Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Grain Silo Acoustic Anomaly Detection (Blockage, Friction & Explosion Risk Prevention) — ATEX
Detects friction / dust ignition risks
Acoustic
Quick Overview
| Problem | Grain silos and handling systems are exposed to acoustic anomalies caused by friction, material bridging, abnormal flow, or mechanical contact. These events can precede blockages, structural stress, smouldering grain, or dust ignition—often occurring without visible warning. |
| Solution | Sensa.io’s ATEX-certified acoustic sensors continuously monitor sound signatures inside and around grain silos to detect abnormal noise patterns associated with friction, blockage, or ignition risk. |
| Value | Reduced fire & explosion risk • Early blockage detection • Improved operational safety • Lower downtime |
| ATEX | Dust Zones 20–22 • Ex ia IIIC T135°C Db certified acoustic sensors |
The Operational Challenge
Grain silos and associated equipment (discharge chutes, conveyors, reclaimers) face several hidden risks:
- Material bridging or arching during discharge
- Grain friction against steel walls or liners
- Abnormal flow patterns creating mechanical stress
- Dust accumulation combined with ignition sources
Typical failure scenarios include:
- Sudden discharge blockage requiring emergency intervention
- Mechanical overheating due to friction
- Smouldering grain leading to fire
- Dust explosion triggered by ignition and confinement
Traditional monitoring relies on:
- Visual inspection during unloading
- Operator experience and audible checks
- Reactive shutdown after flow stops
These methods expose personnel to hazardous dust zones and often detect issues too late.
Why Acoustic Monitoring Matters
Acoustic emissions are early indicators of abnormal mechanical or material behaviour.
Continuous acoustic monitoring enables operators to:
- Detect friction noise before heat builds up
- Identify abnormal flow sounds indicating bridging or collapse
- Detect impacts or structural resonance
- Intervene before mechanical damage or ignition occurs
Acoustic monitoring complements temperature and ΔP measurements by detecting dynamic events in real time.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe acoustic monitoring solution for grain silos and bulk handling systems.
Core Components
Acoustic Sensor (ATEX Ex ia IIIC T135°C Db)
Wide-band acoustic detection capturing friction noise, impacts, and abnormal flow signatures.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, ideal for large agricultural storage sites
Installation & Power
Battery-powered clamp-on installation on silo walls, chutes, or discharge zones — no wiring, no hot work.
Operational Benefits
- Early detection of blockages and friction
- Reduced dust explosion risk
- Safer unloading operations
- Lower emergency intervention frequency
Results and ROI
ATEX Compliance and Safety
All acoustic sensors for grain silo monitoring comply with:
- ATEX Directive 2014/34/EU
- Ex ia IIIC T135°C Db (Dust Zones 20–22)
- IECEx certification for combustible dust
The intrinsically safe design allows monitoring in explosive dust environments without ignition risk.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Grain management platforms, SCADA, safety dashboards |
| Deployment | Centralised or multi-silo monitoring |
| 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
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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.
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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.
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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.
