Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Hoist Motor Vibration & Brake Temperature Monitoring (Shaft Safety & Uptime Protection)
Prevents hoisting failures — critical safety system
Vibration
Temperature
Quick Overview
| Problem | Mine hoists are safety-critical systems transporting personnel, ore, and materials through shafts. Bearing degradation, imbalance, or brake overheating can escalate rapidly into emergency stops, equipment damage, or severe safety incidents. Manual inspections are infrequent and expose staff to risk. |
| Solution | Sensa.io’s wireless vibration and temperature sensors continuously monitor hoist motors and braking systems, detecting early mechanical and thermal anomalies to ensure safe, reliable shaft operations. |
| Value | Enhanced shaft safety • Reduced unplanned stops • Lower maintenance risk • Predictable operations |
| ATEX | Shaft and motor rooms may be classified • ATEX-certified vibration & temperature sensor variants available |
The Operational Challenge
Hoisting systems are among the most critical assets in underground and deep open-pit mines.
They operate under demanding conditions:
- High dynamic loads and start/stop cycles
- Continuous operation over long shifts
- Strict braking performance requirements
- Limited tolerance for failure or downtime
Common failure modes include:
- Bearing wear in hoist motors or gearboxes
- Rotor imbalance increasing vibration
- Brake overheating due to friction or misadjustment
- Progressive mechanical fatigue in shafts and couplings
Traditional monitoring relies on:
- Scheduled inspections
- Manual temperature checks
- Reactive intervention after alarms or abnormal noise
These approaches do not provide continuous safety assurance.
Why Vibration & Brake Temperature Monitoring Matter
Vibration and brake temperature are the earliest indicators of hoist degradation.
Continuous monitoring enables operators to:
- Detect bearing defects weeks before failure
- Identify imbalance or misalignment early
- Monitor brake thermal load during braking cycles
- Prevent emergency stops and safety incidents
Reliable hoist performance is essential for worker safety and production continuity.
Sensa.io Solution
Sensa.io delivers a wireless monitoring solution designed for hoist motors and braking systems.
Core Components
Vibration Sensor
Measures acceleration and frequency spectra to detect bearing wear, imbalance, misalignment, and structural resonance.
Temperature Sensor
Monitors brake and motor temperature to detect overheating, excessive friction, or cooling issues.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, suitable for shafts, motor rooms, and underground installations.
Installation & Power
Battery-powered clamp-on installation — no wiring, no shutdown, minimal disruption.
Operational Benefits
- Continuous shaft safety monitoring
- Early detection of mechanical degradation
- Reduced emergency stops
- Improved maintenance planning
Results and ROI
ATEX Compliance and Safety
Where required, Sensa.io sensors support:
- ATEX Directive 2014/34/EU
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
This enables safe monitoring in hazardous or confined hoist environments.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Hoist control systems, mine SCADA, safety platforms |
| Deployment | Shaft infrastructure 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.
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Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
