A vibrating screen is the heart of a mineral processing operation. It’s the deciding factor in whether or not your product meets your specifications. Deadlines and quotas might tempt producers to overload the screen while attempting to increase their bottom line. However, this contributes to downtime due to premature wear and might create a safety hazard for workers near an unbalanced screen. And just as monitoring a heart rate is essential for optimal health, the same idea applies to a mineral processing operation.
Think of manufacturers as an operation’s cardiologist, there to diagnose and remedy operating issues before they become a safety hazard or halt production altogether. They provide producers with the necessities to streamline an operation and minimize downtime or injury. And, these days, that starts with diagnostics.
Like a house call from a doctor, onsite diagnostics enhance mineral processing operations through vibration analysis service programs without having to transport the equipment into a shop. These programs offer producers insight into their screen’s performance to achieve optimum efficiency and ensure minor operating issues don’t become major hazards. Certain manufacturers offer service programs that provide producers the opportunity to monitor screening performance in real-time using wireless technology. These advanced systems offer a hands-off approach to analyzing screening equipment by allowing operators to stand out of harm’s way — from a potentially off-balanced screen — when performing diagnostics.
In addition to safety, wireless technology offers operators remote, real-time monitoring, which ensures equipment is properly maintained and running optimally. This means less risk that strain is placed on the screen or other parts of the operation to maintain production quota. The increased efficiency and enhanced safety is the healthy choice for all areas of the operation.
Sound interesting? Here’s how it works:
It all begins with a close relationship with the OEM and is enhanced by real-time equipment monitoring. Finding a key partnership where an OEM approaches the application as a solution provider rather than an equipment supplier is key to productivity and success. If your OEM isn’t providing consultative advice and real-time, proactive monitoring, it might be time to seek another solution.
A key aspect of safety is having equipment that runs at peak performance and knowing when and how to maintain it. The more time spent fixing and maintaining the equipment heightens the risk of injury. That is where real-time monitoring comes in handy.
An advanced vibration analysis program specifically monitors the health of vibrating screens. That real-time feedback ensures optimized screen performance and equipment durability. The hands-free system uses a wireless, industrial-grade tablet computer and eight tri-axial sensors to detect abnormalities the human eye cannot, such as a hairline crack in a side plate or an uneven or twisting motion. Even the slightest irregularities can result in diminished performance, decreased efficiency, and safety risk for the operator.
The programs use wireless accelerometers to detect any irregularities, allowing operators to stand as far as 300 feet out of harm’s way. Each sensor attaches to key places on a machine to send 24 channels of data to the tablet via Wi-Fi — illustrating the machine’s orbit, acceleration, deviations, and more.
After the sensors record the data, trained and experienced engineers review, study and interpret the results through the system’s database. This provides the engineers and producer with a detailed report of any concerns that might diminish productivity or risk operator safety. If an irregularity is detected, the service team travels to complete on-site service, which keeps producers on top of preventative maintenance and ensures a safe operation that runs at maximum efficiency and lower risk. Some vibration analysis systems store each machine’s historical data, which allows for quick comparison over time and easy troubleshooting.
More and more often producers rely on diagnostics for safer work environments and a streamlined operation. Its hands-off approach ensures a healthy operation, which helps producers efficiently meet deadlines and provide quality products for their customers.
About the Author:
Wilm Schulz is the parts and service manager at Haver & Boecker Niagara, a leading provider in screening, pelletizing, and mineral processing plants and systems. His more than one decade of experience with the company helps him lead a team focused on providing customers with processing equipment solutions and services that offer prolonged equipment life and increased efficiency. Contact Wilm at email@example.com.
*All images courtesy of Haver & Boecker Niagara