Archives: Products

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Baldor-Dodge CST drives achieve record coal production in NSW and QLD

Baldor Australia says its Baldor-Dodge CST drives have helped several longwall mines in NSW and Queensland achieve record production figures.

Six of Australia’s leading longwall operations use the CST drives to deliver millions of tonnes of coal over distances of up to eight kilometres of underground and above-ground conveyors.

There are more than 2500 CSTs in operation around the world and more than half of those are installed in China.

The CST drive’s success is due to its inherent simplicity and reliability together with its low long-term cost of ownership.

The CST is a two-in-one drive combining a planetary speed reducer with an integral hydro-viscous clutch.

The company says this provides efficient transmission of motor power and torque with consistent acceleration and deceleration, regardless of varying loads on the conveyor or ambient conditions.

Multiple drive arrangements are very common and the shock-absorbing nature of the clutch technology makes synchronisation easier to implement and maintain than alternative drive technologies.

Long-term reliability is paramount to reaching consistent high production rates and of course vital in achieving record production figures, Baldor says.

With correct maintenance, CST clutch life has been proven to be more than seven to 10 years between overhaul and gear life can exceed 25 years.

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AMS Instrumentation Calibration releases VIP-VORTAB flow conditioner

AMS Instrumentation & Calibration has released the VIP-VORTAB flow conditioner, which can remove flow disturbances that commonly occur in piping and duct runs and cause flow meter inaccuracies.

The Vortab Insertion Panel (VIP) flow conditioner is designed to neutralise flow profile irregularities caused by elbows, valves, blowers and compressors.

According to the company, the VIP-VORTAB provides a swirl-free, symmetric and repeatable flow profile that meters require for accurate measurement.

AMS Instrumentation says the conditioner is effective with wide-turndown and low flow sensitive flow meter technologies, like thermal dispersion devices.

The units can work with these types of meters to provide a highly repeatable flow profile during laminar, transitional and turbulent flow conditions.

According to the company, the VIP-VORTAB can be used with control valves, blowers, compressors, burners and other critical process equipment.

It can also be used for pipe networks with inadequate straight-runs or diameters larger than 50 mm.

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Datafactory repair service for electronic servo drives and boards

PRODUCT SHOWCASE

Datafactory provides a thorough repair service for electronic servo drives and complex electronic boards across Australia.

Electronic ServoDrive Systems Repaired…fast

Complex Electronic Boards Repaired…fast

Complex electronic servo drives do break down!

Production stops and down-time costs go up. This is where Datafactory provides a unique service.

With a combination of in-depth theoretical knowledge of electronic drives, coupled with years of experience on both designing and servicing them; we repair and refit these units — FAST.

Importantly, this full service is provided across Australia at a moments notice; no need to wait on some overseas engineer, or having to send the equipment offshore. Datafactory is local and available with a well equipped lab. Our new ‘vision system’ means we can not only inspect, but also repair complex boards with surface mount components.

We are well experienced with a wide range of servo and industrial drives ; including Yaskawa, Okuma, Mazak, Control Techniques, Siemens, etc.

We are on the spot and provide the highest level of skilled service at competitive rates. That’s why you should call Datafactory as soon as a difficult problem occurs — let us get you going again — FAST.

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Enware releases spill containment basins

Enware Safe-Equip has released the Storm Sentinel catch basin for filtering oil and run off.

The spill containment insert protects drain run off by capturing oil and sediments that would normally flow into pipelines on sites.

The screened bag is equipped with oil-absorbent material for unforeseen discharges.

It is designed to handle flow rates of up to 8870 litres per minutes to prevent ponding, and will not fall into the basin even when fully loaded.

The containment equipment require no special tools to install, and come in sizes of up to 61x91cm for rectangular catch basins and 61x66cm for round basins.

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Rockwell Automation launches 193-EC5 E3 Plus overload relay

Rockwell Automation has released the Allen-Bradley 193-EC5 E3 Plus solid-state overload relay, featuring voltage protection and energy monitoring.

Part of the E3 Plus family, the 193-EC5 E3 Plus overload relay combines current and voltage protection with enhanced power monitoring and diagnostic capabilities.

The company says this can help users improve energy efficiency and safeguard critical electric motor loads to minimise downtime and reduce energy costs.

The overload relay is designed for low voltage applications in materials handling, minerals processing and mining.

