An integrated machine and process monitoring system called IP500/IP700 has been developed by Metso Minerals and CC Systems to improve the efficiency of rock crushing operations. The system monitors the performance of an excavator and primary crusher in real-time, displaying information to the excavator operator via a touchscreen computer. This allows the operator to optimize the feeding of rock into the crusher using a traffic light system. The monitoring system aims to increase productivity, reduce unplanned downtime, and improve safety by avoiding the need for operators to inspect the crusher directly. Initial customer implementations showed increases in crushing capacity and equipment uptime.

1. PRODUCTS & SERVICES PRODUCTS & SERVICES
marko elo
Rock star
An efficient monitoring system thAt enhAnces the
collAborAtion between excAvAtor And crusher for mAximum-
efficiency minerAls processing sounds like A surefire hit
Machinery uptime is critical in the module for wireless CAN. When paired
rock-crushing business, but it is also with a second unit, a wireless CAN bridge
crucial to optimise the total crushing is established, channelling the CAN
process, both in sense of quality and communication via Bluetooth Class 1. This
quantity. Metso Minerals, a global supplier solution is typically used for the connection
of equipment and services for rock and of CAN networks on different machines
minerals processing, has developed a and vehicles. Two CrossLink BTC units are
system solution that helps its customers to paired so that they can communicate only
improve efficiency and productivity of the with one another, eliminating the risk of
crusher plant. The IP500/IP700 integrated other wireless devices interfering. One of
machine and process monitoring system the CrossLink BTC units is mounted in the
has been developed by Metso Minerals in excavator, and the other is anchored on Figure 3 (TOP): CC
co-operation with advanced control system the primary crusher. Systems CC Pilot XS
specialist CC Systems, and enables the onboard computer
excavator operator to control and optimise Safety on board Figure 4 (CeNTre): CC
the performance of the primary crusher. The application of IP500/IP700 is built with Systems Crosslink BTC
The system is based on CC Systems’ CoDeSys SoftPLC programming framework. communication module
CrossTalk concept, a generic control system It improves safety at the workplace, and
Figure 5 (BOTTOM): a
platform for machine controls. The created provides essential information to the GUI screen
architecture can reduce the number of excavator cabin. As the operator can see
components in the control system, and at the feeder status in the camera view,
the same time future-proof Metso Minerals’ personal injuries that could occur if the
system solution. operator had to go up onto the feed
It provides the operator with easily stockpile are avoided.
interpreted information about how the Both metric and imperial units are
machine is performing so that he can supported, and an online, context-sensitive
adapt the feeding of rock into the crusher, help system gives the operator instant
and increase plant productivity by setting guidance when required. Like a GPS
machine parameters for optimal use. navigator in a car, IP500/IP700 is an
intrinsic part of daily use and everyone can
Figure 1 (BelOw): metso
minerals, a global supplier The key: a powerful HMI enable worldwide unified usage of the reducing the time needed for robustness; the excavator and crusher use it. Three user levels are provided,
of equipment for rock and A CC Pilot XS onboard computer mounted system. It uses a simple traffic light system, troubleshooting, and includes a real-time environment means exposure to dust, specifying necessary access for operator,
minerals processing in the excavator cabin runs the system helping to feed the primary crusher in the video camera view to the crusher feed inlet extreme temperatures and severe shock maintenance and supervisor user levels.
control software and the graphical user most efficient way. The pace of feeding is via a wireless link. All error and warning loads. The hardware components are Experiences of field prototyping with the
Figure 2 (MAiN iMAge):
Total machine and process interface (GUI, Figure 5). The GUI language the key factor, to enable the optimising of occurrences are logged into the system, supplied by CC Systems, which specialises IP500/IP700 system have proven to
control system for rock and symbols have been designed to be capacity while maintaining a high scalping and the logged data can be used for in rugged control system hardware. increase productivity through more stable
crushing international and not culture-dependent, to efficiency of the grizzly feeder. A green planned maintenance, reducing the need for As the central component, the CC Pilot operations and better efficiency, especially
light implies that the crusher is running at unplanned repairs. XS is used as the operator’s control panel, at rock feeding. The product was
full speed, and the operator is encouraged Usage logs help to further improve the running the GUI with the control and introduced to Metso customers in May
to continue feeding more rock; an amber process, and all logged data can be copied diagnostics application. With its XScale 533 2008, and first customer deliveries began
light means that the operator should wait to a USB memory device. System MHz CPU and a 6.5in or 10.4in graphical during the fourth quarter of the year.
before feeding the next bucket; while a surveillance features include – but are not SVGA display and touch-screen, this panel The IP500/IP700 system provides the
red light tells the operator to stop feeding, limited to – engine rpm, fuel consumption, is used in a wide range of industrial excavator operator with new tools to get
and not to restart until the cause of the jaw crusher pressure, hydraulic oil applications. It has received a great deal of the most out of the crushing equipment
stop has been rectified. temperature and device pump pressure. In credit for its all-integrated ability as a investment. iVT
In addition to the traffic light system, a addition, the conveyor belts and their controller, HMI, video screen and as host
Stop symbol is shown when there is a fault operational parameters, such as speed and for auxiliary systems such as diagnostics, Marko Elo is R&D manager at CC Systems
that requires human intervention. safety switches, are monitored. remote access, etc. Oy, Finland. He has worked in the field of
The onboard computer also displays A general requirement of the hardware The CrossLink BTC, also developed by industrial control and communication
warnings and errors in the crusher system, components in the IP500/IP700 system is CC Systems, is a compact and robust systems since 1990
CoNTaCT
www.cc-systems.com
info@cc-systems.com
?? iVT International October/November 2008 iVT International October/November 2008 ??