Case Study: Wireless Condition Monitoring Deployment
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OVERVIEW
A large mining operation in Asarco, Arizona partnered with Machinery & Reliability Institute (MRI) to modernize its reliability program using wireless IIoT technology.
The initiative was part of the company's broader condition monitoring and innovation strategy for its critical assets, including:
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Improving Equipment Uptime |
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Reducing Manual Data Collection |
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Enabling Earlier Fault Detection |
SOLUTION
MRI deployed CTC Connect wireless vibration monitoring hardware along the main conveyor system feeding the SAG mills, targeting equipment including:
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Gearboxes |
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Electric Motors |
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Pillow Block Bearings |
HARDWARE DEPLOYED
MRI deployed the following CTC hardware in the mining operation:
WS300 Series ConnectSens Wireless Sensors
- Dynamic triaxial vibration and temperature monitoring
- IP67 rated and well suited for long-term reliability in harsh mining environments
- Enables fast, secure installation on rotating equipment
- Eliminates the need for drilling or permanent modification
ACCESS2000 Series Long-Range Wireless Gateway
- Centralized data aggregation and transmission
- Scalable architecture for expanding sensor networks
Sensors were strategically installed at critical measurement points along the conveyor system to capture early indicators of:
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Bearing Wear |
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Imbalance |
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Misalignment |
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Gear Defects |
The Connect wireless architecture allowed rapid deployment with minimal infrastructure requirements and coverage of previously inaccessible or unsafe locations.