The relay communicates status and diagnostic information using DeviceNet and Rockwell Software’s RSEnergyMetrix software.

According to the Rockwell, the 193-EC5 E3 Plus overload relay is also equipped with Allen-Bradley DeviceLogix Intelligent Component Technology, which integrates logic-solving capabilities.

This provides users with basic digital control when a programmable controller is not available.

It also can be used to turn off a motor in the event of lost communications within a control system.

The new EC5 E3 Plus solid-state overload relay also helps protect against voltage issues, such as under voltage, voltage unbalance, phase loss, frequency and phase rotation before the contactor coil is energised.

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Eriez Magnetics Australia release magnetic materials handling technology

PRODUCT SHOWCASE

Eriez Magnetics Australia has released a range of magnetic materials handling technology, including metal detectors, wet drum separators and flotation equipment.

 

Suspended Electromagnets

These are large electro magnets for suspending above conveyors carrying mineral ore and other dry bulk materials. Designed to remove damaging tramp steel to protect the conveyor belts and downstream crushers and can be supplied both as manual or self clean units. They operate from standard three phase power through a transformer rectifier to convert to DC current.

Of rugged construction and standard magnet widths to 2.2 meters; larger models are also available with forced cooling as an option in hot environments.

Metal Detectors

Eriez metal detectors are designed to suit most belt conveyor widths and troughs; can detect from small to large sized tramp metals. Ideal for installing after suspended magnets to detect any non ferrous non magnetic metals that magnets cannot remove. They are of a robust construction specifically for the mining industry.

There are different models available for many applications including both under belt and bridge design search coils… They are capable of differentiating between tramp steel and magnetic mineral ores which eliminates false tripping. Suitable for both spliced or mechanical joins and steel cored belts.

Trunnion Magnets

The Eriez Trunnion magnet is designed as a powerful permanent magnetic separator for the automatic separation and removal of steel processing balls and broken ball pieces from milled ores exiting Ball and SAG mills. These pieces are typically the result from ore processing in mills. Whilst simple in concept yet very efficient these units can be retrofitted to the mill trunnion discharge providing maximum recovery with zero energy consumption. Comprise of a rugged construction ensuring long life and minimal maintenance.

Wet Drum Separators

Eriez wet drum separators are market leaders in design, operating efficiency and safety aspects. Innovations in both magnetic circuit design and materials of construction are applied to Eriez wet drum magnetic separators. This results in maximum magnetite and ferrosilicon recovery while operating with a minimum amount of wear and maintenance. Refinements to the magnetic circuit, tank design, and drive system have resulted in further improvements in metallurgical performance and operation. Eriez wet drums are currently operating in coal and iron ore applications.

Eriez Advanced Flotation Technology

Over recent years Eriez have expanded their product range to include products that do not rely solely on magnetic separation. To be a more complete supplier of process equipment for the mining industry, Eriez are offering advanced flotation technology to a wide range of industries including fine coal flotation, recovery of base and precious metals and industrial minerals.

Eriez Australia, targeting the coal mining industry has sold 28 units over the last four years. Columns for flotation applications range in size depending on the application from 1.2 meter dia. to 4.9 meter dia. and up to16 meter in height and treating up to 100 tons per hour of fine coal per column…

Eriez columns offer high recovery with low ash products in a single pass.

Benefits include;

• Low capital, operating and maintenance costs.

• On-line maintenance

• Ease of operation

• Built-in scavenging with internal recycle

• Patented technology for optimal bubble generation

• Optional recycling sparger or slam jet air design.

Eriez Vibratory Feeders

Eriez range of feeders includes electro magnetic Hi Vi and mechanical designs.

The electro-permanent magnetic drive provides a simple yet powerful solution to difficult material feeding applications. Incorporate a totally enclosed patented magnetic drive which can provide precise feed control. Operates via AC 240 volt power supply with simple variac or PLC compatible AC controller. Variety of tray sizes and materials of construction available and custom built with design limits. Dust covers and grizzly screens are optional additions to the range.

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ABB unveils conveyor control software

ABB Australia has developed the Mining Conveyor Control Program (MCCP) which is a software package designed for bulk materials handling and conveyor applications.

The mining software allows for the setting of conveyor functions and managing of the critical and high speed conveyor communication requirements on multi-motor conveyors.

