Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Mobile Equipment Engine Vibration Monitoring (Haul Trucks & Loaders)
Reduces maintenance costs for haul trucks & loaders
Vibration
Quick Overview
| Problem | Haul trucks, loaders, and mobile mining equipment operate under extreme mechanical stress. Engine, drivetrain, and auxiliary component failures lead to unplanned downtime, high repair costs, and production losses. Manual inspections are infrequent and often detect issues only after damage has occurred. |
| Solution | Sensa.io’s wireless vibration sensors continuously monitor engine and drivetrain behaviour on mobile mining equipment, detecting early signs of mechanical degradation and enabling predictive maintenance without wiring or intrusive installation. |
| Value | Reduced breakdowns • Lower maintenance cost • Increased equipment availability • Extended asset lifetime |
| ATEX | Generally non-ATEX on vehicles • ATEX-certified vibration variants available for fuel or hazardous zones |
The Operational Challenge
Mobile equipment represents one of the highest OPEX contributors in mining operations.
Typical assets include:
- Haul trucks
- Loaders and shovels
- Dozers and graders
- Mobile crushers and drills
They operate under conditions such as:
- Continuous vibration and shock loads
- Dust, mud, and extreme temperatures
- Variable duty cycles and payloads
- Remote operation far from workshops
Common failure modes include:
- Engine bearing wear
- Drivetrain imbalance
- Mount degradation
- Cooling fan and auxiliary failures
- Progressive fatigue leading to catastrophic breakdowns
Traditional monitoring relies on:
- Scheduled maintenance intervals
- Oil analysis at fixed periods
- Driver-reported noise or vibration
These methods rarely detect early-stage failures.
Why Engine Vibration Monitoring Matters
Vibration analysis is a proven method for detecting early mechanical issues.
Continuous vibration monitoring enables operators to:
- Identify bearing defects before seizure
- Detect imbalance or misalignment
- Track engine degradation trends over time
- Schedule maintenance before failure
This approach transforms maintenance from reactive to predictive.
Sensa.io Solution
Sensa.io delivers a wireless vibration monitoring solution designed for mobile mining equipment.
Core Components
Vibration Sensor
Measures acceleration and frequency spectra to detect bearing wear, imbalance, misalignment, and structural resonance.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, suitable for open-pit mines and fleet operations.
Installation & Power
Battery-powered magnetic or bolted mounting — no wiring, no vehicle downtime.
Operational Benefits
- Early detection of engine and drivetrain faults
- Reduced unplanned breakdowns
- Improved fleet availability
- Lower maintenance and spare part cost
Results and ROI
ATEX Compliance and Safety
Where required, Sensa.io vibration sensors support:
- ATEX Directive 2014/34/EU
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
This allows deployment near fuel systems or hazardous mine zones.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Fleet management, maintenance systems, mining SCADA |
| Deployment | On-vehicle monitoring with central data aggregation |
| 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.
