Accurately predicting when to change liners in COS (coarse ore stockpile) feeder hoppers can be problematic. Running down the stockpile to take 3D scans is expensive and disruptive. External ultrasonic thickness testing of the liners may be possible but often gives false information if composite materials (such as weld overlay) are being used.
Benefits
Improved sustainability
through better utilization of the liner material
Effective maintenance
thanks to predictions, items with long lead times can be ordered in advance
WearSense™ predicts liner replacement
Using knowledge of historical wear profiles, or DEM simulations, wear sensors are installed at selected locations within the COS hopper. Sensors can be installed in existing liners or supplied as part of a new liner package. The WearSense system monitors the remaining liner thickness in real time while the equipment is operating and without having to empty the stockpile. Information from the WearSense system is displayed on a web app and provides the user with current liner thickness and the wear trend, which can be used to estimate the end of liner life.
More effective planning
The WearSense system provides insight into the current condition of wear liners through the strategic placement of wear sensors that monitor remaining thickness. Some of the benefits provided by the installation of WearSense in COS hoppers include:
- Identification of accelerated wear that would not have been anticipated based on past liner performance
- Orders can be placed for items with long lead times, thanks to predictions for the end of liner life
- More effective maintenance planning
- Improved sustainability through better utilization of the liner material
