Mobile Mining Equipment

 Electric Mining Shovels (P&H, Bucyrus Erie)

 Draglines (P&H, Bucyrus Erie, Page, Marion)
 Hydraulic Excavators (O&K, Liebherr, Hitachi,
etc)
 Haul Trucks (Liebherr, Caterpillar, Hitachi, Terex,
Komatsu)
 Blast Hole Drills (Atlas Copco, P&H, Bucyrus,
Ingersoll Rand, Terex)

09/17/20
 The 6500/4500 on Mobile Equipment
 The value of Machinery Health technologies is
widely accepted in the mining industry, but has
been difficult to apply on mobile equipment.
 The operating conditions of mobile equipment
make it difficult to capture valid vibration data
under normal operating conditions.

09/17/20
 Challenges to Monitoring Mobile Mining
Equipment
 Speed/Load/Direction Changes

 Cyclic Systems
 Complex Systems
 DC Motors
 Multiple Reduction Gearboxes
 Multiple Rolling Element Bearings
 Harsh Environments
 Accessing the data

09/17/20
 CSI Machinery Health Monitors
Technical Details

Sensor monitors Tach Channels Processor / Comm

CSI4500 – 12/16/32 1x Peak and Phase - Ethernet HUB and NIC
CSI6500 – 12/24/36/48 - Pulse-type speed inputs - 1 Predictive Processor
- Frequency divider - 1 Processor feeding live updates
Alerts in less than - Up to 32 Mb memory
- Adaptive tach feature
100mSec - auto-locks on speed
- Accelerometers
- Velocity probes
- Displacement probes Transient Option
- 60+ Hour buffer of raw data
- AC signal Digital I/O - Dedicated Processor
- Flux/Dynamic pressure - Input and outputs
- DC signal - Automated data archival
- OPTO relay modules
TM

- Temperature/Load - Live monitoring

- Playback features

CSI 4500 CSI 6500

09/17/20
 CSI 6500/4500 Machinery Health Monitor
Technical Details
 Adaptive monitoring

Speed

Data Collection Set

Resolution
Fmax
Analog Input Periodicity
Boolean
Trends
Alarms

Digital I/O

09/17/20
 Ja

0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
n-
0

09/17/20
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b-
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M 6
ar
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Ap 6
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M 6
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No 6
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Fe 7
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ar
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GM Freq

Ap 7
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M 7
ay
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Ju 7
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Predicate Based Data Collection

ct
Apply a predicate for direction or rotation

-0
No 7
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07
GM Freq
 Predicate Based Data Collection
1

0.9

0.8

0.7

0.6

Swing R
0.5
Swing L

0.4

0.3

0.2

0.1

0 6 06 06 06 06 0 6 06 06 06 06 0 6 0 6 0 7 07 07 07 07 0 7 07 07 07 07 0 7 07
an- eb- ar- pr- ay- un- ul- ug- ep- ct- o v- e c- an- eb- ar- pr- ay- un- ul- ug- ep- ct- o v- e c-
J F M A M J J A S O N D J F M A M J J A S O N D

09/17/20
 Predicate Based Data Collection
1
Alarm Swing
0.9 Right

0.8

0.7 Alarm Swing

Left
0.6

Swing R
0.5
Swing L

0.4

0.3

0.2

0.1

0 6 06 06 06 06 0 6 06 06 06 06 0 6 0 6 0 7 07 07 07 07 0 7 07 07 07 07 0 7 07
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09/17/20
 Challenges to Monitoring Mobile Mining
Equipment
 Speed/Load/Direction Changes


 Cyclic
• CSI’sSystems
adaptive monitoring allows you to set windows
for data collection based on speed, analog and/or
 Complex Systems
digital signals. The trends will always reflect data
collected
DC Motors under the same conditions.
 Multiple Reduction Gearboxes
• With four data collection sets per channel different
alarms
Multiplelevels
Rolling Element
can Bearings
be applied depending on the
 conditions.
Harsh Environments
 • The 4500/6500
Accessing can do order tracking and time
the data
synchronous averaging to correct for speed changes
in the data.

