Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Crusher & Mill Vibration Monitoring
Earlier mechanical degradation detection
Vibration
Quick Overview
| Problem | Crushers and mills operate under high mechanical stress, and vibration behavior is not always continuously monitored across all assets. |
| Solution | SENSAiO vibration sensors provide continuous monitoring of mechanical vibration patterns. |
| Value | Improved visibility on mechanical condition, supporting earlier detection of abnormal operating behavior. |
| ATEX | Suitable for hazardous mining environments (dust zones), compliant with ATEX / IECEx where required. |
The Operational Challenge
Crushers and mills are critical equipment in mining and metals processing, used for:
- Size reduction of ore
- Material preparation for downstream processes
- Continuous high-load mechanical operation
These machines involve:
- Rotating shafts and bearings
- Impact forces (in crushers)
- Grinding media interaction (in mills)
From a physical perspective:
- Mechanical movement generates vibration due to rotating imbalance, impacts, and friction
- Normal operation produces a characteristic vibration signature
- Deviations from this baseline may reflect changes in mechanical condition
Typical issues include:
- Bearing wear
- Misalignment
- Imbalance in rotating components
- Structural looseness
- Material buildup or uneven loading
Detection challenges include:
- Equipment often located in harsh, dusty environments
- Limited instrumentation on legacy assets
- Reliance on periodic inspections or handheld measurements
- Difficulty detecting gradual degradation
As a result, abnormal mechanical conditions may evolve without continuous visibility.
Why Vibration Monitoring Matters
Vibration is a direct physical indicator of mechanical behavior.
By continuously monitoring vibration:
- Baseline operating conditions can be established
- Changes in amplitude or frequency can be tracked
- Abnormal mechanical patterns can be detected
Typical interpretations include:
- Increased vibration amplitude may indicate imbalance or wear
- Changes in vibration frequency may correlate with mechanical faults
- Intermittent vibration spikes may indicate impacts or transient issues
Vibration data reflects how mechanical energy is distributed and dissipated in the equipment.
SENSAiO Solution
SENSAiO deploys wireless vibration sensors mounted on:
- Crusher housings
- Mill structures
- Bearing locations
Sensors capture vibration signals and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous vibration monitoring
- Trend analysis over time
- Alerts on abnormal vibration levels
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not perform automatic fault diagnosis
- It does not predict failures with certainty
- It does not replace condition-based maintenance systems or safety protections
The system supports earlier investigation and maintenance planning.
Results and ROI
ATEX Compliance and Safety
Mining environments often involve combustible dust. SENSAiO sensors:
- Are available with ATEX / IECEx certification for dust zones
- Are designed for harsh industrial environments
- Can be installed on critical rotating equipment
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace protective devices, machine safeguards, or regulatory requirements.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with maintenance and monitoring platforms |
| Deployment | Suitable for retrofit on existing crushers and mills |
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.
