Coal Age

MAY 2019

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36 May 2019 product news Screen Data Gives Insight into Circuit Performance Performance data provided by extra sensors fitted to a pro- totype vibrating screen is substantially improving the un- derstanding of screen operation. It is also giving indicators around the overall performance of the processing cycle. Designed and developed in Australia by Schenck Pro- cess, the prototype screen is undergoing site trials. The com- pany believes this new screen has the potential to change the way vibrating screens are developed and operated. The standard condition-monitoring system comprises two sensor nodes, including six degrees of freedom MEMS accelerometers, a high-resolution accelerometer and a temperature probe. On the prototype screen, four addi- tional sensors have been fitted, one on each corner. "The measurement regime for the additional sensors includes spring amplitude and mean compression, allow- ing the estimation of tonnage and load bias (to determine if the feed is presented square to the screen or favoring a side) and the determination of spring operating characteristics and cumulative fatigue damage," said Schenck Process' se- nior R&D engineer, Doug Teyhan. "We are also looking into the development of a predictive failure program to improve overall productivity and efficiency and significantly reduce the possibility of unplanned downtime." Historically, failure prediction has been determined by running components to the point of failure and assessing a mean time to failure based on a known operating history. The data generated by the prototype screen is utilized to estimate the operating stress of the screen at the most ag- gressive fatigue areas and assessing the cumulative dam- age of those areas based on the measurement of non-ideal operating characteristics. Using a Cumulative Damage System, which counts machine cycles and also trend characteristics that have the potential to adversely affect vital component life ex- pectation, the plan is to make the machine monitoring system a lead measure in predicting the potential for component failure. The expanded monitoring system will also provide in- put into machine development of the next generation of vibrating screens by filling in the unknowns in the design process with real-time field data. According to Teyhan, the benefits for the customer — including increased availability and improved screen performance — are substantial and have the potential to initiate improvements in the processing cycle. "And from a screen operation point of view the addi- tional data is bringing to light characteristics not previ- ously known. It is highlighting transient feed characteris- tics — not visible using traditional condition monitoring techniques — that impact the loading of the screen and affect machine life expectation," he said. "We also believe there are potential industry-wide bene- fits, through new design parameters and possible changes to machine construction techniques and materials," he added. To optimize the greater range and scope of data the screen is generating, the company is collaboratively inves- tigating and assessing other performance variables. The potential is for control of the variability in the feed rate, more consistent performance and improved overall effi- ciency of the cycle. Improved Haul Truck Tires After six years of development and testing, Michelin North America re- cently introduced the XDR3 surface- mine haul tire in size 27.00R49. Ad- dressing the productivity and endur- ance issues found in today's surface mines, the XDR3 — developed for a range of rigid dump trucks with pay- load capacity up to 400 tons — is designed with new com- pounds and a revolutionary new tread pattern that helps provide exceptional tire life. The use of corrosion-isolating cables in the tire architecture is a significant upgrade in situations where this equipment is always moving as it is operated for up to 23 hours per day in extreme terrain. These innovations allow customers to select the bene- fit that best fits their needs. Customers can choose not to According to Schenck Process, this new screen has the potential to change the way vibrating screens are developed and operated.

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