09/17/20
Challenges to Monitoring Mobile Mining
Equipment
 Speed/Load/Direction Changes



 Cyclic Systems
 Complex Systems
•CSI provides continuous power to its sensors,
 DC Motors
eliminating the need to wait for the sensor to settle,
 Multiple Reduction
decreasing Gearboxes
data collection time.
•Multiple Rolling Element
CSI’s Machinery Health Bearings
Monitors can trigger off of
 Harsh Environments
multiple inputs; ensuring data is collected under
identical conditions each time.
 Accessing the data
•If the data collection triggers change during
collection, the 4500/6500 will not store the data. It will
resume data collection from that point the next time the
09/17/20predicates are met.
 PeakVue™
 PeakVue™ is a patented technology designed to detect
and analyze stress waves using peak value analysis.
 Allows for early detection of bearing and gear defect.
 Filters out background and non-repetitive vibration.
 Amplitudes are not affected by data collection settings –
Bandwidth does not affect the values, so data is
repeatable and trendable.
 Documented failure progression for bearing and gear
problems with recommended alarm levels. With PeakVue
you can determine the stage of failure and severity.
 Even without detailed information problems are easily
identified.
 Accepted in Mining Industry – used as part of OEM
Quality testing.
09/17/20
 Challenges to Monitoring Mobile Mining
Equipment
 Speed/Load/Direction Changes



 Cyclic Systems

 Complex Systems
•PeakVue can filter out complex background vibration
DC Motors

and focus
 on developing
Multiple bearing and gear defects.
Reduction Gearboxes
•The
 Machinery
Multiple Health
Rolling Software
Element allows you to assign
Bearings
the fault frequencies from the entire gearbox to each
 Harsh Environments
point, not just information at that bearing. This allows
 Accessing
you the data
to rapidly identify transmitted frequencies.

09/17/20
 Challenges to Monitoring Mobile Mining
Equipment
•The 4500/6500 uses theChanges
 Speed/Load/Direction
 VX Works operating system;
an industrial operating system designed for industrial
 environments.
 Cyclic Systems
 Complex
 Systems
•The 4500/6500 has no moving parts to wear out and
all
the
DC cards
Motorscan be replaced in the field.

•The
Multiple Reduction
4500/6500 Gearboxesrestarts data collection
automatically
following
Multiplea reboot, no operator
Rolling Element action is required.
Bearings

 Harsh Environments
 Accessing the data

09/17/20
 Data can be access through the
corporate WAN for remote
System
Data Architecture
can be accessed across a – Dragline Monitoring
analysis
wireless network via theAlarm
AMS Suite: (Optional)
conditions and vibration
Machinery Health Manager Software.
parameters can be sent to the control
system via OPC or Modbus protocols.
(Optional) The historical trend data, spectrum
Weand
canwaveforms are stored
provide a Device Net on the
server.
interface for either protocol
All the signal processing is done at
the 4500/6500, the processed data is
transmitted to the server via Ethernet

With the Oilview LIMS module data from a 3rd party

oil lab can be imported into the same database and
viewed on the same screens.
Data from the CSI 2120/2130 Portable Analyzers
can be viewed in the same software on the same
09/17/20
screen
(Optional)
 •All communication
Challenges is Ethernet
to Monitoring and wireless
Mobile Miningcan be
used.
Equipment
•The 4500/6500 has onboard
 Speed/Load/Direction
 storage and will buffer
Changes
data during a loss of communication.

 Cyclic Systems
•The software provides alarming on loss of
 connectivity
 Complex Systems
to the server or the 4500/6500.
DC Motors

•The 4500/6500 provides relays to allow for alarming
Multiple

directly fromReduction Gearboxes
the Machinery Health Monitor.

