Wear Monitoring System. How it works.

Architecture of Wear monitoring system
The whole Wear Monitoring System can be divided into the following components:
  • Sensor – Comprised of sacrificial probe and transmitter.
  • Gateway.
  • Monitoring Software.


The sensor is the piece of equipment that is installed in the field and continuously measures asset wall thickness. The sensor is comprised of two components: the sacrificial probe and the transmitter.

The sacrificial probe is at the heart of the Wear Monitoring System. This probe is responsible for continuously measuring the thickness of the asset wall and reporting it back to the transmitter.

abrasive wear control


online wear monitoring

The Gateway works as a bridge between the Sensors deployed in the field and the server (either local or remote). In the default configuration, the Gateway can communicate with other networks over the following mediums: 4G / LTE, Ethernet and WiFi. The Gateway architecture can be easily expanded to be compatible with other protocols, including satellite, private LTE, fibre, and more (ask existing options).


Once the data has been collated by the gateway and sent to the server, the server is then responsible for distributing this data to the Web Portal and Industrial Control System (ICS) protocol converter. Alarm conditions can also be set at the server-level.

Predict asset abrasive wear

How the Abrasion Monitoring System works

Sensor probe of the Wear Monitoring system is installed at known high wear areas of fixed plant assets. This could be a slurry process pipe, a Bin or Chute, as well as the wear plates that line these assets.
A battery powered transmitter is connected to the probe, transmitting a low powered signal to the gateway. The gateway receives this data, sending it to the customised cloud based software.

As your asset internally wears, the Wear Monitoring system monitors each millimetre of wear. Showing this data in your custom dashboard. Algorithms in the software allow us to forecast and show when maintenance is required.

Alarm notifications sent through to your Maintenance Team, streamlining your planning and budget forecasting. Alarms are custom set, allowing for lead-time on supply and time to plan into a scheduled maintenance day with no failure.

Wear Monitoring system will monitor all pipes in your processing circuit, cyclones, tailings lines, HDP, ceramic lined steel pipe. Any pipe that transports abrasive material can be monitored to minimize critical failures and your operation risk.