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Bently Nevada helps smart mining: core technology to extend equipment life

May 21,2025

Introduction

In modern mines, especially in highly automated operation scenarios, sudden failure of key equipment will not only lead to production stoppage, but also may bring safety risks and high maintenance costs. With the continuous development of smart mining, enterprises have an increasingly strong demand for preventive maintenance and condition prediction systems. As a global leading provider of asset health management and equipment monitoring solutions, Bently Nevada is using its advanced technology to help mines significantly extend the service life of core machinery. This article will analyze the specific application and value of its technology in automated mine operations.

 

High-reliability condition monitoring, designed for complex mining environments

In automated mines, rotating mechanical equipment such as crushing equipment, conveying systems, ore dressing mills and ventilation equipment are the core of production. These equipment need to deal with a variety of harsh working conditions such as dust, vibration, high temperature and high load, and are prone to performance degradation. Products such as the 3500 series equipment protection system launched by Bently Nevada have the ability to collect vibration, temperature, pressure and speed data in real time.

High-precision proximity sensors, vibration probes and accelerometers can quickly identify hidden dangers such as bearing loss, axial offset and rotor imbalance, allowing maintenance personnel to take targeted measures in time to prevent problems before they occur. Compared with traditional post-maintenance methods, this data-driven maintenance model can achieve higher equipment availability and operating efficiency.

In addition, Bently Nevada's products adopt industrial-grade protection design, with good vibration, dust and temperature resistance, which perfectly meets the stringent operating requirements of surface or underground mines.

 

Predictive technology drives intelligent maintenance decisions

Another major advantage of Bently Nevada is that it converts complex data into valuable maintenance information. With the help of System 1 status management platform, mining users can use graphical analysis tools and trend modeling technology to gain in-depth insights into the operating status of key equipment.

The system's embedded intelligent algorithm can identify abnormal trends in equipment health, such as continuous increase in vibration amplitude and abnormal temperature, thereby triggering early warnings. Maintenance engineers can view the operating status of equipment in real time, generate diagnostic reports and deploy response strategies through remote terminals.

Predictive maintenance also helps companies optimize spare parts reserves and maintenance personnel scheduling resources, abandon time-based maintenance cycles, and instead formulate intervention plans based on the actual status of the equipment, which not only saves resources but also reduces the risk of unplanned downtime.

 

Extending the life of machinery and improving overall operational stability

The solutions provided by Bently Nevada directly help improve the long-term use efficiency of key mining equipment such as motors, gearboxes and pumps. Diagnosis based on real-time monitoring can effectively prevent system-level crashes caused by equipment abnormalities, while also reducing the frequency of operational interruptions.

Taking vibration monitoring as an example, if the mining truck engine or crusher has eccentricity, looseness and other conditions, it can be captured at an early stage to avoid collateral damage during continuous operation. Continuous optimization of these details can effectively delay component aging, reduce the frequency of overhauls, and maximize return on investment.

It is worth mentioning that Bently Nevada's system supports unified and centralized management of multiple mines. The remote support function enables the technical team to assist on-site staff in the background to comprehensively improve maintenance response speed and safety assurance capabilities.

 

Conclusion

Today, as smart mines continue to advance, ensuring the stable and efficient operation of core equipment is the key to improving production capacity and reducing costs. Bently Nevada relies on powerful condition monitoring technology and intelligent analysis platforms to provide systematic asset management support for mining customers. By deploying these solutions, companies can not only extend the life cycle of equipment and optimize maintenance processes, but also take a solid step towards intelligent operation and maintenance. Bently Nevada is using its technological advantages to lead automated mines to achieve a safer and more sustainable development path.

  • The key to ensuring power stability in industrial automation: Yokogawa PW101 S2 power module 19/06

