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Vibration Monitoring of Shovels and Draglines
Jack DischnerNational Reliability Systems251 Forrester DriveGreenville, SC. 29607800-543-6322 X 100
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
Proof of concept that reliable online data collection is possibleRefine data analysis and collection processSensor application and options Weather extremesOperational challengesExtreme duty cycle
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
100 ton shovelLocated in CanadaIn service for 2 yearsUnique applicationAnalyzed failure modesSecured detailed drawingsDesigned base system
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
Two onboard systemsCrowd systemHoist systemNo swings or propel -yetProvides continuous surveillance of critical pointsStores data on cardsSpeed data from encoders on motors
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
Hoist gearbox ass’yMonitoring main gears, pinion gears, motorHoist drum, drive motor18 sensors total100 mv/g on gearcase500 mv/g on hoist drumAll data is speed stampedData on hoist onlyReference data taken for motion
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
Only need 2 sensors per bearingRadial and axial give us bearing, gearmesh and thrustingXtra-flex mining cable protected by liquidtite conduitMounted to SS pads welded to housingsGreat linear response from sensors
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
Crowd system has 11 sensorsAll 100 mv/gSame type wiring considerationsOne setback due to broken cableContinuous dataModular componentsConfigurable3 options for data collection and storage-time, trigger, condition
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
Data transmission options for phase 2Memory cardsGSM moduleTie into advanced control and communications schemeRunning reports remotelyLooking at data every 2 weeks presentlyMay add hard drive and/or satellite linkWireless network running on locomotives and overhead industrial cranesAlmost any Microsoft or compatible options
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
Draglines are very similarLess motion to extractMG sets are straightforwardDrive, sheave and pinion monitoring Lower speedsLonger time to get samplesF=1/T is limitationNo overlap, one sample
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
Differentiate data from motionMotion is non-synchronousNeed fast data capture, but not too rapidStoring Time Waveforms, integrating in the softwareTrends can be extractedNo more than 3 samplesNo overlap averaging
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
Planned developmentsOnline editing and simplified remote setupAutomated alarming Swing and propel monitoringControl system interfaceDistributed sensor systemsWeb access via mine communicationsLarger data storage capability (Jan 05)Wireless sensors
Nov. 2004 –Jack Dischner and National Reliability Systems – Private and Confidential – Not to be used without permission
Vibration Monitoring of Shovels and Draglines
ConclusionsOnline vibration analysis is possibleSpecial considerations Systems have to be modifiedSensors are no longer limitingData transmission options are the keyCan be affordable, fast and reliable