Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Hydraulic System Pressure & Temperature Monitoring (Excavators, Drills & Heavy Equipment)
Prevents breakdowns, extends machine life
Pressure
Temperature
Quick Overview
| Problem | Hydraulic systems are the backbone of mining excavators, drills, and heavy machinery. Pressure instability, overheating, or contamination can rapidly lead to loss of force, uncontrolled movements, equipment damage, and safety incidents. Manual checks and periodic oil analysis provide delayed visibility and cannot prevent sudden failures. |
| Solution | Sensa.io’s wireless pressure and temperature sensors continuously monitor hydraulic circuit behaviour, detecting overload, leaks, overheating, and efficiency loss in real time—without wiring or intrusive installation. |
| Value | Reduced breakdowns • Improved machine availability • Lower maintenance cost • Enhanced operator safety |
| ATEX | Hydraulic circuits may be in hazardous zones • ATEX-certified pressure & temperature sensor variants available |
The Operational Challenge
Mining hydraulic systems power:
- Excavator arms and buckets
- Rotary and percussive drills
- Mobile crushers and breakers
- Steering, braking, and actuation systems
They operate under extreme conditions:
- High pressure cycles and shock loads
- Elevated temperatures during continuous duty
- Dust ingress and contamination
- Variable loads depending on material hardness
Common failure modes include:
- Seal and hose degradation
- Internal leakage reducing pressure
- Overheating due to friction or restricted flow
- Loss of hydraulic efficiency leading to reduced performance
Traditional monitoring relies on:
- Manual pressure readings
- Periodic oil sampling
- Operator feedback after performance drops
These methods rarely detect early-stage issues.
Why Pressure & Temperature Monitoring Matter
Pressure and temperature trends reveal hydraulic system health.
Continuous monitoring enables operators to:
- Detect pressure loss indicating leaks or wear
- Identify overheating before oil degradation
- Prevent uncontrolled movements and safety hazards
- Optimise hydraulic performance and energy use
Stable hydraulic operation is critical for productivity and safety.
Sensa.io Solution
Sensa.io delivers a wireless hydraulic monitoring solution designed for mining equipment.
Core Components
Pressure Sensor
Monitors hydraulic pressure to detect leaks, overload, or loss of efficiency.
Temperature Sensor
Tracks oil temperature to detect overheating and fluid degradation risk.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, suitable for mobile and remote equipment.
Installation & Power
Battery-powered threaded or clamp-on installation — no wiring, minimal downtime.
Operational Benefits
- Early detection of hydraulic faults
- Reduced risk of sudden equipment failure
- Improved maintenance planning
- Extended component and oil lifetime
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 near fuel, gas, or hazardous zones.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Fleet management, maintenance platforms, mining SCADA |
| Deployment | On-machine monitoring with central analytics |
| 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.