    2025
    The key to ensuring power stability in industrial automation: Yokogawa PW101 S2 power module
    Introduction In modern industrial automation systems, stable power output is a key element to ensure continuous operation, reduce equipment downtime and ensure safe operation. Yokogawa's PW101 S2 power module is a high-performance power supply device that provides reliable DC power support for control systems. Tailored for Yokogawa's CENTUM VP and ProSafe-RS platforms, the module plays the role of a power hub in a distributed control architecture, providing continuous energy for control units and input/output modules.   Professional design for critical conditions The PW101 S2 is made of high-durability industrial components to maintain stable operation in complex and harsh working environments. Its power supply capacity covers 5VDC and other regulated DC voltages to ensure uninterrupted operation of various modules in the field control station (FCS). In its design, it is endowed with a wide range of input voltage compatibility and redundancy support functions, which greatly reduces the possibility of power outages in critical business environments. PW101 S2 can not only perform hot-swap operations during equipment operation, but also realize non-interruptible replacement during maintenance, thereby shortening the maintenance cycle and improving the continuous availability of the system. More importantly, its compact structure takes up very little space, making it particularly suitable for large-scale automation control systems with strict requirements on the layout of the cabinet.   High-performance performance and multiple intelligent protection mechanisms Whether it is improving energy efficiency or preventing electrical risks, PW101 S2 has shown extraordinary performance. The efficient energy conversion rate not only reduces unnecessary power loss, but also reduces module heating, thereby extending the service life of itself and surrounding components. The module has built-in multiple safety mechanisms including overcurrent protection, overvoltage protection and temperature control shutdown, so that the system can remain under control under abnormal conditions. After being integrated into Yokogawa's overall architecture, the module can work with diagnostic tools to support predictive maintenance strategies. The status and fault signals that can be read by the engineering station enable potential problems to be discovered and handled in time before they cause major accidents.   System compatibility and certification standards The ability to quickly access existing DCS systems and ensure coordinated power supply and communication is a major advantage of the PW101 S2. It fully complies with industrial standards such as electromagnetic compatibility (EMC) and insulation reliability, and is particularly suitable for high-standard industries such as chemicals, energy, and oil and gas. In situations where highly reliable power supply is required, the 1+1 or N+1 redundant configuration schemes it supports are particularly critical. With...
  • Improving digital signal acquisition accuracy: Yokogawa ADV141-S12 S1 digital input module 18/06

    2025
    Improving digital signal acquisition accuracy: Yokogawa ADV141-S12 S1 digital input module
    Introduction In industrial automation systems, digital input modules serve as an important interface between field devices and control systems, playing a key role in signal acquisition. Yokogawa ADV141-S12 S1 digital input module is designed to accurately acquire signals from discrete devices such as switches, relays and sensors. The module can be seamlessly integrated into Yokogawa's CENTUM VP and ProSafe-RS platforms, and has efficient data processing capabilities, making it ideal for application scenarios where control and safety are critical.   Rugged structure and functional reliability The ADV141-S12 S1 is designed for harsh industrial environments, emphasizing the module's structural strength, electrical insulation and signal integrity. Each of its input channels uses an optoelectronic isolation design to effectively prevent electrical noise interference and ensure stable operation of the equipment under complex working conditions. The module is usually equipped with 16 input channels and supports standard DC voltage input to ensure compatibility with various field devices. At the same time, the module has extremely high signal recognition accuracy and is equipped with a de-jitter filter function, which can stably collect clear switch signals, which is particularly critical in emergency shutdown systems (ESD) and safety instrument systems (SIS). The LED indicator on the front of the module can display the channel status in real time, greatly simplifying the fault diagnosis and daily maintenance process.   System Adaptation and Flexible Configuration The ADV141-S12 S1 module is designed with full consideration of the convenience of system integration, and can be easily matched with the Yokogawa control system architecture to reduce the time cost of engineering deployment and debugging. The module transmits the collected signal data to the field control station (FCS) quickly and stably through the internal bus. Its input voltage range is wide (typically 24VDC) and meets the insulation standards between channels, field wiring and systems. It can be installed on a standard I/O baseboard with other digital or analog modules to support flexible system structure design. At the same time, its hot-swappable capability allows maintenance personnel to replace modules without downtime, effectively improving the ability to support the continuity of key processes.   Self-diagnosis function, reliability and certification guarantee ADV141-S12 S1 not only performs well in performance, but also has powerful self-diagnosis function, which improves the level of system visualization. The module can automatically identify channel abnormalities, disconnections and short circuits, and promptly feedback the status to the central control system, helping operators to quickly respond to on-site problems and avoid equipment downtime. The module meets many international reliability standards and is certified by CE, UL and other certifications. It is suit...
  • Yokogawa PC10031-AAA0 Servo Drive: A Highly Reliable Choice in Precision Motion Control 17/06