Multiple Rolling Element Bearings
• Data from the 4500/6500 can be accessed across
 the
 Harsh
plantEnvironments
LAN or corporate WAN (optional)
 Accessing the data


09/17/20
 Vibration Monitoring of Electric Mining
Shovels

09/17/20
 The 4500/6500 on Electric Mining Shovels
 The current accepted practice for electric mining

shovels is to collect data in staged testing out of

production, which can take 1 - 8 hours depending
on the skill of the analyst. During the testing no
additional maintenance can be performed.
 Because of the time involved many mines only
test their shovels quarterly.
 We have developed a solution that not only
eliminates the need for downtime for a staged
test; it also can collect data during production.

09/17/20
 Shovel System Overview
 The system will continuously monitor the shovel
Swing, Drag, and Hoist systems.
 Data will be stored on the shovel and can be
accessed via wireless networking.
 A touch screen Graphical User Interface (Asset
Graphics) is provided to inform the operator of
alarm conditions, and provide instructions for
staged testing.

09/17/20
 Sensor Locations
 Radial vibration will be measured on each
accessible bearing in the load zone where
possible.
– It is preferable to mount the accelerometers on the
lower portion of the gearcase to allow the opening of
the gearcase for maintenance and inspection without
removing sensors.
 Axial vibration will be measured on each shaft at
the bearing that will transmit the axial vibration.
 Where ever possible sensor will be installed at
the manufacturers recommended location.

09/17/20
 Sensor Locations – P&H Mining Shovels
 P&H Mining Equipment has
calculated the load zone of
each bearing and prepared
position in the optimal sensor
location.
 These locations have drilled
and tapped holes and a
machined finish.
 Vibration data is collected at
these locations as a part of
acceptance testing.
 For installation the protective
bolts will be removed and the
area cleaned and polished.
09/17/20
 Sensor Locations – Bucyrus Erie Shovels
 Bearing load zones

can be estimated
based on the contact
angle of the gears.
 In most cases it will
be on the lower half of
the gear case at each
bearing.

09/17/20
 Example – P&H 4100A
Shovel System Overview – Swing System
2 Total
Can be run continuously
DC motor with simple first
reduction and planetary
second reduction
All rolling element bearings
Motor speed ~15.83 Hz
Highest fault freq (GM) 269
Hz
Output shaft 0.37 Hz (22
RPM)
14 Accelerometers

09/17/20
 Example – P&H 4100A
Shovel System Overview – Hoist System
1 per shovel
8 - 10 second cycle time at
full speed
2 DC motors coupled to a
double reduction gearbox
All Rolling Element Bearings
Motor speed ~11.17 Hz
Highest fault freq (GM)
178.7 Hz
Output shaft 0.20 Hz (12
RPM)
21 Accelerometers

09/17/20
 Example – P&H 4100A
Shovel System Overview – Crowd System
1 per shovel
7 - 10 second cycle time at
full speed
DC motor belt driving a
double reduction gearbox.
Motor and first two shafts
rolling element bearings,
output sleeve
Motor speed ~12.50 Hz
Highest fault freq (GM) 225
Hz
Output shaft 0.26 Hz (15.6
RPM)
9 Accelerometers
09/17/20
 Staged Testing
 Systems can be
tested out of
operation to provide
higher resolution
data.
 Operator will have a
selector switch in the
operators cab.
 Asset Graphics will
walk the operator
through the test and
inform him when data
collection is
completed.

09/17/20
 Proposed System – Shovel Components
 The Sensors will connect to three CSI4500M8 or two
CSI6500MR-48 Machinery Health Monitors.
 A touch screen ruggedized laptop will service as both an
online server and the GUI running AMS Suite: Asset
Graphics.

