Heavy industries like mining and power generation have long relied on underground conveyor systems to enable efficient bulk material handling. But as Kris Jaryn, Bonfiglioli National Product Manager: Heavy Duty Products explains, a growing number of plants are looking for smart solutions that will not only power these conveyor systems, but will also support safer, more sustainable operations.
Smart selection is key
Kris highlights that – as is the case for other heavy-duty applications – the selection of a gearbox for a conveyor system is a critical consideration. “The units require a good service factor – about 1.8-2.0 on motor power. Because of the dusty environments in which these are typically used, the gearboxes are always supplied with taconite seals and desiccant breathers,” he says.
In mining applications, there are additional criteria which must be met. Australian underground coal mines, drive assemblies should not have exposed parts made of aluminium, motors should meet mine specifications and specific requests according to the site and type of product also come into play.
Kris adds that some mines have site-specific requirements, like special oil sight glass, stainless steel drain valves, breathers, bearings and oil temperature monitoring. Choosing a partner that can meet these requirements is key.
Tech-enabled innovations are gaining favour
Mines and other heavy industry operations are faced with a host of challenges, including rising operational costs, safety legislation, labour shortages and a pressing need to reduce their environmental impact, as well as demand for increased capacity and efficiency.
Remote monitoring holds the key, enabling improved preventative maintenance – which in turn enables improved efficiency and optimisation.
“Remote monitoring of underground conveyor drive systems is gaining more traction,” says Kris, “Factors like bearing vibration, oil temperature, overload events, etc can be monitored and recorded without the need for someone to take these measurements in person. This helps to prevent equipment damage and faults, contributing to a safer working environment for personnel. In addition, remote monitoring data contains valuable information that can be used to identify and remedy inefficiencies early on, and assists in maintenance planning and providing operational insight.”
Supporting success in demanding applications
Having developed solutions for heavy-duty industries for over six decades, Bonfiglioli offers a range of solutions that are ideal for use in underground conveyor applications.
The company’s HDO Bevel Helical and HD (Heavy Duty) series gearboxes are firm favourites, renowned for their robustness, reliability and ability to operate in extreme environments. They’re available in an Atex option, for use in explosive environments.
The HD Series features tough SG iron housing, offers high torque rating, wide range of ratios as well as varied output shaft configurations and motor mounting options. It’s a cost-efficient solution, with long service intervals and low maintenance costs.
In addition to the HD series, helical and bevel-helical units, the 300 Series Planetary gearboxes are also used in various conveyor applications.
When used in combination with the HDO reducers, they offer an excellent solution in cases demanding high torque with lower output speeds, such as feeder conveyors.
Bonfiglioli’s latest 3/H catalogue lists drives with torque rating up to 1,102 kNm.
“The versatility of Bonfiglioli products is a key differentiator, making it easy for us to combine products in order to develop a solution that can achieve the customer’s required speed and torque,” says Kris.
Partnering with the right supplier
In industries where safety and operational performance are non-negotiable, it’s essential to have the support of a partner who will go the extra mile. Bonfiglioli carries out site visits, to inspect and assess the condition the gearboxes and drive assemblies. In cases where a repair is needed, the gearbox can be sent to Bonfiglioli workshop for the necessary overhaul. “We have dedicated fitters on the team, to do repair jobs in-house, ensuring quick turnaround,” said Kris.
Looking ahead, Kris anticipates growing demand for underground conveyor systems and solutions, which facilitate continuous, reliable operation and efficient bulk material handling. “We’re proud to play a role in the success of local industries and support our customers with world-leading solutions,” he concluded.