Heavy-Duty Encoders for Mining Conveyors: Preventing Failure in Extraction, Sizers & IPCC Drives
Bulk material handling conveyor systems in extraction and run-of-mine (ROM) operations are some of the most severe in terms of the operating conditions they are subjected to throughout the mining life of the operation. Conveyors in open-cut in-pit crushing & conveying (IPCC) and in underground longwall maingate panels are subjected to constant high-amplitude mechanical shock, heavy fugitive dust, abrasive slurry wash and wide temperature swings.
Rotary encoders on the drive motors and tail pulleys must cope with very high levels of mechanical vibration while still providing the VFDs/VSDs and supervisory safety PLCs with clean, low-latency velocity and position data.
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Operating Conditions: Open-Cut IPCC vs. Underground Face Conveyors
Both open-cut and underground conveyor systems face similar challenges: a wide range of vibration and frequent high shock transients; however, each has unique challenges, highlighted below.
Open-Cut Extraction: High-Impact Shock on In-Pit Crushers & Feeder Drives
The primary feeder and discharge belts receive direct rock dumps from haul trucks and excavator buckets. The encoders on the high-torque electric drives are subjected to continuous harmonic vibration, transient shock loads of up to 100g to 200g, direct solar radiation, ingress of fine red dust and high-pressure hose downs during washouts.
Underground Extraction: Dust Suppression, Confined Footprints & Group I Compliance
Very tight physical clearances, constant structural movement as the boot end advances, and water spray for dust control all require a compact footprint and high ingress protection. Of course, underground coal is a Group I hazardous area (AS/NZS 60079) because of the presence of both firedamp (methane) and coal dust, and the equipment must be appropriate for this (Ex d or Ex ia).
Visit our range of Heavy-Duty Encoders
To support customers in both fields, our Avtron and Posital ranges provide the ruggedness these applications demand.
Avtron Severe Mill-Duty for Main Drives and Sizers
For primary open-cut IPCC conveyor drives, feeder motors, and sizer shafts where impact and vibration will destroy standard components, Avtron severe-duty encoders are the benchmark for survivability.
The AV485 (solid shaft) and AV685 (hollow shaft) mill-duty models, along with the HS40 and HS45 heavy-duty series, are designed for these high-stress points. They feature magnetoresistive sensors, large bearing sets, fully potted electronics, and cast enclosures rated IP65/IP66, so there are no fragile optical glass discs.
The Avtron encoder range is known for its high tolerance for operational vibration up to 18g and high impact mechanical shock up to 100g (AV485, AV685, HS45) and 200g (HS40). The Avtron range is designed to absorb heavy radial and axial shaft loads easily. Operating temperature ranges from -40°C to +100°C (or +120°C on the AV series where available) and are well suited to the harsh Australian summer heat.
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Explore Avtron's range of rugged encoders
Posital IXARC IECEx-Certified Encoders for Coal & Dust Zones
Whether you need certified explosion protection or ultra-compact absolute feedback, the Posital IXARC heavy-duty magnetic encoders are the ideal solution.
Available in electropolished 316 stainless steel casings, the IXARC range is IECEx certified for both intrinsically safe (Ex ia) and flameproof (Ex d) configurations. It is suitable for use in underground Group I and Group IIIC dust atmospheres.
Rated to IP69K, the Posital IXARC units can withstand hot water washdowns and heavy slurry build-up. These absolute encoders use battery-free, gear-free Wiegand energy harvesting to maintain accurate position tracking during power outages, without internal batteries that would otherwise degrade in a mine's hot, humid conditions.
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Explore Posital's range of encoders and inclinometers
Need a Hand? Call Today!
If you need rugged speed or position feedback for an open-cut IPCC line or an underground mining conveyor, PCA Encoders offers time-tested solutions designed for the Australian environment. Send any questions through our contact page here, or call us directly on 1300 236 467
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