This article explores the initial stage that enables mining sector engineers to harness the power of highly accurate models, incorporate tangible data, and convert this data into meaningful intelligence: the act of Model building. To illustrate this procedure, we will build a model of a stacker, but it’s worth noting that the methodology is relevant to other key mining infrastructures.

Revolutionizing Mining Integrity Management: The Power of RB-FEA Technology

Conventional methods for integrity management often lean on Finite Element Analysis (FEA) which, due to its dependence on assumptions and averaging, leaves room for potential inaccuracies, errors and oversights. Consequently, the mining industry stands to benefit from an innovative shift towards enhancing operational efficiency and extending equipment lifespan, enabled by a new approach to simulation:

• Akselos’ physics-based simulation solutions, using RB-FEA technology, enable users to identify hotspots with millimetre-level precision to drive actual risk-based inspection and maintenance at the speed of operations.
• The accuracy of these simulations, and the ability to calculate fatigue consumption as it happens in the field, allows you to determine remaining life on a component level so that parts can be replaced only when needed and with minimal impact on uptime.

Step 1: Breaking Down before Building Up

The first step to build a model of a stacker involves assembling any available blueprints or models of the asset from various software applications. Akselos distinguishes itself with its modular, component-centric approach. Instead of regarding the structure as a whole, Akselos deconstructs it into numerous “building blocks”, each of which corresponds to a specific component or segment of the asset.

By proactively defining the interactions between these components across a spectrum of material and load conditions, Akselos can solve large and complex models in a matter of seconds. This is a crucial step to build a model of a stacker as it means that engineers no longer need to balance between model size and accuracy and can solve even the largest models with guaranteed precision in real time.

Step 2: Incorporation of Real-World Data into the Model of a Stacker

The second step to build a model of a stacker is to update it with all pertinent structural data relating to the asset. This can encompass load history, inspection records, repair information, and loading levels of the reclaimer. The inclusion of actual usage patterns is pivotal to provide an accurate estimate of the remaining fatigue life based on real-life usage (as opposed to traditional methods that rely on assumptions). This step is also vital to attain precise knowledge about the equipment’s stress concentrations, load distribution, and potential weak points.

By harnessing relevant data, engineers can make informed predictions about how future usage of the equipment impacts its operational lifespan, identify potential failure modes, and devise proactive/predictive maintenance strategies.

What Does the Akselos Approach Offer?

Adopting the Akselos methodology to build a model of a stacker can offer several key advantages to engineers in the mining sector:

• Workflow Efficiency: Our ‘build once, always use’ model means that an Akselos model, once built, can be updated easily using our cloud-based platform or by connecting it directly to data in the field. (This will be explored further in future articles).
• Enhanced Accuracy & Hotspot Detection: Akselos offers a more accurate portrayal of the equipment’s behavior at a millimeter level, enabling the identification of critical hotspots and detection of potential problems before they amplify.
• Improved Maintenance Planning & Uptime: Detailed insights into areas prone to fatigue and the remaining asset life allows engineers to plan maintenance activities more effectively, thus minimizing downtime and optimizing equipment availability.
• Cost Savings: By identifying potential failure modes and weak points early on, Akselos helps to reduce costly repairs and unplanned shutdowns for Reclaimers, leading to significant operational expenditure savings over time.
• Regulatory Compliance: Akselos validates all simulation outcomes for compliance with industry regulations so that you always know whether your equipment is ‘fit-for-service’.

Regaining Control over Structural Integrity

In the mining sector, accurate structural analysis is pivotal for maximising operational efficiency and ensuring equipment safety, especially for machines like stackers and reclaimers. Akselos offers a novel modelling approach, incorporating a modular, component-centric strategy and leveraging real-world data.

By utilizing Akselos software to build a model of a stacker, engineers can develop comprehensive and accurate models, gain detailed insights on a millimeter scale, and make data-driven decisions regarding maintenance and repair strategies. Adopting Akselos paves the way for the mining industry to boost productivity, curtail costs, and ensure the longevity of critical equipment.

Are you ready to reclaim control? Contact us today to build a model of a stacker!