The MCC program provides management of the start/stop controls, acceleration and deceleration, mechanical brake control, alarm processing, as well as the setting of speed limits and torque limits.

The software can become the speed regulator or master control for an entire conveyor system.

It has the ability to send torque reference signals to individual drives which then act as followers and transmit back to the master control.

This is then used to determine speed regulation and the monitoring functions.

The communication cycle time is less than five milliseconds.

Traditionally, every conveyor required these functions to be custom developed for each application in the over riding PLC program.

With the use of the MCCP, these functions are no longer required in the PLC.

The mine software helps to reduce the effort for PLC programming, allows for conveyor parameters to be set without the need for specialised staff, and cabling is reduced to a single fibre optic connection between each drive.

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Advanced rope shovel

Bucyrus has released an updated safer electric rope shovel, the 495HR2 (pronounced 495HR Super 2).

This latest rope shovel has incorporated Bucyrus; Hydracrowd technology which provides vibration free operation and negates the heavy inertial loading of rack and pinion style crowd systems by locating the hydraulic power pack on the machinery house deck.

The 495HR2 also contains the LatchFree Dipper system which replaces the latch assembly with a strong steel link, removing the critical latch components from the harsh conditions of the lower dipper door.

This allows for more predictable maintenance schedules, fewer incidents of unplanned maintenance, increased shovel “uptime”.

The shovel has an updated operator’s cab with a fully adjustable seat as well as minimised vibration and noise through internal and external sound dampening.

The cab provides increased stability by being bolstered by an extended machine house underneath and mounted on shock absorbing rubber isolators.

The cab comes with an adjacent positioned trainer seat which provides optimum visibility for trainers and ready access to a new second emergency stop (e-stop) button.

The rope shovel operator’s station is now repositioned for unobstructed vertical line-of-sight extending from the crawler tracks to the point sheave.

It also comes with overhead video monitors with closed circuit cameras which have been installed on the machine allowing for greater situational awareness during digging, haul truck spotting, and propelling.

Another feature of the rope shovel is an enhanced propel system, garnering a 12% increase in maximum propel torque.

This system was designed to combat propel challenges encountered in the mine environment, most notably in the soft footing found in oilsands and wet digging environments.

The 495HR2’s incorporates the AC-IGBT drive system which provides immediate fault identification, condition monitoring, and troubleshooting tools.

These integrated systems provide the platform for remote diagnostics packages that allows shovel monitoring from any remote location across the globe.

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ABB commissions world’s largest high pressure grinding roll drive

ABB has commissioned the world’s largest High Pressure Grinding Roll (HPGR) drive system for Newmont Mining’s Boddington gold mine expansion project in Western Australia.

The original, mainly oxide open-pit mine was closed at the end of 2001, but was re-opened this year after exploration identified an extensive 19.57 million ounce gold bedrock resource.

Thyssen Krupp Polysius and ABB worked together to make the mine operational once again.

The delivery comprised two 2800 kW HPGR units of two converter transformers, two medium voltage frequency converters and two squirrel cage induction motors.

This is the largest HPGR drive system in operation anywhere in the world.

By optimising the grinding process, ABB’s ACS1000 drives will help the plant reduce its energy consumption.

The variable speed drive system provides operational flexibility through a variable speed range and is ideal for the processing of inhomogeneous types of ore at different throughput rates.

The Boddington mine, located about 130 km south-east of Perth is expected to operate for at least 20 years, with full production of more than one million ounces of gold per year.

This would make it Australia’s largest producing gold mine.

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Baldor releases DODGE ULTRA KLEEN ball bearings

Baldor has released the DODGE ULTRA KLEEN ball bearings, which are designed with an array of features to provide extended life in harsh washdown conditions.

The ULTRA KLEEN ball bearings feature the QuadGuard sealing system, along with an exclusive ball retainer, the Maxlife cage.

According to the manufacturer, the sealing system and cage help retain lubrication and prevents washout in wet environments.

Baldor says the ULTRA KLEEN bearings are offered in a wide variety of stainless steel and polymer housings, both featuring 100% stainless steel inserts.

The QuadGuard seal consists of a triple lip seal and a rubberised flinger.

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Industrial pressure sensors

Bestech Australia has released the AST4000 industrial grade pressure sensors for a range of applications.

