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Analysis and Performance Investigation of RVS
Analysis and Performance Investigation of RVS
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Procedia CIRP 00 (2019) 000–000
Procedia CIRP 00 (2019) 000–000
ScienceDirect
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1. Introduction
Keywords: Assembly; Design method; Family identification organisation are under pressure to seek for alternative
1. Introduction organisation
beneficiation are under solution
machine pressure thatto seekwill for alternative
address these
Frequent mining machine breakdowns are limiting the beneficiation
challenges. machine solution that will address these
Frequent mining machine breakdowns
competitiveness of mining industries globally, which leads to are limiting the challenges.
1.competitiveness
Introduction
fluctuating of mining
mineral market industries
conditions globally,
[1], which
high leads
cost to of of the product range and characteristics manufactured and/or
fluctuating mineral market conditions
purchasing and maintaining machines [2-4]. Some critical [1], high cost of assembled in this system. In this context, the main challenge in
purchasing
Due to and
the maintaining
fast machines
development in [2-4].
the Some
domain critical
of
problems will be a direct negative influence on the mineral modelling and analysis is now not only to cope with single
problems
processingwill
communication plantbe ifathe
and direct negative
anreliability
ongoing influence
oftrend onscreen
the mineral
of digitization
a vibrating and
cannot products, a limited product range or existing product families,
processing
digitalization, plant if the
manufacturing reliability of
enterprisesa vibrating
are facingscreen cannot
important
meet the production requirements. Preliminary mechanical but also to be able to analyze and to compare products to define
meet themedium-term
challenges
design, production
in today’s requirements.
market environments:
manufacture, Preliminary
and equipment mechanical
a continuing
utilization new product families. It can be observed that classical existing
design,
tendency medium-term
towards manufacture,
reduction of product and equipment
development
are some of the critical activity that have been identified utilization
times and
in pilot product families are regrouped in function of clients or features.
are some
shortened of the
product critical activity
lifecycles. In that have
addition, been
there identified
is an in pilot
increasing
testing in order to improve the design and reliability of vibrating However, assembly oriented product families are hardly to find.
testing
screensinof
demand order into the
improve
customization,
used mining the
beingdesign
at the
industries.andsamereliability
Mosttime of vibrating
in
of the aexisting
global On the product family level, products differ mainly in two
screens
competition used in
with the mining
competitors industries.
all over theMost
conventional screening machines are designed for steady and world.of the
This existing
trend, main characteristics: (i) the number of components and (ii) the
conventional
which is screening
inducing the machines
development are designed
from
predictable production by various mining organisations. But macrofor steady
to and
micro type of components (e.g. mechanical, electrical, electronical).
predictable
markets, production
results in by
diminishedvariouslot mining
sizes organisations.
due
due to increase in demand for mineral particle products, mining to augmenting But Classical methodologies considering mainly single products
due to increase
product varietiesin(high-volume
demand for mineral particle products,
to low-volume production) mining
[1]. or solitary,
Fig. 1.already existing
Productivity pattern forproduct familiesindustry.
mineral processing analyze the
Fig. 1. Productivity pattern for mineral processing industry.
To cope with this augmenting variety as well as to be able to product structure on a physical level (components level) which
identify
2212-8271 possible
© 2019 The optimization
Authors. Publishedpotentials in the existing
by Elsevier B.V. causes difficulties regarding an efficient definition and
2212-8271
Peer-review©under
production 2019responsibility
system, The itAuthors. Published
is important
of tobyhave
Elsevier
the scientific B.V.of the
a precise
committee knowledge comparison
CIRP Design Conference 2019 of different product families. Addressing this
Peer-review under responsibility of the scientific committee of the CIRP Design Conference 2019
2212-8271©©2017
2212-8271 2019The
The Authors.
Authors. Published
Published by Elsevier
by Elsevier B.V. B.V.
Peer-review
Peer-review under
under responsibility
responsibility of scientific
of the the scientific committee
committee of the of theCIRP
28th CIRP Design
Design Conference
Conference 2019.
2018.
