Mechanical review
Check material coverage, bed depth, angle, vibration, abrasion, access and safe maintenance clearance.
Installation and service
Design the measurement point as part of the process
Good sensor physics can still fail at a poor measurement point. We connect model selection with mechanical access, flow behaviour, electrical design, commissioning and lifecycle support.
Installation and service
Good sensor physics can still fail at a poor measurement point. We connect model selection with mechanical access, flow behaviour, electrical design, commissioning and lifecycle support.
Electrical and controls
Define power, shielding, 4–20 mA or RS485 communications, PLC scaling, alarms and data ownership.
Commissioning and training
Verify installation, collect paired samples, tune the calibration and train operations and maintenance teams.
Installation by measurement route
The mounting task changes with the material volume the sensor must represent
A surface sensor, a flush contact sensor and a transmission pair require different access, protection, geometry and acceptance checks. The site review fixes those details before fabrication or wiring begins.
Surface route
NIR above a moving surface
Keep stand-off distance, angle, field of view, ambient light and window access stable.
Explore the route →
Contact route
Microwave at mixers, chutes or hoppers
Confirm material contact, wear protection, build-up risk, sealing and safe removal.
Explore the route →
Transmission route
Microwave across a conveyor bed
Fix transmitter-receiver alignment, bed-depth window, empty-path state, guarding and reference-sample position.
Explore the route →Site feasibility
A stable reading begins with a representative, maintainable measurement point
The measurement point must keep the sensor exposed to representative material while remaining safe to inspect and maintain. Line drawings, operating photos and a short video of normal and abnormal flow are often more valuable than a nominal conveyor width alone. The review also follows the sample path, cable route and distance to the control cabinet.
Survey the point
Record dimensions, flow direction, bed-depth range, speed, vibration, dust, temperature, washdown and operator access during normal production.
Freeze the interfaces
Agree the mounting structure, product-contact boundary, power, cable route, signal destination, guarding and responsibility for every site modification.
Install and verify
Check alignment and material coverage, simulate status and alarm signals, collect paired samples and record the final geometry with photographs and drawings.
Handover the routine
Train operators to recognise valid readings and maintenance staff to inspect windows, wear faces, fasteners, cables, cooling and accumulated material.
Site handover package
What an installation and commissioning project should deliver
Project scope defines site labour, travel, commissioning attendance, warranty coverage, spare parts and service response for the selected location.
- 01Installation concept and responsibility matrix
- 02Wiring and communications checklist
- 03Commissioning and acceptance record
- 04Training and preventive-maintenance plan
Before the site review
Photos, drawings and operating ranges that expose the real geometry
- Process and general-arrangement drawings
- Photos and video under normal load
- Material, bed depth and speed ranges
- Area temperature, dust and cleaning method
- Power, PLC and cable requirements
- Planned shutdown and site-safety rules
Installation failure modes
Three conditions that can defeat a good sensor
Unrepresentative flow
Segregation, empty belt, bridging or intermittent contact can make a mechanically sound position unsuitable.
Protection that blocks measurement
Liners, windows, guards and wear plates must protect the equipment without changing the intended optical or microwave path.
No access after start-up
A sensor that cannot be cleaned, checked or replaced safely will lose availability even when the initial reading is good.
Tell us what you measure, where it moves and how the result will be used
Share a few process details and our application team will recommend a suitable technology, installation concept and validation plan.