With a one-piece stainless steel sensing element, the sensor is used in rugged environments where a high cycle life and media compatibility.

The sensor features a wide operating temperature range, is compatible with a range of liquids and gases, has no oil, welds or internal O-rings and ranges up to 10 000 psi.

It is designed for use in water management, pneumatic and hydraulic equipment, HVAC equipment and for industrial OEM equipment.

The pressure sensor’s accuracy is below ±0.5% and it has an environmental protection rating of IP-66.

The analog outputs include 4-20 mA, 1-5/1-6 VDC, 0-50 mV and 0.5 to 4.5 ratiometric.

The AST4000 comes with a variety of threads, pressure ranges, outputs and electrical connections in order to make system integration seamless.

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Vale selects Oniqua Analytics Suite inventory management system

Brazilian mining giant Vale has chosen the Oniqua Analytics Suite (OAS), developed by Oniqua Enterprise Analytics, to manage its inventory management initiatives across its operations.

Vale, the world’s largest producer of iron ore, went live with the software in December last year.

The miner employs more than 60,000 workers from its headquarters in Rio de Janiero.

The company’s inventory management initiatives include the production of copper, iron ore and potassium as well as the management of port and railroad facilities and power generation plants.

According to Vale, the company’s previous systems were not “sufficiently robust” enough to support the demands of its business.

When implementing the system, Oniqua had to integrate the OAS program with Vale’s existing Oracle Enterprise Resource Planning (ERP) system and other infrastructure applications.

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MineWare to roll out dragline monitoring systems across BMA mines

MineWare has secured an agreement to supply its dragline monitoring and intelligence solutions across all of BHP Billiton-Mitsubishi Alliance’s (BMA) mines in Queensland.

The monitoring systems make use of the latest developments in GPS and wireless Ethernet technologies, mobile functionality and enhanced system integration.

MineWare says it aims to improve how the mining industry captures, analyses and interprets valuable production data from draglines and other heavy mining equipment.

The company’s latest remote, mobile monitoring systems collect and expose a wide range of dragline information for on and off board analysis.

This includes mine plans, GPS stamped production data, delay reporting, detailed PLC information, strain gauge data and video camera footage.

According to the developer, its vendor engagement model was a key driver in securing the partnership and other new client contracts.

Since its establishment in 2005, MineWare says it has enjoyed a significant relationship with BMA, developing and installing its dragline monitor systems for a number of the company’s key sites.

The company’s Pegasys dragline monitor has also been adopted by BHP Billiton Energy Coal South Africa.

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High torque servo motors

SEW-Eurodrive has extended its CMP range of servo motors.

The company has released servo motors with torque ratings of 0.5 to 45Nm in six distinct frame sizes with speed ratings of 3000, 4500 and 6000rpm.

The new CMP models complement the existing CM and CMP servo series, and are light-weight, compact and provide high torque density.

The new CMP servo motor range comes with an option of two brake torques, and two rotor inertias, either high or low, both of which have a low inherent mass-moment of rotor inertia.

In addition it has a four times rated torque overload capacity, and cogging levels minimised to below two per cent. The servo motors emit lower sound levels of between 55 and 75dBA at all speeds.

The extended CMP servo series is provided with an industry-standard round canon plug connectors (both for power, and resolver/encoder connections) to increase equipment compatibility and to ensure quick on-site installation and servicing when combined with pre-manufactured cable assemblies.

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Motor control drives

Rockwell Automation has unveiled the new Allen-Bradley PowerFlex 753 AC drive for motor control.

The latest drive in the 750 series, the PowerFlex 753 has been designed for general purpose induction motor control and for fan, pump and conveyor applications.

It comes with enhanced safety features such as the DeviceLogix embedded control technology and predictive diagnostics.

The motor is available in power ranges from 0.75 to 250 kW at 415 V AC and 650V DC input.

The PowerFlex 753 AC drive’s design incorporates a three-slot mechanical architecture that allows tailoring of the drive.

The PowerFlex 753 comes embedded with Allen-Bradley DeviceLogix control technology in the for drive performance and to simplify programming.

Users can incorporate PLC-style functionality within the drive, allowing standalone control if required.

Added to this is the predictive diagnostics capability which minimises downtime by monitoring drive status—such as cooling fans, I/O relay cycles, motor run-time hours, and fault warnings—and allows preventative action to be taken.