    2025
    Yokogawa PC10031-AAA0 Servo Drive: A Highly Reliable Choice in Precision Motion Control
    Introduction Against the backdrop of the rapid development of modern industrial automation, system design has become increasingly demanding in terms of high precision, high efficiency, and strong stability. As a key actuator, the servo drive is responsible for ensuring the smooth and efficient operation of the equipment. The Yokogawa PC10031-AAA0 servo drive is a high-performance control product designed for complex industrial applications, fully embodying the integration of precise control and continuous reliability.   Solid structure and powerful functions To achieve seamless collaboration with high-end servo motors, the PC10031-AAA0 is designed as an intelligent drive with fast response and closed-loop control capabilities, capable of finely controlling key parameters such as position, speed, and torque. With high-resolution feedback devices, the drive significantly improves the response speed and synchronization performance of the control system. It is equipped with a high-speed digital signal processor (DSP), which enables real-time control and dynamic adaptation. The device incorporates advanced PID algorithms, enabling it to maintain excellent control accuracy even when the load fluctuates drastically. At the same time, it provides compatibility with a variety of industrial communication methods, such as integration with DCS (distributed control system) and PLC (programmable controller) systems. Not only does it excel in functionality, it also excels in physical construction. Made of highly durable industrial components, the PC10031-AAA0 can withstand vibration, electromagnetic interference and temperature fluctuations, and is particularly suitable for long-term operation in harsh environments.   Excellent performance in a wide range of applications This device, known for its flexibility, is suitable for a variety of motor types - whether it is synchronous AC, asynchronous motors or brushless DC systems, it can achieve precise drive. Robot control, CNC machining centers, high-speed conveyors and precision automated chemical cells are all its typical application areas. Because its feedback speed is in the microsecond level, it can provide extremely high consistency in repetitive tasks, effectively reducing errors and waste. Particularly noteworthy is that its automatic gain adjustment function greatly simplifies the initial setting process, making debugging fast and convenient, and adapting to the requirements of modern production for deployment efficiency. In addition, its comprehensive protection mechanism, including overload protection, overheating shutdown and current abnormality protection, fully guarantees the safety of equipment operation. Not only that, the high compatibility with Yokogawa FA-M3 series PLC makes its integration in the control system fast and easy, realizing true plug-and-play.   Excellent system integration and communication capabilities The interoperability advantage of this driver is particularly wo...
  • Performance Analysis of Yokogawa AFV10D-S41201 S2 Field Control Unit 16/06

    2025
    Performance Analysis of Yokogawa AFV10D-S41201 S2 Field Control Unit
    Introduction In the field of industrial process automation, the demand for high-precision, high-reliability and scalable control solutions is increasing. Yokogawa has launched a number of high-performance field control units (FCUs) based on its technical accumulation in the field of industrial control and instrumentation. Among them, the AFV10D-S41201 S2 model has attracted much attention in the industry due to its robust architecture, flexible integration capabilities and wide compatibility in DCS systems. This article will introduce the core design, control functions and advantages of this FCU in practical applications in detail, and demonstrate its key role in improving system stability and operating efficiency.   High-performance architecture and system design The Yokogawa AFV10D-S41201 S2 has a compact and powerful hardware architecture that can handle control tasks under various complex working conditions. As an important part of the CENTUM VP distributed control system, the unit is equipped with a high-speed processor and supports redundant design to achieve high availability and fault tolerance. The device supports flexible combinations of multiple I/O modules and has good modularity and scalability. Its fanless design reduces the risk of mechanical failure, while the rugged and durable housing is also suitable for harsh industrial sites. AFV10D-S41201 S2 follows international standards such as IEC and ISA, ensuring extensive protocol compatibility and engineering interface docking capabilities. The internal bus system enables high-speed communication between modules, while the dual-power input design ensures uninterrupted operation of the system. These structural advantages enable it to efficiently execute real-time control algorithms to meet the control requirements of continuous or intermittent processes.   Powerful control functions Highly compatible with system integration The FCU provides comprehensive control functions, including analog and digital signal processing, PID regulation, sequential logic control, and safety interlock management. It has high-speed data acquisition and low-latency response capabilities, making it very suitable for industries such as petrochemicals, power, and environmental protection that have extremely high requirements for real-time control. Another significant advantage is its deep integration with the Yokogawa DCS system. Native support for Vnet/IP control networks enables it to communicate seamlessly with upper-level operation stations, engineering workstations, and other systems. In addition, AFV10D-S41201 S2 also supports hot-swap function, allowing modules to be replaced or added without interrupting system operation. It is compatible with fieldbus protocols such as FOUNDATION Fieldbus and HART, which facilitates the interoperability and status maintenance of intelligent field devices. The engineering configuration of the equipment can be carried out through Yokogawa's CDT graphical tool...
  • ABB drives heavy industry performance innovation with digital twins 19/06

