THE NEED
Finnish mining heavyweight Metso is looking for a reliable, non-intrusive, cost-effective surveillance and predictive maintenance system based on sound analysis system to pair with its crushing machines. The large-size rotating machines operate non-stop in harsh environments, with high temperatures and humidity, extreme noise and dust – explaining a minimal human presence to monitor the machines.
THE CHALLENGE
The project includes several challenges attached to the core conditions in which the rotating machines operate. First, the extreme environment calls for robust systems designed to resist the constant high temperatures, high degree of humidity and dust, plus permanent noise.
In such an almost unmanned environment, with limited access to technical teams, the audio surveillance system will require extremely reliable hardware.
Additionally, the audio surveillance system will operate in an environment where the rotating crushers cannot be stopped, prompting the need for a non-intrusive, wired and compact solution that should be placed at a distance from the machines.
Last but not least, this audio predictive maintenance should remain within strict budget limitations, without compromise over audio quality despite the extreme environment.
THE SOLUTION
The smartest option to meet Metso’s criteria is to split the audio surveillance into 2 phases. Phase 1 is to capture the crusher’s audio environment from a distance with ruggedized microphone, and send the audio streams to a remote control room via Digigram’s compact PYKO IN encoder. That phase 2 of the surveillance process enables to sort among the recorded information, which audio event signals a potential defect or malfunction in the crusher’s operations.
Capitalizing on Digigram’s proven and cost-effective PYKO IN encoder, Metso benefits from a compact and sturdy system with pristine audio quality, that features an excellent ROI on the long run.
Digigram’s PYKO is lightweight and enables easy scalability or replacement with non intrusive maintenance operations.
With a high detection rate, Digigram has proven its solution is sturdy and efficient despite the extreme conditions of the mining industry.
THE BENEFITS
- Robust jungle-proof hardware
- Cost-effective and scalable
- Lightweight operations and non-intrusive maintenance
