Wireless Equipment Monitoring for Aggregate Operations
Stop Reactive Maintenance. Start Preventing Downtime.
Transform your aggregate operation with continuous, wireless monitoring of critical equipment. Atomation’s IoT sensors deliver actionable insights that help you prevent equipment failures, reduce maintenance costs, and maximize production.
Equipment
Critical Equipment We Monitor
Screens and Shakers
Monitor: Bearing Temperature | Vibration | Impact | Runtime
- Detect screen wear and motor degradation before failure
- Prevent costly emergency repairs and production delays
Conveyors and Elevators
Monitor: Motor Operation | Bearing Temperature | Vibration | Impact
- Ensure continuous material flow throughout your operation
- Identify motor issues before they cause system-wide shutdowns
Crushers
Monitor: Motor Operation | Vibration | Bearing Temperature
- Protect your most expensive equipment investments
- Optimize crusher performance and extend equipment life
Dryers
Monitor: Bearing Temperature | Vibration | Impact
- Maintain consistent product quality and throughput
- Prevent bearing failures that halt production
How Our Wireless Monitoring Works
Our AT-R Atoms attach directly to your equipment, collecting vibration, temperature, and operational data 24/7 via Bluetooth connectivity to Atomation Gateways.
Intelligent Alert System
- Bearing Health Alerts: Temperature increases signal over-lubrication or impending failure
- Vibration Monitoring: Detect equipment degradation before breakdown occurs
- Alert Notifications: Receive notifications when sensor thresholds are exceeded
Actionable Insights: Instead of guessing when maintenance is needed, you’ll know exactly when and where to take action, allowing you to schedule maintenance during planned downtime.
Measurable Business Impact
Reduce Maintenance Costs
- Eliminate expensive emergency repairs
- Replace costly periodic manual inspections
- Optimize maintenance schedules based on actual equipment condition
Maximize Production Uptime
- Prevent unexpected equipment failures
- Schedule maintenance during planned downtime
- Keep materials flowing through your operation
Improve Safety and Efficiency
- Reduce time workers spend manually checking equipment
- Monitor equipment in hazardous or hard-to-reach locations
- Make data-driven maintenance decisions
Real Aggregate & Mining Results
Shaker Table Operations: Unexpected Maintenance Insights
Shaker tables are key components in many manufacturing processes. When springs wear or fail, tables behave erratically, creating safety hazards and requiring line shutdowns for repairs.
A manufacturer installed Atoms on all four springs and added an external temperature probe for bearing monitoring.
What happened: Atoms detected minor changes in spring vibration patterns that indicated impending failure, giving the team time to schedule maintenance rather than face emergency repairs. Bearing temperature alerts provided immediate notification when inspection was needed.
The unexpected insight: Bearing temperature actually increased when tables operated without loads—the opposite of what engineers expected. This finding, validated over several weeks, led to a complete overhaul of the facility’s maintenance program, creating new inspection procedures based on actual operational data rather than assumptions.
Vertical Lift Elevator: $20K+ Save
At a production facility, Atoms monitoring bearing temperature on a vertical lift elevator sent an alert at 4:30 AM indicating temperatures had exceeded normal thresholds by approximately 40 degrees.
Work was immediately halted. Investigation revealed an operator had been overloading the material dryer feeding the elevator, causing excessive strain on both the bearing and the lift system.
The save: Early warning prevented bearing failure and potential motor damage—saving a minimum of $20K in equipment replacement costs plus the additional expense of unplanned downtime.
Operation
Ready to Transform Your Aggregate Operation?
See Atomation in action at your facility.
Our team will conduct an assessment of your critical equipment and show you exactly how wireless monitoring can improve your operation’s reliability and profitability.