Optimizing replacement time for mining shovel teeth using reliability analysis and Markov chain Monte Carlo simulation

Abstract

Purpose The purpose of this paper is twofold: an approach is proposed to determine the optimum replacement time for shovel teeth; and a risk-quantification approached is developed to derive a confidence interval for replacement time. Design/methodology/approach The risk-quantification approach is based on a combination of Monte Carlo simulation and Markov chain. Monte Carlo simulation whereby the wear of shovel teeth is probabilistically monitored over time is used. Findings Results show that a proper replacement strategy has potential to increase operation efficiency and the uncertainties associated with this strategy can be managed. Research limitations/implications The failure time distribution of a tooth is assumed to remain “identically distributed and independent.” Planned tooth replacements are always done when the shovel is not in operation (e.g. between a shift change). Practical implications The proposed approach can be effectively used to determine a replacement strategy, along with the level of confidence level, for preventive maintenance planning. Originality/value The originality of the paper rests on developing a novel approach to monitor wear on mining shovels probabilistically. Uncertainty associated with production targets is quantified.

Reliability, Maintainability, and Availability of Mining Drilling Equipment

“…It is therefore imperative to assess the reliability of these machines and to calculate the likelihood of their continuous operation without failures. In recent times, the reliability analysis of various types of mining equipment, including mining trucks [1,2], Load-Haul-Dump (LHD) units [3,4], shovels [5,6], draglines [7,8], and drilling machines [9,10], has been extensively explored.…”

Electric Shovel Teeth Missing Detection Method Based on Deep Learning

“…If the hard tooth enters the crusher along with the ore material, serious damage to the crusher gears and the production line is expected. At present, it is impossible to completely avoid the fracture of the tooth although many scholars have carried out a lot of research work from the aspects of the tooth mechanical analysis [ 5 ], the optimum replacement time for shovel teeth [ 6 ], the tooth material [ 7 ], and the heat treatment method [ 8 ].…”