Following the final implementation of a similar system on a P&H4100 XPB in 2012, Teck staff recognized the benefits of this innovative payload monitoring system together with its interactive server database, allowing personnel to easily analyze health, production and payload data.  

“Unlike other payload monitoring systems that apply electrical parameter estimation techniques to approximate the payload, the Pulse TerraMetrix RS system employs a loadcell based device and directly measures the inertial and dynamic loads applied to the dipper,” said Charles Constancon, director of BMT WBM Canada. “As a result, more accurate payload measurement is maintained, even under severe dynamic loading conditions.”

Configured to communicate with any third party truck dispatch system, the Pulse TerraMetrix RS system can be applied to different models of electric rope shovels including P&H4100 and Cat 7495 machines. Recent developments of the system have included a comprehensive machine health monitoring capability using strain sensing transducers placed on the A-frame and boom structures.

These transducers allow the system to track boom jacking and adverse swing events, identify alarm events, and quantify the mechanical damage per swing cycle. Productivity indicators provide meaningful online feedback to the operator including average bucket/truck payload, overall shift production, swing cycle time, and operating and delay times.

The system developed for Teck is configured to communicate through the mine wireless mesh to a server located in the mine’s administration offices. Data is saved in a SQL database and is accessible through an advanced server analysis program located on the mine’s intranet. This enables maintenance, training and production staff to easily access, process and analyze the data on a shift basis, to identify where production shortfalls arise, and where further operator training is required.