Machinery House Boom

9 Accelerometers
21 Accelerometers 1 Tachometer
1 Tachometer
Wireless
(((
14 Accelerometers JBOX (((
1 Tachometer JBOX JBOX
14 Accelerometers
JBOX
1 Tachometer Link
JBOX

Operator’s
PLC Room Cab

09/17/20
 )) ) Wireless
Network • Data will be stored and
reside on the shovel.
)
))
• Can be accessed via
wireless network. Maintenance PDM Group
Online
Server Operations Engineering AMS Machinery AMS Machinery
Online Watch Online Watch Manager Manager

)) )
Workstation Workstation Workstation Workstation

Plant LAN

)
))

))
AMS:

)
MHM
Server

) )
)

)) ))
))

09/17/20
 Software
 The server on the computer will be running as an
online server.
 A full copy of AMS Suite: Machinery Health
Manager will be installed, either as a single user
network or a network client off of an existing
LAN/WAN system.
 If there is no connectivity to the LAN system it will
require a SUL at second copy pricing.

09/17/20
 Data Analysis
 Spectral data is crucial in B

complex systems like

those on mobile mining
equipment A
 Trending just an overall
value will only show late
stage failures and will not
allow for fault diagnostics
Field PeakVue Data on a P&H 2800XPB Swing Transmission
0.15

0.12
Outer Race Frequency
Lower Input Shaft
RMS Acceleration in G-s

0.09
Bearing (A)
First Reduction
Gearmesh
Frequency (B)
0.06

0.03

09/17/20 0
0 3 6 9 12 15 18 21 24 27
Frequency in Orders
 Results
Repeatable Data – P&H 4100XPB Hoist – In Production
516 - Hoist System
Hoist -14X Front Interm Inbd Axial (21-Jun-07)
0.12
Max Amp
.11

0
21-Jun-07
15:14:49
21-Jun-07
15:04:32
PK Velocity in In/Sec

21-Jun-07
14:57:35

21-Jun-07
14:50:44

21-Jun-07
14:43:32

21-Jun-07
14:36:50

21-Jun-07
14:29:44
0 10 20 30 40 50 60
Frequency in Orders
09/17/20
 Data
 The system will collect high resolution spectral
and waveform data on all the systems in addition
to trend data for alarming.
 The system will not provide automated analysis,
all data collected will need to be reviewed by an
analyst.

09/17/20
 Results 516 - Hoist System
Hoist -19H Front Pinion Inbd Rad
0.10
Alarm Spectrum

RMS Acceleration in G-s

0.08 24-May-07 16:17:23
RMS = .1592
LOAD = 100.0
0.06
RPM = 883. (14.72 Hz)

0.04

High Resolution Data 0.02

Normal and PeakVue Data

0
0 10 20 30 40 50 60 70
Frequency in Orders

Collected in Production
0.6
Alarm Waveform
24-May-07 16:17:23

Acceleration in G-s
0.3 RMS = .1538
PK(+/-) = .4635/.5124
CRESTF= 3.33
0

-0.3

516 - Hoist System

Hoist -19H Front Pinion Inbd Rad -0.6
0.06
Routine Spectrum
RMS Acceleration in G-s

0 0.4 0.8 1.2 1.6

0.05 24-May-07 13:50:40
Time in Seconds
(PkVue-HP 1000 Hz)
0.04 RMS = .3942
LOAD = 100.0
0.03 RPM = 883. (14.72 Hz)
0.02

0.01

0
P&H 4100XPB Hoist
0 10 20 30 40 50 60 70
Frequency in Orders
3.2
Alarm Waveform
2.8
24-May-07 13:50:40
Acceleration in G-s

2.4 (PkVue-HP 1000 Hz)

2.0 RMS = 1.13
PK(+) = 2.88
1.6 CRESTF= 2.55
1.2 DCoff = .7079
0.8
0.4
0
0 0.4 0.8 1.2 1.6
Time in Seconds
09/17/20
 Quoting
 The core system with 96 channels will cover 90% of
the shovels out there. The only variation will be in
number of sensors. We can provide a budgetary
quotation without sensors.
– For the P&H shovels the only variation will be in early shovel
models (pre-1990) and the 4100XPC.
– For the BE shovels we will need to estimate sensor counts.
 For software:
– Does the customer have current MHM software, the type
(LAN/WAN/SUL) and if they currently have online.
– Is there wireless connectivity to the shovel.

09/17/20