Optimizing Reclaimer Reliability in Open-Pit Mining

Country: Serbia
Application: Open-pit mining

EXECUTIVE SUMMARY

In an open-pit mining operation in Serbia, a reclaimer was exposed to extreme dynamic forces, increasing the risk of critical failures. To prevent these failures and improve reliability, a combined monitoring system was implemented. A total of 32 MV-x units were installed for vibration monitoring.

The Challenge

Operating in a rock-filled environment, a reclaimer was exposed to extreme dynamic forces, leading to increased risks of unexpected failures on critical components such as bearings and gears. Unplanned downtime could result in high maintenance costs, safety risks, and disruptions in production.

The Solution

To ensure continuous monitoring and prevent failures, an advanced online condition monitoring system was deployed, combining:

Vibration monitoring with a multi-channel Client/Server configuration using MV-x units, providing 32 channels for real-time data collection across critical components.
Strain gauge monitoring for structural analysis, with 40 channels dedicated to measuring key stress points.
Seamless data integration – Both systems, along with the server, are connected to the same LAN on the reclaimer, which communicates wirelessly with the factory’s network and diagnostic center for continuous real-time analysis.

The Results

Early fault detection – Within just three weeks, the system identified multiple bearing and gear defects, enabling proactive maintenance.
Towards automated diagnostics – The project is progressing towards a fully automated system that will alert operators and management to abnormal reclaimer usage.
Smart correlation of key parameters – The system integrates vibration, RPM, strain, and reclaimer boom angle data with operational factors such as material type and handling speed, enhancing diagnostic accuracy and predictive maintenance.

The Impact

Improved machine reliability and extended component lifespan
Reduced unplanned downtime and maintenance costs
Enhanced safety by minimizing the risk of major failures

By implementing an advanced online monitoring solution, the mining operation is taking a proactive approach to maximizing efficiency, reliability, and safety in one of the most demanding industrial environments.