    2025
    ABB drives heavy industry performance innovation with digital twins
    Introduction At present, the wave of Industry 4.0 is sweeping the world, and digital innovation is profoundly changing the operating mechanism of heavy asset industries, especially mining, oil and gas, metallurgy and energy. At the forefront of this transformation is the digital twin technology deployed by ABB, an intelligent means of building a virtual mirror of a physical system. By integrating real-time data streams with advanced simulation models, this technology helps companies achieve accurate perception, scientific prediction and efficient management of the entire life cycle of the system. In complex industrial environments, digital twins are becoming a key force to reduce the risk of interruptions, improve operational efficiency and ensure safety.   Intelligent construction of virtual mapping: the core foundation of ABB's digital twins Deeply embedded in ABB's digital twin system is the close integration of operational data and physical modeling technology. These virtual models not only reproduce the geometry of the actual equipment, but also simulate its dynamic performance and behavior mechanism. The sensor network, intelligent control platform and AI algorithm deployed by ABB continuously collect operating data from the field and synchronously feed it back to the twin model. As a result, the digital mapping can always remain consistent with the real state. In the process of simulating different operating scenarios, operators can verify the operating effect in advance, avoid potential failures, and optimize process parameters without interrupting the production rhythm. For example, in the metal smelting industry, ABB's virtual model can reproduce the operating status of the furnace under various heat load conditions, helping engineers to find energy consumption blind spots and achieve energy saving and consumption reduction; in mining scenarios, its platform can analyze mechanical wear trends, terrain stress and automatic transportation paths, thereby extending equipment life and improving operational efficiency.   Full-cycle collaborative optimization and intelligent predictive maintenance Not only limited to visual presentation, ABB's digital twin also covers the entire life trajectory of assets: from engineering design, system debugging to operation and maintenance. Continuous data analysis capabilities enable the system to implement forward-looking maintenance strategies, thereby effectively avoiding unexpected downtime events. The machine learning mechanism hidden in the ABB Ability™ platform has the ability to identify changes in operating trends and micro-anomalies; thereby, equipment maintenance can be dynamically adjusted, greatly reducing maintenance costs and total cost of ownership (TCO). More importantly, before the actual deployment of the control strategy, operators can use the twin model to simulate parameters and select the best solution. This not only ensures a smoother system startup, but also effectively en...
  • Relying on artificial intelligence: How ABB is revolutionizing industrial process automation 18/06

    2025
    Relying on artificial intelligence: How ABB is revolutionizing industrial process automation
    Introduction As industrial digitalization continues to deepen, artificial intelligence (AI) is gradually becoming the core driving force for automation innovation. ABB, as a pioneer in the global electrical and automation field, is deeply integrating AI technology into its diversified products and solutions from a forward-looking perspective, in order to improve operational intelligence, optimize process efficiency and prevent faults. With the help of advanced machine learning, real-time data analysis and intelligent prediction technology, ABB is leading the upgrading and reconstruction of automation models in multiple industries such as manufacturing and energy.   Using AI to achieve predictive maintenance and equipment efficiency improvement Among many AI application scenarios, ABB's most striking achievements are reflected in predictive maintenance. By deploying self-learning algorithms in the control platform, the equipment can self-monitor the operating status, identify operating anomalies and predict potential faults in advance. This forward-looking maintenance method not only reduces the probability of unplanned downtime, but also significantly improves equipment utilization. For example, ABB's Ability™ asset performance management platform uses AI to perform pattern recognition and trend analysis on sensor data of motors, pumps and compressors, thereby triggering early warning or automated response mechanisms. This not only extends the service life of equipment, reduces maintenance costs, and effectively curbs safety risks. In addition, AI models for optimizing production scheduling and energy distribution are also widely deployed. It is this set of intelligent scheduling strategies that minimizes resource use and maximizes operational efficiency. In high-risk industries such as petrochemicals, mining, and fine chemicals, this AI optimization method is particularly economic and operational.   Process control optimization leverages real-time intelligent analysis It is the embedding of artificial intelligence technology that makes process control smarter and more adaptive. ABB has achieved precise control and dynamic response mechanisms based on real-time data by integrating AI algorithms into its distributed control system (DCS). If changes occur on key parameters such as temperature or pressure, the system can autonomously complete parameter correction and optimal adjustment based on adaptive modeling and reinforcement learning algorithms without human intervention. For example, in chemical processes, this capability ensures the continued stability of product quality and production capacity. AI not only extracts value from data collected by sensors, but also integrates multiple data sources such as historical records and enterprise resource information to output operational suggestions and even automatically optimize closed-loop control strategies. Such functions not only improve production yields, but also help companies meet t...
  • ABB collaborative robots enable small-batch manufacturing to improve flexibility 17/06

