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Mining Equipment Challenges
Mining equipment operates in the harshest conditions on earth. Traditional maintenance approaches can't keep up with the demands of 24/7 operations.
Extreme Downtime Costs
Primary crusher or conveyor failures can halt entire operations. Costs of $100,000-$500,000+ per hour make every minute of unplanned downtime devastating.
Harsh Operating Conditions
Extreme dust, vibration, temperature swings, and moisture destroy conventional sensors. Equipment health is often invisible until failure occurs.
Safety Risks
Equipment failures create serious safety hazards. Conveyor belt fires, haul truck brake failures, and ventilation system problems put workers at risk.
Long Lead Times
Critical mining components have 12-24 week lead times. Waiting for failure means waiting for parts while production sits idle.
Remote Locations
Mining operations are often far from service centers. Emergency repairs require flying in technicians and parts at premium costs.
Component Wear Variability
Ore hardness, moisture content, and operating conditions vary constantly. Time-based maintenance either wastes component life or misses failures.
Critical Mining Equipment Monitoring
Our AI monitors the equipment in your critical production path, providing weeks of advance warning for equipment that would otherwise fail without notice.
Crushers & Grinding Mills
Gyratory, cone, jaw crushers and SAG/ball mills. Liner wear, bearing health, gearbox condition, and structural integrity monitoring.
Conveyor Systems
Overland conveyors, in-pit systems, and stackers/reclaimers. Belt tracking, splice health, idler monitoring, and drive system analysis.
Haul Trucks & Mobile Equipment
Drivetrain, wheel motors, suspension, and brake system monitoring for haul trucks, loaders, and drill rigs.
Pumps & Slurry Systems
Dewatering pumps, slurry pumps, and tailings systems. Impeller wear, seal condition, and cavitation detection.
Mining Operation Types
Mining-Grade Specifications
- IP69 dust and water ingress protection
- -40°C to +85°C operating temperature
- 10g vibration and 100g shock resistance
- Wireless mesh for underground connectivity
Mining Operations ROI
The high cost of mining downtime means predictive maintenance delivers exceptional returns, typically paying for itself within months.
Prevent catastrophic failures in crushers, conveyors, and mills
Optimize replacement timing based on actual condition
Eliminate emergency repairs and overtime labor
Fast payback from prevented downtime events
Cost Savings Example: Copper Mine
Before Predictive Maintenance
- Annual downtime cost:$12,500,000
- Emergency repairs:$3,200,000
- Component waste:$1,800,000
- Total Annual Cost:$17,500,000
After Predictive Maintenance
- Annual downtime cost:$3,125,000
- Planned maintenance:$1,600,000
- Optimized components:$900,000
- Total Annual Cost:$5,625,000
Equipment Solutions for Mining
Explore our equipment-specific monitoring solutions used in mining operations worldwide.
Conveyor Monitoring
Belt, splice, and idler monitoring for mining conveyors
Learn more →Bearing Monitoring
Heavy-duty bearing health for crushers and mills
Learn more →Motor Monitoring
High-power motor health for mining applications
Learn more →Pump Monitoring
Slurry and dewatering pump predictive maintenance
Learn more →Transform Your Mining Maintenance
Join mining operations worldwide already preventing equipment failures and maximizing production with AI-powered predictive maintenance. Our mining specialists will assess your operation and design a custom monitoring solution.
Mining Predictive Maintenance FAQ
Common questions about AI predictive maintenance for mining operations.