Monitoring Remote Conveyors
Deep inside a mining belt, a 22-kilometer conveyor winds through the jungle — carrying ore from the mine to the processing plant. But behind this mechanical marvel was a hidden struggle: no reliable way to monitor or control the system from the distant control room, nearly 18 km away.
That’s when Macnman Technologies stepped in. With a LoRaWAN network woven through the forest, MacSync nodes, Andon indicators, and a rugged LoRaWAN gateway, we turned isolation into intelligence — connecting every checkpoint, every signal, and every relay into one seamless IoT ecosystem.
The Challenge: Distance, Disconnection, and Downtime
For the mine operators, the 22 km conveyor was their lifeline — yet it often became their biggest bottleneck.
No Real-Time Control
Each checkpoint had manual RS485 buttons that could only be triggered on-site. Starting or stopping the conveyor meant physically traveling kilometers across the jungle.
Communication Gaps
The main control room sat nearly 18 km away, and no wired or cellular network could sustain that distance reliably.
High Maintenance Costs
Frequent breakdowns and cable faults turned simple restarts into hours of downtime and loss of productivity.
Safety Risks
Delayed responses during belt jams or overloads put both equipment and personnel at risk.
Proposed Solution: A Network That Travels With the Conveyor
Macnman Technologies designed a LoRaWAN-based wireless control network that brought intelligence and reach to every corner of the mine’s 22 km conveyor system. The goal build a low-power, long-range network that could carry commands and data reliably through dense jungle terrain.
- 01
Long-Range LoRaWAN Connectivity
A seamless long-range network connected all conveyor checkpoints to the central room, spanning 22 km through dense terrain.
- 02
MacSync RS485 Nodes
Each unit linked with existing RS485 panels, instantly converting manual push-button points into wireless LoRaWAN nodes
- 03
Central LoRaWAN Gateway
A rugged LoRaWAN gateway captured signals from all nodes and transmitted them to the SCADA room 18 km away.
- 04
Andon Indicators
Bright Andon lights gave instant visual confirmation of commands and operational status at each checkpoint.
- 05
SCADA Integration
The entire system synced with the mine’s SCADA interface, enabling remote control, monitoring, and event logging.
- 06
Low-Power Design
Ultra-efficient MacSync nodes ensured years of operation with minimal maintenance ideal for remote, harsh environments.
LoRaWAN Architecture: for conveyor belt monitoring in the mines
Deployment: From Control Room to Conveyor Belt
The deployment turned a rugged mining corridor into a connected IoT network — stretching 22 km through dense terrain and linking every conveyor checkpoint to the central control room.
MacSync LoRaWAN Node (RS485)
Converted legacy wired systems into smart, wireless endpoints with real-time communication..
Industrial LoRaWAN Gateway
Central communication hub ensuring reliable long-range connectivity through the jungle terrain.
SCADA System Interface
Centralized data visualization and full remote control capability.
Andon Light Indicators
Provided quick on-site indication to maintenance teams, reducing response time and manual checks.
Deployment Challenges: Overcoming Distance, Jungle, and Reliability
Long-Range Connectivity 📡
The control room sat 18 km from the farthest checkpoint, and jungle vegetation blocked direct signals.
Legacy RS485 Integration ⚙️
Configuring MacSync nodes to convert them into wireless endpoints required careful mapping, calibration, and protocol tuning.
Environmental Stress 🌦️
Rugged IP67 enclosures and vibration-resistant mounting kept the nodes and controllers operational.
Multi-Hop Signal Optimization 🔗
We implemented multi-hop routing to ensure every checkpoint stayed connected without signal loss.
Impact of Smarter Farming with LoRaWAN
Reliable Remote Control ⚡
Operators in the control room, 18 km away, can start, stop, and monitor each checkpoint without traveling into the jungle.
Reduced Downtime ⏱️
Operators in the control room, 18 km away, can start, stop, and monitor each checkpoint without traveling into the jungle.
Seamless SCADA Integration 📊
All LoRaWAN nodes communicate with the existing SCADA system, providing centralized monitoring.
Enhanced Safety 💡
Immediate Andon light signals reduce manual interventions and keep personnel away from moving conveyors
Testing & Validation: Ensuring Reliability Across 22 km
Connectivity & Signal Strength 📡
Verified end-to-end LoRaWAN communication from the farthest checkpoint to the central gateway.
RS485 Data Accuracy ⚙️
Tested all existing push-button panels connected via MacSync nodes.
Andon Light Response 💡
Simulated conveyor faults & remote start/stop scenarios.
SCADA Integration Verification 📊
Validated real-time data sync between LoRaWAN network and the control room SCADA system.
Conclusion: Connecting the Mine, Commanding the Conveyor
Macnman’s deployment turned a 22 km jungle conveyor into a fully connected, smart industrial operation. By integrating MacSync LoRaWAN nodes, industrial gateways, Andon lights, and the SCADA system, we enabled real-time remote control, monitoring, and automation from a control room 18 km away.
Read Rohit's perspective on the smart BMS solution for tracking & safety
