Unveiling the Power of Engineering Expertise: High-Mat Case Studies
The success of any mining operation hinges on reliable and efficient equipment. At High-Mat, we understand this critical reality. This collection of case studies delves into real-world challenges faced by our clients in the mining equipment manufacturing and fabrication sector. By showcasing our approach to design, analysis, and inspection, we demonstrate how our team of dedicated engineers collaborated with clients to overcome obstacles, optimize performance, and ensure the safety and longevity of their equipment. Explore these case studies to gain valuable insights into how High-Mat's expertise can translate into tangible results for your own mining equipment needs.
Crane Failure Analysis and Redesign
Challenge: clients approached after a critical crane or excavator failures (two separate cases) occurred on their mining site. The unexpected breakage caused significant downtime and potential safety hazards. Solution: Mat conducted a comprehensive investigation to identify the root cause of the failure. We employed finite element analysis (FEA) to evaluate the crane's design under various load conditions, including worst-case scenarios. This rigorous analysis process helped us pinpoint the specific design element that couldn't withstand the operational demands.
Extending Mining Shovel Lifespan through FEA and Repair Design
Challenge: A mining operation encountered a critical crack in the structure of their shovel crane. This unexpected failure threatened production and posed a safety risk. Solution: Mat engineers conducted a thorough inspection of the damaged shovel. Utilizing finite element analysis (FEA), we created a detailed model of the entire shovel structure. This analysis allowed us to pinpoint the exact location and cause of the crack, taking into account factors like stress distribution and fatigue loading. Result: Based on the FEA results, we designed a targeted repair strategy. The modifications focused on reinforcing the weakened area while optimizing the internal compartment of the shovel. This approach not only addressed the immediate crack but also improved the overall stress distribution, significantly extending the fatigue life of the shovel. By implementing these recommendations, the mining operation was able to safely resume production with a more reliable and durable shovel.
Eradicating Fatigue Cracks in Crane Boom with FEA and Welding Design
Challenge: A crane operator was plagued by recurring fatigue cracks at a specific location on the boom. These repeated failures resulted in costly downtime and jeopardized operational efficiency. Solution: Mat employed finite element analysis (FEA) to meticulously examine the stress distribution within the crane boom structure, particularly focusing on the problem area. This advanced analysis method helped us identify the root cause of the fatigue cracks, which was likely related to stress concentrations. Result: Leveraging the FEA insights, we devised a targeted solution to eliminate the fatigue issue. We recommended strategically placed welding stiffeners to reinforce the vulnerable section of the boom. These reinforcements aimed to redistribute the stress more evenly, significantly enhancing the fatigue life of the entire truss structure. This approach not only addressed the recurring cracks but also ensured the long-term reliability and safety of the crane boom.
Predictive Maintenance for Rotating Equipment with Telemetry-based Stress Measurement
Challenge: Traditional maintenance schedules for rotating equipment in mining operations can be inefficient, leading to unexpected failures and costly downtime. Solution: Mat implemented a cutting-edge solution for a client by installing a telemetry system on their critical rotating equipment. This system continuously monitors real-time stress levels at key points. Result: The collected data allows for a more proactive approach to maintenance. By analyzing the stress patterns, we can predict potential fatigue issues before they lead to failure. This enables targeted maintenance interventions, maximizing equipment uptime and minimizing the risk of unexpected breakdowns. This case study showcases the power of practical stress measurement using telemetry systems for extending the fatigue life and optimizing maintenance schedules of rotating equipment in demanding mining environments.
Ensuring Drilling Machine Safety through Rod Loading Risk Assessment
Challenge: A drilling machine manufacturer needed to guarantee the safety and reliability of their machine during the certification process. A crucial aspect of this involved assessing the risks associated with rod loading. Solution: Mat engineers conducted a comprehensive risk assessment focusing on the rod loading mechanism of the drilling machine. This assessment considered various factors, including the maximum load capacity, potential failure modes, and operator safety. Result: By meticulously evaluating the risks, we were able to identify areas for improvement and recommend design modifications to mitigate potential hazards. This proactive approach ensured the drilling machine met the necessary safety standards for certification. Our risk assessment not only secured the certification but also provided the manufacturer with valuable insights to optimize the design for safe and efficient operation in real-world drilling applications.