New payload monitoring system for rope shovels developed

P&H equalizer loadcell assembly

BMT WBM has developed the PULSETerraMetrix (PTM) system for managing the machine health, production, and payload measurement on large rope shovels.

The system provides a real time dipper payload estimate during the swing cycle prior to dumping. Immediate and accurate dipper-by-dipper load indication to the shovel operator is required in order for the final dipper load to be trimmed to match the target load for the truck. Automatic dipper carry back measurement and compensation supports real time differential payload calculation – important for operations where material often sticks to the dipper.

Unlike other payload monitoring systems which are based on electrical parameter or structural model estimation techniques to approximate the payload, the PTM deploys a smart loadcell sensing device, directly measuring the inertial and dynamic loads applied to the dipper and the payload. This allows high fidelity payload measurement to be maintained, even under tough loading conditions.

Configured to communicate with any third party truck dispatch system, the PTM can be applied to both P&H and CAT rope shovels. It is fully supported by comprehensive data base analytics and automatically generated SQL Server email reporting. Recent advances include the definition of a robust diggability algorithm and efficiency reports mapping digging conditions on the mine plan. This provides feedback on the effectiveness of blast patterns in differing conditions within the mine, so that patterns can be improved and blasting adjusted to suit those conditions, resulting in further cost savings.

The system deploys high accuracy shear pin loadcell technology in the equaliser of the P&H machines (for configurations with and without a bail) or in the reeving blocks of the CAT machines. This increased load resolution and ease of installation represents a significant advance in the already demonstrated PTM approach of direct load and inertial measurement.

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