Smart Sensors for Critical Mining Equipment: A Strain Gage Application

Digital transformation is enabling the mining industry to access real-time operational data to improve process safety and reliability. By integrating strain gage sensors, communication technologies (LoRaWAN), and remote monitoring platforms, Llaqta Ingenieros developed a solution capable of continuously monitoring critical bolts in highly essential operational equipment.

Challenge

In large-scale mining operations, SAG and ball mills represent some of the most critical assets for operational continuity. The integrity of the bolts securing liners and structural components is fundamental to ensuring the safety, reliability, and availability of this equipment.

Traditionally, assessing bolt condition has relied on periodic inspections and manual on-site checks, making early detection of tension loss or fractures difficult during operation. The end client, Minera Chinalco, required a solution capable of continuously monitoring the behavior of these critical elements and providing real-time data for decision-making.

Solution

Llaqta Ingenieros developed and implemented a monitoring solution based on tension sensors (utilizing strain gages) specifically designed for highly demanding mining applications. The sensors, mounted directly onto critical bolts, allow for the continuous measurement of applied tension during operation.

The communication infrastructure was implemented using LoRaWAN technology, enabling reliable data transmission from the field-installed sensors to industrial gateways located within the concentrator plant. During implementation, stable communications were achieved at distances exceeding 500 meters within complex industrial environments, with the potential to reach considerably greater coverage depending on site conditions.

The network is managed using LORIOT's Network Management Server, which handles the connectivity, security, and availability of the IoT devices deployed across the operation. The collected information is then integrated into an intuitive visualization platform that allows users to monitor trends, consult historical data, and generate automatic alerts for critical events.

"The field validation of fractured bolts previously detected by the system confirmed the value of having continuous monitoring and real-time data to anticipate failures and optimize our maintenance decisions.” said the Engineering Team, Llaqta Ingenieros S.A.C.

The Return

The solution made it possible to incorporate continuous monitoring on assets that previously could only be inspected periodically.

One of the most significant results was the detection of events where specific sensors reported an abrupt drop in tension to values close to zero. Subsequent inspections conducted by maintenance personnel confirmed that the monitored bolts were indeed fractured, validating the system's ability to detect real failures at an early stage.

Key benefits achieved include:

• Early detection of fractured bolts
• Continuous, remote tension monitoring on critical elements
• Increased operational reliability
• Improvement of predictive maintenance strategies
• Greater availability of information for decision-making
• Reduction of risks associated with structural failures

The project supports multiple United Nations'sustainable development goals (SDGs).

Conclusion

The integration of specialized strain gage sensorization with LORIOT’s robust LoRaWAN infrastructure marks a critical shift in heavy industry asset management: the transition from periodic, reactive inspections to continuous, predictive safeguarding.

By capturing high-fidelity tension data directly from the field and translating it into real-time actionable insights, this solution proves that the true value of industrial IoT lies in its ability to intercept catastrophic structural failures before they occur. It transforms critical, high-wear assets, like SAG and ball mills, into intelligent, self-reporting systems.

For mining operators navigating complex, high-stakes environments, this project offers more than just downtime prevention. It establishes a scalable, resilient, and future-ready foundation for autonomous industrial monitoring worldwide.