The motor comes with the added safety options of Safe Torque-Off or Safe-Speed Monitoring.

Safe Torque-Off prevents drive restarts after the safety circuit is tripped.

Safe-Speed Monitoring reduces and monitors the speed of an application to allow an operator to safety inspect and perform some process maintenance work without stopping the machine completely.

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Enerpac releases mobile hydraulic POW’R-RISER Lifting Jack

Enerpac has released the POW’R-RISER Lifting Jack, which combines a 54 to 181 tonne capacity cylinder with an electric or air-powered hydraulic pump unit.

The whole system is integrated into a mobile cart.

The POW’R-RISER has the speed, power and versatility for a wide variety of on-site site applications, including servicing tyres, tracks and other maintenance functions on heavy equipment.

The unit can also be used for applications that require heavy lifting and positioning equipment in remote locations.

The jack can be rolled into position for easy placement and has a narrow width for hard-to-reach areas.

Enerpac says there are no exposed hoses or fittings to damage and the electric motor is fully enclosed to withstand elements.

According to the company, the SUP-R-STACK Extension System allows lifting at all heights without blocking.

For safe mechanical cribbing of a lifted load, accessory Locking U-Rings can be placed around an extended piston and come in four lengths for each POW’R-RISER capacity.

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Heavy duty bulk materials handling

Baldor has released the Dodge MagnaGear XTR reducer for heavy duty bulk materials handling.

Manufactured to operate in harsh environments, the Dodge MagnaGear was designed to work in sites ranging from coal mines and aggregate quarries through to cement mills.

The reducer comes with Dodge planetary and helical gear technology in a powerdense design to produce greater torque in less space.

The MagnaGear XTR comes with torque ratings ranging from 100 000 to 920 000 in0lbs, which can accommodate horsepowers greater than 2500 HP.

It is available in modular designs for either parallel shaft or right angle configurations, and comes with the option of right-hand or left-hand mounting.

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Motors for explosive atmospheres

Baldor has released a new line of motors designed to operate in hazardous or explosive environments.

The company has unveiled its new Ex dI / IIB Gb motors for explosive gas atmospheres and Ex tb IIIC Db IP6X motors for atmospheres containing explosive dusts.

The Baldor motors are designed for use in these potentially explosive environments while maintaining the required level of safety.

The motors have seen use in oil refineries, chemical processing plants and underground coal mines.

Quality records are maintained on every motor shipped with all fully certified by the independent International Electrotechnical Commission.

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Honeywell Process Solutions announces automation workshop

Honeywell Process Solutions (HPS) is hosting a systems automation workshop in Brisbane on 17 March.

This interactive workshop will focus on Programmable Logic Controllers (PLCs), Remote Terminal Units (RTUs), small and flexible distributed control systems and Supervisory Control and Data Acquisition (SCADA).

The event will also feature seminars on wireless, security and safety, field instrumentation, inventory management and tank measurement.

The company will feature its asset management solution, Field Device Manager, throughout the event.

The workshops will demonstrate the ease of implementing PLCs, RTUs and controllers while connected to an Experion system.

Participants will also get the chance to view the latest control solutions technology and interact with product experts.

The workshop is free to attend and open to Honeywell clients and industry professionals.

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Hydraulic bulk materials handling

Flexicon has released a Bulk Bag Conditioner, designed to loosen bulk solid material that has solidified during storage and shipment.

The company says this allows bulk bag unloaders to discharge the material through bag spouts.

The stainless steel conditioner features two hydraulic rams with specially-contoured end plates that press opposite sides of bulk bags.

An optional hydraulically-actuated, variable-height turntable allows conditioning of the bag at all heights on all sides.

The number and pressure of hydraulic ram actuations, the height of the turntable and the number of 90-degree rotations can be adjusted by the user.

According to the manufacturer, the hygienic model is intended for bulk bags containing other contamination-sensitive products that cannot be loosened using pneumatically-actuated flow promotion devices.

Carbon steel models with durable industrial coatings are offered for general industrial applications.

The unit accommodates bulk bags of all popular sizes.

The machine is fully enclosed on all four sides for operator safety and includes full-height doors that are interlocked to disallow operation of the system when the doors are open.

The system controller and hydraulic pump can be mounted remotely or on the exterior of the safety cage and require only an electrical power connection for operation.