection of imbalance & wear → reduces catastrophic damage
Vibration
Quick Overview
| Problem | Crushers and grinding mills operate under extreme mechanical stress. Bearing degradation, imbalance, liner wear, or resonance can escalate rapidly into catastrophic failures—causing unplanned shutdowns, costly repairs, and production losses that can exceed €50,000 per hour. Manual inspections are infrequent and often too late. |
| Solution | Sensa.io’s wireless vibration sensors continuously monitor crushers and mills, detecting early mechanical anomalies and enabling predictive maintenance without wiring or production interruption. |
| Value | Prevents catastrophic failures • Increases equipment availability • Reduces maintenance OPEX • Protects production throughput |
| ATEX | Generally non-ATEX; ATEX-certified vibration sensor variants available in dusty or explosive zones |
The Operational Challenge
Crushers and mills are core assets in mining and quarrying operations, including:
- Jaw crushers
- Cone and gyratory crushers
- Ball mills and SAG mills
- Vertical and roller mills
They operate under harsh conditions:
- High vibration and shock loads
- Abrasive material impact
- Variable feed size and hardness
- Continuous or near-continuous duty cycles
Common failure mechanisms include:
- Bearing fatigue and lubrication breakdown
- Rotor or shaft imbalance
- Misalignment after liner replacement
- Structural resonance and foundation issues
Traditional monitoring methods rely on:
- Periodic vibration campaigns
- Manual listening and visual inspection
- Reactive shutdown after alarms or damage
These approaches provide limited temporal coverage and expose operators to hazardous zones.
Why Continuous Vibration Monitoring Matters
Vibration analysis is the most reliable early indicator of mechanical degradation in crushers and mills.
Continuous monitoring enables operators to:
- Detect bearing defects weeks before failure
- Identify imbalance caused by liner wear or material buildup
- Detect misalignment after maintenance
- Monitor structural resonance and fatigue
Early detection allows maintenance to be planned during scheduled shutdowns rather than emergency stops.
Sensa.io Solution
Sensa.io delivers a wireless vibration monitoring solution designed for heavy mining equipment.
Core Components
Vibration Sensor
Measures acceleration, RMS velocity, and frequency spectra to detect bearing wear, imbalance, misalignment, and resonance.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, suitable for large processing plants and remote mine sites.
Installation & Power
Battery-powered clamp-on installation on bearing housings or structural frames — no cabling, no hot work.
Operational Benefits
- Early detection of mechanical degradation
- Reduced risk of catastrophic failure
- Improved maintenance planning
- Increased equipment availability
Results and ROI
ATEX Compliance and Safety
Where required, Sensa.io vibration sensors support:
- ATEX Directive 2014/34/EU
- Ex ia IIIC T135°C Db (Dust Zones 20–22)
- IECEx certification
This enables safe monitoring in dusty crusher houses and transfer points.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Plant SCADA, condition monitoring platforms, CMMS |
| Deployment | Crusher house, mill building, 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
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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.
