Underground » Maintenance
The objective of this project was to prototype, test, develop and manufacture a low cost wireless, intrinsically safe sensor for use in underground coal mines. The focus was to produce a sensor which would be initially applied as an inclinometer for deployment on the longwall and that would send sensor acquisition data by radio to a gateway in a format compatible with longwall control systems. The secondary focus was to ensure that the design of the sensor enabled it to be used in alternative contexts and applications with minimal alteration to the device.
The goals of the project were to:
- Utilise existing wireless condition monitoring technology for re-deployment in an underground coalmine Longwall system with enough flexibility to also be able to be applied in other use-cases that require remote condition sensing;
- Develop a low-cost, wireless Ex Inclinometer for Longwall roof-support and pan line inclination monitoring; and
- Use wirelessly connected devices utilising accelerometers and output XYZ data to determine early defects within bearings and rotating equipment.
The project successfully designed, built, and trialled prototypes of wireless inclinometer in the following settings:
- Longwall surface build - panline and roof support mounting; and
- Underground operational longwall - panline and roof support mounting.
The project also:
- Conducted data analysis and validation of sensor capabilities on field trial data gathered;
- Collected data using it to develop and finalise Inclinometer sensor software and algorithms;
- Produced tooling for devices;
- Laboratory assessed/tested devices and validated as IS Ex ia Group 1 devices;
- Product design Ex Certification was achieved;
- Manufactured 50 commercial units for delivery to underground mine operators.