Instructions for Installing Sensors into Crushers, Slurry Pipes, and Wear Liners

Instructions for Installing Sensors into Crushers, Slurry Pipes, and Wear Liners

Our sensors can be installed into the lining walls of crushers, slurry pipes, and wear liners in several ways, depending on the specific application and environment. Below are the different methods for installation:

1. Direct Embedment in Wear Liners

• Description: Sensors can be directly embedded into the wear liner material during the manufacturing process. This method ensures that the sensor is flush with the wear surface, providing accurate measurements without interference.
• Installation Process: During the casting or molding of the wear liner, a cavity is created to house the sensor. The sensor is placed into this cavity, ensuring it is securely positioned. The liner material is then poured or applied around the sensor, fully embedding it. After curing or hardening, the liner with the embedded sensor is installed in the equipment.

2. Insertion into Pre-Drilled Cavities

• Description: Sensors can be inserted into pre-drilled cavities within the lining walls of crushers or pipes. This method is ideal for retrofitting existing equipment with monitoring capabilities.
• Installation Process: Drill a hole or cavity in the lining wall at the desired location, ensuring it is the correct size to accommodate the sensor. Insert the sensor into the cavity, ensuring a snug fit to avoid movement or damage during operation. Secure the sensor with a mounting socket welded on the outside of the asset being monitored.

3. Weld-On Mounts

• Description: Sensors can be attached using weld-on mounts. This method ensures a secure attachment that can withstand extreme conditions.
• Installation Process: Prepare the mounting area by cleaning and smoothing the surface. Position the sensor in the desired location on the lining wall. Weld the sensor's mount oto the outside of the asset using a 12mm BSP female Socket. Ensuring full contact and a secure bond. Inspect the welds for integrity and make sure the socket is positioned correctly and in the right location.

4. Embedding into Liner Bolts

• Description: Sensors can be embedded into liner bolts by drilling a hole through the center of the bolt to house the sensor probe. This method is particularly effective for monitoring wear and tear without direct exposure to the abrasive environment.
• Installation Process: Drill the Bolt: Select a liner bolt and drill a hole through its center, deep enough to house the sensor probe.
• Insert the Sensor Probe: Place the sensor probe into the drilled hole, ensuring it fits snugly and securely.
• Install the Bolt: Install the bolt into the wear liner as usual, ensuring that the sensor is properly aligned to measure the desired parameters.
• Connect the Sensor: Connect the sensor to the monitoring system.

Final Considerations:

• Inspection: Regularly inspect the sensors and their mounts for wear, damage, or loosening, and replace or repair as necessary.
• Environmental Conditions: Consider the operating environment (e.g., temperature, moisture, abrasion) when selecting the installation method to ensure sensor longevity and accuracy.

By following these installation methods, our sensors can effectively monitor abrasive wear and tear in crushers, slurry pipes, and wear liners, helping to optimize maintenance schedules and extend the life of the equipment.