What sensors does the MagTrack use for automated surface tracking?

The MagTrack uses permanent magnets rather than electronic sensors to maintain contact with steel surfaces. These magnets are height-adjustable, allowing the crawler to adapt its holding force to different surface conditions and curvatures. Supporting this magnetic system are omni-wheels and a modular carrier design that together handle surface variation without requiring active sensor-based correction. The sections below unpack how each element of this system works, what feedback the operator receives, and why this approach delivers strong safety outcomes in high-pressure jetting environments.

How does the MagTrack maintain contact with curved or uneven surfaces?

The MagTrack maintains contact with curved or uneven steel surfaces through a combination of height-adjustable permanent magnets and omni-wheel support. The magnets can be raised or lowered to tune the holding force to the surface geometry, while the omni-wheels allow the crawler to change direction without losing grip. This passive mechanical approach means the system does not rely on continuous electronic correction to stay attached.

On flat surfaces, the four-wheel carrier distributes the magnetic pull evenly, giving the robot a stable, predictable footprint. On curved surfaces, the adjustable magnet height becomes critical. By lowering the magnets closer to the steel, operators can increase attraction force where the geometry reduces the effective contact area. The MagTrack Mini, for example, includes both a height-adjustable main magnet and extra height-adjustable magnets on its omni-wheel rear support, giving it a layered approach to adhesion on both straight and curved surfaces.

The Curved Blast Can accessory extends this capability further. Engineered to handle surfaces with a radius of up to 3 meters, it allows the MagTrack to clean the curved contours of ship hulls and small storage tanks without losing the vacuum seal that keeps water blasting closed and dry. The combination of adjustable magnets and purpose-built tooling means the crawler can handle a wide range of surface profiles without manual repositioning between passes.

What role do magnetic sensors play in MagTrack navigation?

In the MagTrack system, the magnets themselves are functional components rather than sensing devices. They provide the adhesion force that keeps the crawler on vertical and overhead steel surfaces. Navigation is handled by the operator through a remote controller, not by onboard sensors interpreting magnetic field data. The magnets are passive and adjustable, not active detectors.

This distinction matters for maintenance engineers and field technicians trying to understand how the system behaves in practice. There is no sensor fusion algorithm processing magnetic field readings to steer the robot. Instead, the operator uses the remote controller to direct movement, while the permanent magnets ensure the crawler stays attached regardless of orientation. The height-adjustable design gives the operator a physical tuning option when surface conditions change, such as moving from a thick steel plate to a thinner section where the magnetic pull needs to be moderated to avoid excessive drag.

The rotating manifold and jet inserts on the blast can are also mechanically driven rather than sensor-guided. The cleaning path is consistent because the tooling geometry is fixed, not because a sensor is actively correcting for surface variation. This simplicity is a deliberate design choice: fewer electronic components in the cleaning zone means fewer failure points in wet, high-pressure environments.

How does the MagTrack detect obstacles and surface discontinuities?

The MagTrack does not use automated obstacle detection sensors. Discontinuities such as welds, brackets, or surface edges are managed by the operator using visual feedback and direct remote control. The omni-wheel configuration allows the crawler to manoeuvre around obstructions without needing to reverse and reposition, but the decision to do so comes from the operator, not from an onboard detection system.

This operator-led approach is well suited to the environments where the MagTrack is typically deployed. Oil storage tanks, ship hulls, and cargo holds contain a predictable range of structural features that experienced technicians learn to navigate quickly. The remote controller gives the operator precise directional control, and the crawler’s low-profile, compact design helps it pass through narrow spaces and around standard structural elements without requiring complex path planning software.

For the MagTrack Mini specifically, the compact footprint makes it easier to work in confined areas such as offshore oil rigs, where obstacles are frequent and repositioning space is limited. The two omni-wheels at the front support the blast can and allow smooth directional changes even when the operator needs to work around a structural feature mid-pass. The result is a system where human judgement handles the unpredictable, and the mechanical design handles the physics of adhesion and movement.

What data does the MagTrack’s tracking system feed back to the operator?

