Open Cut

DC Motor Duty Meter

Open Cut » Maintenance & Equipment

Published: April 17Project Number: C16030

Get ReportAuthor: Galina Mirzaeva | University of Newcastle

Compared to other machines, DC machines are relatively complex, since they require a commutator to mechanically rectify large armature currents. This mechanical commutation is inherently a source of maintenance and lost time. However, the robustness and simplicity of control of DC machines, together with the vast experience accumulated within the industry, make them an attractive solution for mining applications, such as rope shovels and draglines. Hence, although AC motor technology is gaining an increasing market share, DC machines will continue to be used for up to several decades. Aging of the motor fleet will intensify maintenance problems during this transition period. To assist in maintenance and reduce the downtime of the production critical DC machines, it has been proposed to develop an online condition monitoring and life prediction system called a 'DC Motor Duty Meter'.


Traditional on-line condition monitoring is based on identification of early signs of faults or malfunctions. The approach proposed is different in that: (a) it tracks causes rather than the signs of motor deterioration; (b) it gives a recommendation for DC motor maintenance needs based on the cumulative duty estimation.


This report concludes the final stage 3 of the ACARP C16030 project. The main objectives of this stage were: (a) to develop a prototype Duty Meter suitable for installation with a full size electric rope shovel DC motor; and (b) to validate this prototype on a scaled version of the DC motor under conditions matching those experienced by a rope shovel DC motor.


Note that the laboratory DC motor design, the grade of the brushes, the type of the drive, etc. were carefully selected to be as close as possible to those of the full scale DC motor. The operating conditions were obtained by field

measurements on a rope shovel DC motor, scaled in proportion to the ratings of the laboratory DC motor, and exactly reproduced by using a programmed laboratory dynamometer.


This report provides a detailed description of the DC Motor Duty Meter prototype, its underlying principles, algorithms and results. The report is structured in the following way. Chapter 1 explains about the project history and objectives, summarises the main findings, outlines application and directions for future research. Chapter 2 describes the laboratory equipment used to build the Duty Meter prototype. Chapter 3 presents results of the additional experiments conducted within the final stage of the project. Chapters 4 described the Duty Meter models developed throughout the project. Chapter 5 explains how the Duty Meter models were implemented in the algorithm of the National Instrument CompactRIO system, and presents validation results. Chapter 6 briefly explains the software, and how to install and use the Duty Meter. Chapter 7 discusses technology transfer activities.



Health and safety, productivity and environment initiatives.

Recently Completed Projects

C28026Measuring The Height Of Fracturing Above Extracted Longwall Panels To Improve Reliability Of Groundwater Impact Predictions

Longwall mining is a mining method widely used in the Australian und...

C25059Development Of An Intrinsically Safe, Integrated Wireless Communications Network With A Distributed Array Of Geotechnical Sensors

For over 20 years, SCT Operations (SCT) have provided a range of ind...

C26051An On-Machine Bolting And Geotechnical Monitoring System

The primary objective of this project was to investigate how laser s...


Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C27046Estimation Of True Deformation Vector From Slope Radar Monitoring

Slope deformation radar monitors are now widely used in open cut coa...

C29003Wear Debris Removal From Dragline Commutators

The original aim of this project was to establish a method of removi...

C28037Local Scale Dispersion Modelling To Support ACARP Emission Factors

There remains significant concern in the industry regarding the accu...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C27032Coal Grain Analysis Applications Handbook

This Handbook sets out recommended practices for using coal grain an...

C26012Improved Flotation Recovery Via Controlling Froth Behaviour

There is no real-time measurement for coal flotation performance, ma...

C27012Towards Better Fine Coal Classification

It is well recognised that the efficient classification of fine coal...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C26039Nanoporosity In Cokes: Their Origin, Control And Influence On CO2 Reactivity

This project using the outcomes of previous project C24060, examine...

C28063A Comprehensive Technical Review Of High-Efficiency Low-Emission (HELE) Pulverised Coal Combustion Technologies For Power Generation

Research and development has been undertaken worldwide to realise co...

C28064Carbon Structure Transformation During Coking Of Australian Coking Coals: Better Understanding The Coke Formation

Carbon structures of coke that are formed during the plastic layer a...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C26004CFD Modelling Of Reverse Thermal Oxidisers For VAM Abatement - CFD Modelling Of Fixed-Bed RTO Devices

The project is part of a larger multi‐phase program of study a...

C27058Technological Assessment Of A Recycle Reactor For VAM Abatement

Underground coal mining emits high volumes of methane, diluted in ve...

C27008Selective Absorption Of Methane By Ionic Liquids

The connection of a ventilation air methane (VAM) abatement plant di...

Mine Site Greenhouse Gas Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community


National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook