Mining is one of the most demanding industrial environments on the planet. The equipment that keeps operations running — conveyor systems, motors, pumps, gearboxes, fans — runs hard, runs hot, and runs continuously. When something fails unexpectedly, the consequences aren't just inconvenient. They're expensive. A single unplanned shutdown can cost tens of thousands of dollars per hour, and in remote mining locations, getting the right technician or replacement part on-site quickly isn't always straightforward.
That's why more mining operations are turning to condition-monitoring solutions — specifically Banner Engineering's Asset Monitoring Gateway (AMG).
What Is the AMG?
The Asset Monitoring Gateway is a hardware-and-software solution from Banner Engineering that provides maintenance and operations teams with real-time visibility into the health and performance of their most critical equipment. It works by connecting to an array of sensors that continuously measure parameters like vibration, temperature, humidity, pressure, and current. That data is then processed, displayed, and — when something looks wrong — it triggers an alert so teams can act before a small problem becomes a catastrophic failure.
Banner offers two AMG versions to suit different operational needs. The AMG with SNAP ID is a wired solution designed for situations where you need to monitor many points on a single asset. It supports up to 20 wired sensors connected via simple M12 cables and features an onboard touchscreen display for local monitoring. The AMG with CLOUD ID, on the other hand, is a wireless solution better suited to facilities or sites where you need to keep an eye on many different assets spread across a large area. It can support up to 40 wireless sensor nodes and feeds data directly into Banner's Cloud Data Services platform, accessible from anywhere via a web browser or mobile device.
Both versions share one standout feature: they require no coding, no special software expertise, and no lengthy commissioning process. The gateways automatically recognize compatible sensors the moment they're connected, enabling teams to go from unboxing to actively monitoring equipment in minutes rather than months.
Why Condition Monitoring Matters in Mining
In mining, the assets being monitored are often massive, mission-critical, and expensive to replace. A conveyor belt motor in an underground coal mine or a slurry pump at a processing facility doesn't get regular check-ups the way a car does. Traditionally, maintenance has been either reactive — fix it when it breaks — or scheduled at fixed intervals regardless of the equipment's actual condition. Both approaches have serious drawbacks. Reactive maintenance means unplanned downtime. Scheduled maintenance means spending money and labor on equipment that may not yet need attention.
Condition monitoring flips both of those models on their head. By continuously tracking real-time data from sensors on the equipment itself, maintenance teams can spot the early warning signs of a developing problem — a gradual rise in vibration levels, a bearing running hotter than usual, a subtle change in motor current — and intervene at exactly the right moment. Maintenance becomes proactive rather than reactive, and it's based on the actual condition of the equipment rather than a calendar.
Banner's AMG supports this approach with VIBE-IQ, a machine-learning algorithm built into the system. VIBE-IQ establishes a unique performance baseline for each piece of monitored equipment over time. Once that baseline is set, the system can detect deviations that might be invisible to the human eye and send an alert via email or text before a fault develops into a failure.
What This Looks Like in Practice
Picture a large-scale mining operation with kilometers of conveyor belts moving ore from the pit to the processing plant. Each conveyor has motors, drive pulleys, and idler rollers — all rotating assets that wear over time. With Banner AMG units deployed along the conveyor system, maintenance teams receive continuous data on vibration and temperature at every critical point. Instead of walking the line on a weekly inspection that may or may not catch a developing bearing failure, the system is watching constantly and will send an alert the moment something changes.
The result is fewer surprise failures, better-planned maintenance windows, longer equipment life, and significant cost savings — exactly the kind of operational gains that mining companies are looking for as they face increasing pressure to maximize productivity and control costs.
In an industry where the ground never stops moving, and the equipment can never afford to stop either, Banner Engineering's AMG and condition-monitoring approach gives mining operations something genuinely valuable: the ability to see trouble coming and get ahead of it.
