Conveyor Monitoring Sensors & Components

In isolated production islands or standalone conveyor cells, a conveyor sensor continuously monitors belt stress, force distribution, and wear in real time. SensorData's wireless system transmits data up to 750 feet via 915 MHz — no license required — allowing remote monitoring without cabling across isolated production environments, enabling predictive maintenance decisions.

SensorData's turnkey system uses a 915 MHz ISM-band wireless transmitter mounted on-board the sensor assembly. Data is transmitted in real time to a remotely located FM base station transceiver connected via USB to a PC running data acquisition and archiving software. The system operates up to 750 feet with no wireless license required.

Predictive wear analysis continuously compares live conveyor stress measurements against predetermined maximum allowable values. The system flags developing issues — such as abnormal bending moments or tensile overloads — before mechanical failure occurs. This allows maintenance teams to schedule repairs proactively, avoiding unplanned downtime and costly emergency repairs in automotive or industrial facilities.

Yes. SensorData Technologies offers custom sensor designs for non-standard conveyor capacities and configurations. Their engineering team can develop sensors with specific force and torque ranges, physical dimensions, and mounting interfaces. Custom designs retain proprietary engineering details, and SensorData provides consultation throughout the design and validation process.

For complete turnkey systems, free in-house calibration is included. For individual multi-axis sensors supplied with customer-provided electronics, calibration is available for a fee. SensorData's experienced engineers and technicians perform all calibration in-house, ensuring measurement accuracy across all axes with crosstalk typically below 2% for torque/thrust axes.

Automotive manufacturing plants, material handling facilities, industrial production lines, and structural testing laboratories benefit most. These environments rely on continuous conveyor operation where unplanned failures are extremely costly. Real-time monitoring and predictive maintenance enabled by SensorData's systems help these industries maintain throughput, reduce repair costs, and extend conveyor service life.