The MagTrack provides operational feedback through the main control unit rather than through a data-logging or telemetry system. The operator receives real-time control response through the remote controller, which gives immediate tactile and visual confirmation that the crawler is responding to inputs. The control unit manages the electrical drive system and allows the operator to monitor and adjust crawler behaviour during operation.

For the MagTrack Mini, an optional LED light can be fitted to improve visual feedback in low-light environments such as tank interiors or confined offshore spaces. This allows the operator to see the cleaning path and surface condition directly, which is often more useful in practice than processed sensor data when working in close proximity to the crawler.

The vacuum system connected to the blast can provides an indirect form of feedback as well. A consistent vacuum seal produces a clean, dry result on the surface. If the seal is compromised, for example by a surface irregularity or an incorrect magnet height setting, the result becomes visibly wet or uneven. The 2025 MagTrack Mini model introduced an improved vacuum vent valve and bellows design specifically to make this feedback more reliable, reducing the likelihood of seal loss and making it easier for the operator to identify when an adjustment is needed.

How does sensor-based tracking improve safety in high-pressure jetting operations?

Consistent surface tracking directly reduces safety risk in high-pressure water blasting by keeping the cleaning head stable and the vacuum enclosure sealed. When the blast can maintains full contact with the surface, water and debris are contained within the closed circuit rather than escaping into the surrounding area. At pressures up to 3,000 bar “43,511 PSI”, an uncontrolled jet is an immediate hazard to anyone nearby.

Safety organisations including SIR in the Netherlands, EWJI across Europe, WJA in the UK, WJTA in the USA, and DIRV in Germany all recognise that operator separation from the jetting zone is one of the most effective risk controls in water blasting operations. The MagTrack system supports this principle by allowing the operator to remain at a safe distance while the crawler handles the high-pressure work. The remote controller keeps the operator out of the direct blast zone entirely.

The ReCycleBlaster attachment extends this safety logic to closed-circuit sandblasting. By containing abrasive particles within a vacuum circuit, it prevents the release of harmful airborne particles into the surrounding atmosphere, protecting both the operator and anyone working in the vicinity. The same principle applies across the MagTrack’s tool range: mechanical containment reduces the consequence of any surface tracking variation, whether that variation is caused by a weld seam, a surface curve, or a change in steel thickness.

Consistent adhesion also prevents the most dangerous failure mode in robotic water blasting: the crawler losing contact and falling, which would simultaneously expose the uncontrolled jet to the environment and create a dropped-object hazard. The height-adjustable magnet system gives operators a direct way to manage this risk by increasing holding force before moving onto sections of the surface where geometry or steel thickness might reduce natural adhesion.

How MagTrack supports automated surface tracking in industrial cleaning

We developed the MagTrack robotic crawler system to address exactly the challenges described above: maintaining reliable contact on complex steel surfaces, keeping operators away from high-pressure jetting zones, and delivering consistent cleaning results across a wide range of industrial applications. Here is what MagTrack brings to your operation:

• Height-adjustable permanent magnets that adapt holding force to flat, curved, and uneven steel surfaces without manual repositioning
• Omni-wheel configuration enabling precise directional control and smooth navigation around structural obstacles via remote controller
• Closed water blasting with vacuum containment at pressures up to 3,000 bar “43,511 PSI”, keeping water and debris fully enclosed for a clean, dry result
• Modular tooling including the Curved Blast Can, Swing Arm, Sandblaster, and ReCycleBlaster to cover surface preparation, industrial cleaning, cargo hold cleaning, and abrasive blasting
• ATEX Zone 2 certification available on the MagTrack Mini for use in hazardous offshore and petrochemical environments
• Operator separation from the jetting zone, directly supporting the safety standards set by SIR, EWJI, WJA, WJTA, and DIRV

Whether you are preparing ship hulls, cleaning oil storage tanks, or tackling cargo holds, MagTrack gives your team a safer, faster, and more consistent alternative to manual jetting. Contact us to discuss your specific surface preparation challenge and find out which MagTrack configuration fits your application.