MINING

TORQUE AND POWER MONITORING 

TORQUE AND POWER MONITORING IN THE MINING INDUSTRY 

With the enormous cost of downtime in mining operations, Binsfeld understands how important it is for companies in the mining industry to keep their operation running efficiently. TorqueTrak products are used in the development, commissioning, and operation stages of a variety of mining equipment including conveyors, excavators, and mills. Our products allow clients in the mining market to measure the true mechanical torque and power on virtually any rotating shaft, helping minimize downtime and increase operational efficiency.

 

RECOMMENDED TORQUETRAK PRODUCTS & SERVICES

TORQUETRAK TPM2

Sealed torque and power monitoring system with digital data output.

TORQUETRAK REVOLUTION

Torque and power monitoring system with analog data output.

TORQUETRAK 10K

Temporary torque measurement system for rotating shafts.

TORQUE MEASUREMENT SERVICES

When you need to know the real torque (or horsepower) on your machinery or drive system consider Binsfeld Torque Measurement Services. 

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VIEW PRODUCT DETAILS                       >

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VIEW PRODUCT DETAILS                       >

TORQUETRAK TPM2

Sealed torque and power monitoring system with digital data output.

VIEW PRODUCT DETAILS                                   >

TORQUETRAK REVOLUTION

Torque and power monitoring system with analog data output.

VIEW PRODUCT DETAILS                                   >

TORQUETRAK 10K

Temporary torque measurement system for rotating shafts.

VIEW PRODUCT DETAILS                                   >

TORQUE MEASUREMENT SERVICES

When you need to know the real torque (or horsepower) on your machinery or drive system consider Binsfeld Torque Measurement Services. 

VIEW PRODUCT DETAILS                                   >

BENEFITS OF USING TORQUETRAK PRODUCTS & SERVICES

Reduced downtime

  • Know when shaft performance is degrading when maintenance is needed (Predictive Maintenance)

Increased efficiency

  • Ensure machine is running at peak performance and identify excessive energy losses in couplings, gears, and bearings

Reduced operation costs

  • Keep things running at peak efficiency to increase equipment longevity and ensure less downtime

Smart troubleshooting

  • Quickly and accurately determine the root cause of malfunctioning equipment

MINING APPLICATIONS

Diagnostics/Testing

  • Root cause pulley and bearing failures 

Process Monitoring & Control 

  • Reduce downtime by knowing when coupling, gearbox, or bearing performance is degrading
  • Initiate preventative maintenance or replace worn components only when needed

Performance Validation

  • Verify actual conveyor performance against theoretical models (demand power, shaft torque, dynamic behavior)
  • Confirm adequate load sharing and VFD functionality 

Process Improvement

  • Increase conveyor capacity by knowing power losses in gears/coupling
FEATURED APPLICATION: Troubleshooting Overland Conveyor VFD's

The following application story is taken from the “THE VALUE OF FIELD MEASUREMENTS ON OVERLAND CONVEYORS” by David J. Kruse and Ryan Lemmon of Advanced Conveyor Technologies (AC-Tek). The TorqueTrak 10K temporary torque measurement system was used to provide the torque data.

“The first conveyor installation is located inside the Arctic Circle with extreme temperatures variations from -40°C to +25°C. This particular conveyor was one of several new systems. It is over 3 km in length with approximately 200 m of elevation gain and transports 8000 t/h of copper ore. The conveyor has four VFD drives totalling 9200 kW of installed motor power.

During commissioning there were significant vibration issues during starting, which prevented the system from starting with tonnages above 3000 t/h. AC-Tek was requested to visit the site and obtain accurate torque measurements on each of the motor shafts.

Figure 1. Vibration during starting – motors in load sharing control

Figure 2 zooms in on the torque of the primary drive during the second vibration. The torque varies from 0 kN-m to 540 kN-m which is almost 90% of the motor nameplate rating for that drive shaft. This figure shows that motor 2 (M2) and motor 4 (M4) are oscillating against each other. These two motors are both located on the primary drive shaft.

Figure 2. Zoom-in of primary drive torque of vibration during starting

The vibration was likely caused by a natural vibration mode of the motor and brake disk masses on the shaft.

The control of the motors was a master-slave relationship. The master VFD drive was controlled by a velocity feedback loop. The torque on the other three motors was set to load share with the master drive.

After careful analysis of the resulting measurements, and after performing several dynamic simulations, the authors recommended changing the control philosophy such that each drive was controlled individually using only speed control. It was predicted that this type of control would eliminate the vibrations occurring between motors on the same shaft. Figure 3 shows the motor torque and belt velocity after the control had been changed. Both the initial and secondary vibrations were almost entirely eliminated after the control change.

Figure 3. Motor torque and belt speed – motors in speed control

The design of the conveyor required a pre-tension step, which was not implemented in the control system. The belt should be held at 5% of full speed for a short time. This ensures the entire system is in motion before starting the main acceleration ramp. Pre-tensioning the belt provides smoother acceleration, lower belt tensions, and minimizes transient tension waves. Figure 4 shows the final start-up with the pre-tension step. The belt was fully loaded at 4750 t/h (which was the maximum available at that time). The belt started smoothly and without any problems. The system has now been in full operation for more than two years.

Figure 4. Motor torque and belt speed – start with pre-tension step

Even though the conveyor was equipped with VFD drive control, direct strain gage measurements were still crucial in accurately identifying and correcting the drive control issues. Combined with dynamic analysis and theoretical predictions, a stable starting control was implemented quickly and successfully.

 

MINING CLIENTS

KOMATSU

CAT

AC-TEK

VOLVO

KVÆRNER

KOMATSU

CAT

AC-TEK

VOLVO

KVÆRNER

BINSFELD ENGINEERING INC.

4571 W. MacFarlane Rd.
Maple City, MI 49664 USA

231.334.4383

TORQUETRAK

Binsfeld's Torque Measurement Systems measure true mechanical torque and power on rotating shafts. We also offer consultation, strain gaging and installation services.

TEMPTRAK

Binsfeld's Rotary Temperature Transmitter Systems provide accurate and reliable temperature control on heated godets and calendars.

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