10.1016/j.procir.2019.04.180
Boitumelo Ramatsetse et al. / Procedia CIRP 84 (2019) 936–941 937
2 Author name / Procedia CIRP 00 (2019) 000–000
Authors Baragetti [5], proposed new structural solution for showed how production lost due to machine downtime and
vibrating screens, while other authors such as Csizmadia et al. failure can be recovered. Makinde et al. [3] showed how
[6], Csizmadia et al. [6], Jiang et al. [7], Li et al. [8], Li et al. production can be recovered from a production halt due to
[9], Nianqin et al. [10], Wang et al. [11], Wolny et al. [12], Yan maintenance by utilising a RVS machine in a mining industry.
et al. [13] determined optimal parameters for vibrating screens. Park and Matunhire [24] investigated factors that influence the
This study introduces the newly developed mineral processing determination of discount rate in the economic exclamation of
machinery called reconfigurable vibrating screen (RVS) that mineral development projects. Based on the analysis of
can be utilised to sieve various mineral particles to required literature, it can be noted that most developments in screening
specification as well as to deal with the fluctuation demands. machines are intended to enhance the operation and
Fig. 1 depicts a typical productivity pattern that could be performance of the machine. Some of the developments
experienced in a particular time frame in the mining industry. include combining two screening units of different drive
Thus, this paper introduces the design and structural systems to improve the efficiency and processing capacity [10].
optimization of the newly developed mining and mineral Other interesting research in this field; investigates the increase
processing machine called the reconfigurable vibrating screen of the degree of freedom of the vibrating screens, dynamic
(RVS) that can be utilized to sieve various mineral particles to analysis, parametric resonance, static & modal analysis
required sizes. This novel machine design was achieved by [25][26][27][28][29]. To date some of these aforementioned
adopting ideas of reconfigurable manufacturing system (RMS) authors have proposed novel solutions to solve problems of
technologies originating from Koren [14]. The characteristics particle size, moisture, intensity of screens, feed rate, screen
that was adopted in the design of this machine as indicated by size, which, as mentioned, are some of the factors affecting the
the research works of Mehrabi and Koren [14] are performance of the screen. Research and development in the
convertibility, scalability, modularity, integrability and area of screening machines is gradually gaining popularity in
customization. Conventional screening machines with a addressing problems faced by mineral processing industries.
dedicated screen structure produces a specific mineral The current conventional screening methods are largely based
concentrates which is equal carter for demand to account for on the demand at the time of processing, but due to uncertainty
the low peak seasons, resulting in in companies not meeting associated with the demands, these screening solutions are
their monthly and yearly production targets, thereby reducing unable to address the issue of varying demand levels. Hence, to
the their competitiveness. However, the proposed design called optimally design, prototype and commecialise the RVS
RVS machine equipped with an adjustable structure allows machine that has the potential of meeting fluctuating mineral
more production and provides larger capacity intakes as concentrate demands.
compared to its counter parts. Ramatsetse and Makinde [2], [3]
and [4] explained the important characteristics of the RVS 3. Materials and methods
machine; the most screening ensures that the machine can
perform a wide range of functions such as dry and wet The step by step process of how the study was carried out in
screening. The next section of this article presents literature order to determine the performance of the RVS machine.
carried out on the various works on screening performance and
new emerging screening technologies. Step 1: Selection of the material used for screening the RVS
machine
2. Related works on performance evaluation of vibrating Step 2: Dynamic modelling and simulation of a RVS machine
screens model using ANSYS software to establish the critical stresses
at which the RVS machine subsystems will fails when operating
Vibrating screens are understood by various mineral at the highest mineral loading conditions.
processing experts to be an effective solution to address Step 3: Fitting and connection sensors to the machine and the
separation of mineral particles into various sizes as demanded DAQ for the machine performance condition monitoring.
by the customer in mining and mineral processing industries Step 4: Analyse the results obtained from the dynamic
[15-19], but a wide gap remains between conventional modelling and experimental results.
screening machineries and their capability to respond to
fluctuating market conditions [21-23]. Despite this, current 3.1 Selection various mineral samples and description of the
conventional screening technologies such as inclined, grizzly, RVS machine
horizontal, resonance, dewatering, oscillating, banana,
modular, revolving and high frequency have already achieved The first step carried out in the RVS machine involves the
commercial success in the steady and predictive market selection of various mineral products such as granite (crushed),
conditions around the globe. In addition to this, production coal, iron ore, gold ore, chrome ore and limestone. The samples
losses owing to downtime experienced during the maintenance were collected from various mines and quarries. The properties
of conventional screening machine have also contributed to the of these minerals are depicted in Table 1. Various screen mesh
inefficiency of this machine. In addressing these problems, a sizes used on the RVS machine were collected from one of the
radical shift to introduce new technological solutions that will leading suppliers known as Multo-tec. The authors specified a
be able to deal with ever change market condition is required set of design criteria that suit the problems that the RVS is
in the mining and mineral processing industries. To date, addressing. Fig. 2 shows a proposed materials and methods
various authors have proposed various strategies and ideas that used for the RVS machine performance evaluation.
