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We identify the events that cause fatigue damage in shovels and quantify their impact on boom crack-prone zones. We show that structural damage is avoidable if certain operating practices and conditions are improved without impacting productivity. We define operator performance indicators and issue periodic reports that include videos of the damaging events to provide operational context for the structural monitoring.
We characterise the truck’s typical duty cycle and the loads on its chassis. We identify route segments that generate the highest demands. We record fatigue-damage events and categorise them by root cause. We generate periodic reports with fleet-level, per-truck and per-operator indicators. We can propose a chassis redesign or reinforcements to extend service life, accounting for the real operating conditions the structure experiences.
We evaluate fatigue safety factors of the mill structure under real operating conditions, removing uncertainty from the static and dynamic loads it bears. We adapt the monitoring solution to defects such as wall-thickness loss and flange seating deficiencies. We detect bolt tension loss and breakage using easy-to-install load cells. We can simulate and measure the structural impact of changes in operating conditions such as filling level and media. For existing cracks, we can estimate propagation rate and set inspection intervals if growth is stable. We have also deployed crack-growth sensors that provide early alerts while the mill is running.
We continuously assess fatigue safety factors in real operation. We log fatigue-damage conditions, when present, together with videos that contextualise the measurements. We correlate measured structural demands with loading-rate performance to understand how throughput affects the structure. We record the efforts borne by the structure under wind, manoeuvres and even earthquakes, yielding actionable knowledge of operating limits for safe and efficient operation.
We continuously measure both bucket-wheel torque and transverse loads due to advance, and assess their effect on the structure and the motor-gearbox set. We train and alert the operator in real time when preset limits are exceeded to avoid accumulating fatigue damage. We correlate structural demands with the machine’s position on the piles to understand conditions that generate over-stressing. These conditions are localised and can be addressed with operational improvements to significantly extend asset life without affecting production.
We continuously evaluate the demands on all sections of the stacker bridge and its tripper car. We trigger alerts for events that generate fatigue damage and can identify their causes, such as track misalignment or high-speed tripper travel. We run a pass-by-pass comparative analysis of the tripper over the bridge to pinpoint zones with over-stressing, such as rail joints, and generate alerts to focus structural inspection. Knowing the real operating conditions lets us prioritise maintenance actions and objectively assess the effectiveness of redesigns or reinforcements.
Using purpose-built algorithms, we capture and process vibration and temperature signals on hoist, crowd, swing and propel transmissions during normal operation. We continuously monitor indicators tied to failure modes, derived from spectral-analysis fundamentals and tuned by 16 years of continuous shovel monitoring. We track and control condition evolution in close collaboration with the client’s analysts, generating knowledge and value for operations.
We continuously monitor mechanical vibrations, temperature and control signals on drives and pulleys. With AI tools we identify conditions affecting each component and issue 24/7 automatic alerts without human intervention. Alerts are grouped and managed as analysis cases, allowing action scheduling and tracking through closure. We automatically issue periodic reports including availability, production and threat dashboards ranked by criticality.
We gather background data and symptoms to frame testable hypotheses. We plan and execute a field-measurement protocol with a multichannel vibration system that can include run-up and coast-down, impact tests and stationary measurements under various operating conditions. Analysis may involve advanced techniques such as Experimental Modal Analysis (EMA), time–frequency transform (TFT) for transients and Operational Deflection Shape (ODS). When needed and depending on study goals, we complement with Finite Element Method (FEM) analysis. Based on results, we deliver a thorough diagnosis with recommended actions.
We perform a wide range of finite-element structural analyses, linear and non-linear. We have broad experience defining boundary conditions, load cases and combinations to cover possible operating conditions. We conduct static and dynamic-response analyses. We optimise designs via parameterised analysis to meet client objectives.
We assess a structure’s service life based on its real operating conditions. We account for existing defects such as thickness loss or cracks, which must be characterised to quantify their effect. We determine the real loads acting on the structure through strain and/or vibration measurements. This approach reduces the uncertainty inherent to life assessments and lets us interpret results with the client to decide if additional actions are needed for safe operation.
Following an in-service failure, we help determine its root cause. We advise whether to complement existing inspection reports with material tests from the failure zone. We evaluate structural strength under nominal operating loads, perform sensitivity analyses when useful and compare the results with the failure location. We analyse pre-failure operating conditions and, if needed, add measurements under current conditions. We then determine the root cause, present cause-and-effect relationships and propose corrective actions or improvements to prevent recurrence.
Damage mechanisms are not always due to construction, assembly, operation or maintenance issues, but also to physical and/or chemical phenomena driven by internal transport or transformation processes. These phenomena are hard to diagnose because they are inherent to operation; one assumes the OEM considered and mitigated them, and the mechanisms are complex to quantify. We simulate internal behaviour via CFD/DEM, including heterogeneous flows, temperatures, turbulence and chemical reactions, to quantify how operating parameters drive erosion, corrosion, FAC, splitting and creep, among others. This targets root causes to recover equipment reliability and integrity.
During commissioning or after upgrades to raise throughput or operate outside design conditions, uncertainty about actual efficiency or the effectiveness of modifications is common. Discovering in operation that performance will fall short with no way back can be costly. Conversely, accepting poor performance without analysis to show that the cost of improvement outweighs inefficiency is not ideal. We address these issues by detailed simulation of unit operations using CFD/DEM. We identify root causes and then simulate solutions to choose the best action plan to recover productivity, efficiency and reliability.
