Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Conveyor Belt Valve/Actuator Position Monitoring
Reduced misconfiguration risk during material routing
Valve position
Quick Overview
| Problem | Valves and actuators associated with conveyor systems are not always continuously monitored, leading to uncertainty in material routing and system configuration. |
| Solution | SENSAiO valve position sensors provide continuous monitoring of actuator and valve states. |
| Value | Improved visibility on conveyor system configuration, supporting earlier detection of incorrect or unexpected positioning. |
| ATEX | Suitable for mining environments including dust zones, compliant with ATEX / IECEx requirements where applicable. |
The Operational Challenge
Conveyor systems in mining and metals operations are used to transport bulk material across:
- Crushing circuits
- Transfer points
- Storage and processing areas
These systems often include:
- Diverter gates
- Isolation valves
- Actuated routing mechanisms
Correct positioning of these components is essential to:
- Ensure proper material flow direction
- Avoid misrouting or spillage
- Maintain process continuity
From a physical perspective:
- A valve or gate position determines the path taken by bulk material
- Incorrect positioning can redirect material unintentionally
- Partial positioning may lead to obstruction or uneven distribution
Typical issues include:
- Incorrect manual operation
- Actuator malfunction or incomplete movement
- Lack of confirmation of actual position
- Discrepancy between control signals and physical state
Detection challenges include:
- Large and distributed conveyor networks
- Limited instrumentation on mechanical routing components
- Reliance on operator confirmation or visual inspection
- Difficulty verifying position in real time
As a result, configuration errors may persist until operational impact occurs.
Why Position Monitoring Matters
Valve and actuator position directly determine system configuration.
By continuously monitoring position:
- Actual mechanical state can be verified
- Unexpected changes can be detected
- Process routing can be confirmed
Typical interpretations include:
- A gate expected to be open but detected closed may indicate operational error
- Incomplete movement may correlate with mechanical issues
- Unexpected position change may indicate actuator malfunction or human intervention
Position data provides direct insight into how material flow paths are configured.
SENSAiO Solution
SENSAiO deploys wireless valve position sensors installed on:
- Diverter gates
- Actuators
- Conveyor routing valves
Sensors detect position state (open / closed or movement) and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous position monitoring
- Real-time visibility of system configuration
- Alerts on unexpected position changes
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control actuators or conveyor systems
- It does not execute routing logic
- It does not replace control systems or safety interlocks
The system supports operational verification and awareness.
Results and ROI
ATEX Compliance and Safety
Mining conveyor environments may involve combustible dust. SENSAiO sensors:
- Are available with ATEX / IECEx certification where required
- Are suitable for installation in dust zones
- Are designed for harsh industrial environments
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace interlocks, emergency stops, or regulatory safety requirements.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with conveyor monitoring and maintenance platforms |
| Deployment | Suitable for retrofit on existing conveyor routing systems |
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, SENSAiO delivers rugged sensor solutions to the toughest environments — everywhere.