938 Boitumelo Ramatsetse et al. / Procedia CIRP 84 (2019) 936–941
Author name / Procedia CIRP 00 (2019) 000–000 3
3.2.4 Applying Constraints machine which include in the overall assembly of the RVS
machine structure such as bolts, motors and suspension units
Without constraints, the model is free to float in space and on the model developed. This simplification could be achieved
there would be no deflections in the model. Therefore, a model by representing the motor with a point mass, while the bolts
is required to be constrained so that it is allowed to deform, but and suspension units can be represented by mathematical
restricted from a rigid body motion in any of the coordinate equations that depict the nature of the function on the structure
directions. Another important step is the simplification and as shown in Fig. 3.
ease of representation of off-the-shelf components used on the
Fig. 4. Methodology for performing the stress analysis on the RVS machine.
3.3 Experimental procedure for the determining the Fig. 5 below present a schematic diagram of the
performance of RVS machine experimental set-up consisting with the different materials used
for this study.
This section presents experimental work carried out during
the performance evaluation of the RVS machine prototype. A
16-channel module analyser, was used to capture the signal RVS Feeder
responses via sensors during the operation. Furthermore, the Machine
paper established different parameter of interest under different Stock pile
working conditions using laboratory experiments. The step by
step procedure used to carry out the experiments is presented Sensors
below.
Step 1: Selection of the material and devices needed for the Screened PC& DAQ
experiment. product system
Step 2: Perform sample characterisation and preparation.
Step 3: Fitting and connection sensors to the machine and the
DAQ for the machine performance condition monitoring.
Step 4: Feed the crushed mineral particle products on the
surface of the screen and time the process accordingly.
Step 5: Analyse the results captured through the DAQ device Fig. 5. Experimental set-up for RVS machine performance evaluation
and analyse the stress values recorded over time.
940 Boitumelo Ramatsetse et al. / Procedia CIRP 84 (2019) 936–941
Author name / Procedia CIRP 00 (2019) 000–000 5
4. Results and discussions of the stresses acting on the 4.3 Comparative analysis between FEA and experimental
various subsystems of the RVS machine results
The need for such structural improvements is closely In this section, the theoretical and experimental stress
associated with the type of loads imposed to that particular area distribution values are compared to each other as shown in
of interest as well as the application there of. The results imply Table 4. Any significant and minor deviations are discussed in
that stress concentration may arise on the interfaces of the side order to determine the source that lead to the changes.
plates and may further spread to other area of the RVS machine Regardless of the side plates showing the highest stress
structure if used continuously during screening. Thus, concentrations compared to other RVS machine subsystems,
interventions are required to avert these issues from occurring. the drive beam assembly is still considered the core of the RVS
The next section presents the results of the critical threshold machine systems, due to the fact that it holds the rest of the
obtained from the FEA analysis. structure in a stable position and holds the drive excitation
motors which ensure efficient movement of particles across the
4.1 Results of the critical stress thresholds obtained from the surface of the screen.
dynamic simulation analysis
Table 4. Comparative analysis of simulated stress vs experimental results
For the 1st RVS machine configuration, the maximum stress RVS machine subsystem Experimental stress Stress simulations
of 16 MPa was experienced by the back plate assembly, (MPa) (MPa)
followed by the stringer with the maximum stress of 15 MPa Subsystem I 3.9 4.5
when the machine is loaded with granite. On the other hand, for Subsystem II 16 16.4
the 2nd RVS machine configuration, the maximum stress of 24
Subsystem III 40 21.2
MPa was experienced by the side plate assembly when iron ore
is loaded, in addition the same side plate assembly showed Subsystem IV 12 15.6
maximum stress of 21.7 MPa when the machine is loaded with Subsystem V 15 8.0
gold ore. Lastly, for the 3rd RVS machine configuration, the
maximum stress of 22 MPa was experienced by the drive beam An experimental study carried out by Zhang et al. [33]
assembly when iron ore is loaded, moreover the drive beam
proved that a realistic reduced scale model of a vibrating screen
assembly again showed maximum stress of 21.8 MPa when the
machine can substitute the prototype vibrating screen for modal
same material.
testing analysis, which can provide a shortcut to structural
modification and substructure coupling analysis of the
4.2 Results of stress values using strain gauges
prototype of the large vibrating screen. In this study a
functional prototype of the RVS machine was build using
The results of the experimental study indicates that the
current stresses that the RVS machine subsystems are subjected similar specification as computed in the ANSYS ® software in
to during the granite screening operation, which are 4 3.9 MPa, order to ascertain the accuracy of the results obtained through
16 MPa, 40 MPa, 12 MPa and 15 MPa, respectively as simulation and experiments. The final prototype machine of the
determined through experiments. This implies that the RVS RVS is presented in Fig. 7.
machine will still be able to operate under normal condition and
its subsystems will not experience failure. In addition, it means
that mining machine managers should always be alert not to
over load material on the RVS machine as this would increase
the stress values beyond the critical threshold.
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