    2025
    ABB collaborative robots enable small-batch manufacturing to improve flexibility
    Introduction With the deepening of the Industrial 4.0 era, manufacturing companies need to constantly adapt to the ever-changing market demand, especially in the production mode of multiple varieties and small batches, where flexibility becomes the key factor in determining success or failure. Although traditional automation equipment performs well in large-scale production, it is often difficult to cope with frequent changes in orders and complex product types. At this time, the collaborative robots launched by ABB are gradually leading the new trend of small-scale manufacturing with their excellent safety performance, flexible automation capabilities and intelligent control. This article will deeply analyze the advantages of ABB collaborative robots and how to innovate manufacturing methods by improving process efficiency, accelerating conversion rhythm and strengthening human-machine interaction.   Innovation of small-batch manufacturing processes: collaborative robots lead the change Unlike traditional industrial robots, collaborative robots - which are essentially automated tools that can coexist with humans - can achieve safe operation without closed protection. The YuMi® and GoFa™ series launched by ABB integrate advanced sensing mechanisms, intuitive operating interfaces and lightweight structures, which provide great convenience for manufacturers who face frequent product switching or handle personalized orders. In the fields of electronics, medical devices and fast-moving consumer goods, small batch customization has gradually become a mainstream trend. In this context, the ability to quickly reconfigure robots to perform new tasks is particularly important. ABB collaborative robots introduce guided teaching and graphical programming, which greatly simplifies the setting process. Because of this, even inexperienced operators can complete deployment and adaptation tasks in a short time.   Enhanced production flexibility and accelerated advancement of human-machine collaboration Enhancing production flexibility and achieving efficient human-machine collaboration are one of the most significant advantages of collaborative robots. By leaving boring, repetitive and potentially stressful processes to robots, while operators focus on more thought-provoking work content, production efficiency is significantly improved, and a safer and more fulfilling working environment is created. With the support of responsive torque sensors and force-limiting designs, ABB collaborative robots can safely and accurately perform demanding tasks such as assembly, material handling and packaging. In addition, with the help of RobotStudio® offline simulation tools, users can perform process testing and path optimization without suspending production, so as to quickly respond to new orders or product changes.   Cost-effective automation solutions for SMEs Deploying traditional industrial robot systems is not only costly but also complex for s...
  • ABB's automation solutions promote safety and efficiency in nuclear power plants 16/06

    2025
    ABB's automation solutions promote safety and efficiency in nuclear power plants
    Introduction In the highly regulated and safety-sensitive nuclear energy industry, the need for stable and reliable control systems is becoming more urgent. Nuclear power plants must ensure the highest level of safety standards while pursuing operational excellence. With its deep experience in process automation and digital integration, ABB is providing nuclear power facilities with robust, scalable and intelligent automation systems to significantly improve safety and operational efficiency.   Improving operational reliability through integrated automation ABB's automation platforms (such as System 800xA) can integrate control systems, safety systems and information systems into a unified architecture. This integrated design simplifies the system structure, improves visibility, and effectively reduces the risk of human operating errors - a critical part of nuclear facility operation. System 800xA has good compatibility and can be easily connected to existing equipment. It also supports redundancy and safe shutdown functions to ensure the continuity of key processes and risk prevention and control. At the same time, the system has advanced diagnostics and condition monitoring functions that can detect potential problems in real time, thereby achieving predictive maintenance and avoiding sudden failures. This strategy not only extends the life of the equipment, but also reduces the number of unplanned downtimes, reduces operating costs and ensures safe operation.   Strengthening safety mechanisms through digital control systems ABB's automation solution follows a multi-level safety design concept, and fully protects the stability of the nuclear power process through dual redundancy of software and hardware. Integrated functional safety systems (such as emergency shutdown systems and reactor protection systems) ensure rapid response and event control at critical moments. In addition, ABB uses digital twin technology and simulation platforms to model and verify nuclear reaction processes under different operating conditions to ensure that all safety strategies are fully tested. The human-machine interface (HMI) is optimized and intuitive to operate, and can provide important indicators to operators in the first time. Together, these functions ensure the minimization of accident handling and comply with international nuclear safety standards such as IAEA and IEC 61513.   Improving operational efficiency through smart grids and data analysis In addition to safety, ABB's solutions also focus on improving nuclear power efficiency. By deploying smart grid interfaces, nuclear power plants can coordinate operations with national grids to optimize load response and grid stability, which is particularly important in the context of the increasing proportion of renewable energy. ABB also uses advanced data analysis and artificial intelligence technologies to conduct real-time analysis of data collected by thousands of sensors to help optimize va...
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