Aplik developed a “Rock-Breaker Condition Monitoring System” that increases its availability for breaking down oversized rocks in gyratory and cone crushers.

The system consists of:

• Measurement of physical variables
• Detecting operational conditions
• Reporting critical conditions

System Description

Sensors are installed in specific points of the rock breaker in order to calculate operational and structural variables.  The sensors measure:

• Structural vibrations.
• Operating position and speed.
• Strains and deformations of critical zones.
• Position and force of the hydraulic cylinders.
• Hydraulic fluid pressure and temperature.

The system generates and displays reports, on-line information and alarms for operators and maintenance personnel. The rock breaker’s state is reported by metrics generated by computational algorithms.  These metrics include operational, structural and overall indicators that show both the current state and predict future condicions.

The alarm thresholds are configurable for each of the different operations detected by the system and for the physical positions of the rock breaker.

All the raw information is stored in a real-time database for both backup and further off-line analysis.

The system’s cam be configured with a 3G module allows for remote access, data download and configuration, as well as with a Profibus port for integration to the mine’s DCS.

System Benefits

The predictive maintenance of rock breaker has several benefits:

• Development of ‘best operational practices’ based on real-time feedback from the sensors and strain gauges to the operators.  This reduces operator caused damages and failures.
• Maintenance effort is centered in low-key problems (lower MTTR)
• Reduces the overall cost of repair (less man-hours and replacement parts)
• Records and analyzes the behavior of the rock breaker after repairs for quality control studies in the maintenance process.  This data is critical to the continuous improvement process.