Bauxite mining: optimised maintenance through real-time alerts and remote monitoring

The scenario

Revolutionising safety and maintenance: TRUST ITM® MOBILE KIT (TMK) with magnetic sensors provide real-time monitoring and alerts 

A business case from a bauxite mine on scraper brake drums. 

What we did

Used for levelling large areas, scrapers are heavy-duty machines that rely on robust braking systems to operate safely. A failure in these systems can lead to significant safety risks, putting operators and equipment in danger. To address this, TMK magnetic sensors have been introduced to monitor brake performance in real time, ensuring that issues are detected early and addressed before they escalate. The system provides immediate alerts when irregularities are detected, such as when a brake is not functioning as expected. This enables operators to take prompt action, preventing potential safety hazards, minimising downtime and avoiding accidents caused by brake failure. 

In addition to in-cabin monitoring, the system can be connected to a cloud-based platform, allowing maintenance teams to remotely track brake performance in real time. With Wi-Fi or mobile connection, the system can provide timestamped data and send live notifications to designated personnel when specific temperature thresholds are exceeded. This feature enhances safety by ensuring that critical issues are addressed as soon as they occur, and the cloud-based system can support long-term maintenance planning by storing performance data. 

What we achieved

The introduction of magnetic sensors on Scraper Brake Drums has revolutionised safety and maintenance, providing real-time alerts and remote monitoring for safer, more efficient earthmoving operations. 

Coal mining: prevention of failure and downtime on a D10

By combining sets of data (real-time temperature notifications, historical temperature information, and GPS data), we can clearly identify when a problem is occurring but also try to find the underlying cause to help prevent the same issue in the future. 

Coal mining: prevention of downtime and further damage on a D10

“With TRUST ITM®, we know in advance exactly when a component is going to fail so we can either avoid it or safely plan its replacement. This system represents a big step forward in our standard procedures in terms of safety and efficiency”.

Field service manager  

Sand mining: detection of hidden problems, thereby preventing further damage on a D11

A D11 equipped with TRUST ITM® rollers experienced a bogie pin problem, causing the misalignment of two rollers and an increase in temperature.

Gold mining: rollers damage on a 6040 due to user ignoring warnings

A CAT 6040 with TRUST ITM® sensorised rollers was operating in a gold mine when the TRUST ITM® system detected overheating in 4 rollers, from 125 °C up to 200 °C in one of the rollers.

Iron ore mining: efficiency, productivity and safety improvement on a EX3600

TRUST ITM® Mobile Kit enhances excavator safety and efficiency, reducing tramming time by up to 50%.

Gold mining: 50% of time saved during tramming phase on a CAT 7495

Increasing mining efficiency and safety: one hour of continuous tramming with the TRUST ITM® Mobile Kit.

Coal mining: customised gearbox monitoring with TRUST ITM® Mobile Kit

Ensuring the continuous and safe performance of large machines in mining operations 

A business case from a coal mine.