ACARP ACARP ACARP ACARP
Open Cut

Design and Evaluation of a Passive Structural Fatigue Gauge

Open Cut » Maintenance & Equipment

Published: October 23Project Number: C33044

Get ReportAuthor: Ian Stevenson, Carlos Gonzalez | EngAnalysis

Metal fatigue is an important consideration in the open cut coal mining industry due to the prevalence of heavy-duty machinery and harsh operating conditions intrinsic to mining operations. Cyclic loading and environmental stresses can accelerate metal fatigue, leading to premature equipment and infrastructure failures. This not only poses significant safety risks but may also result in costly repairs, operational downtime, and decreased productivity.

Typical fatigue management strategies often involve regular maintenance and inspections of equipment based on the number of hours in service. Time based scheduling of these interventions is not an optimal strategy as the number of hours in service is not necessarily representative of the damage incurred. Prioritising maintenance and inspections based on a measurement of structural fatigue presents a more efficient use of mine maintenance resources. This project aimed to develop and assess an unpowered (passive) means of quantifying mechanical fatigue in steel components and structures without requiring the use of specialised data acquisition equipment and niche technical skills.

The project produced three different fatigue gauge designs for evaluation. Each gauge variant was designed on the basis of different approaches in assessing mechanical fatigue. These include:

  • Based on the observation of crack initiation in samples with varying strain amplification factors;
  • Based on the observation of crack initiation in samples with varying notch geometries; and
  • Based on the observation of crack growth rates in a pre-cracked sample.

Unfortunately, given the limitations and caveats of passive fatigue sensor performance, this method of fatigue assessment was not considered a suitable alternative to conventional strain gauge measurement strategies.

Underground

Health and safety, productivity and environment initiatives.

Recently Completed Projects

C34019Longwall Bretby Cable Handling Monitoring With Fibre Optics

This project examined the potential of using fibre optic sensing tec...

C28028The Inclusion Of High Interest Native Plants In Mine Site Restoration Programs: Propagation, Translocation And Field Re-Introduction

This report synthesises over 10 years of ex situ and in si...

C27049Mine Machine Radar Sensor Integration

The aim of this project was to develop an integrated radar sensor an...

Underground

Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C34028Guidelines For Assessment Of Geotechnically Safe And Stable Post-Mining Landforms

The purpose of this project was to develop a guidelines document as ...

C29047Reducing Uncertainty In Long Term Void Water Quality Predictions For Final Void Management

The aim of this project was to generate new data and undertake predi...

C29048Image Based Automated Characterisation Of Waste Materials

Accurate geotechnical characterisation of mine spoils is critical to...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C26016Determining The Benefits Of Online Thickener Underflow Rheology Measurements

The aim of this project is to determine how useful the rheology meas...

C33056Modelling And Control Of Classifying Cyclones

Hydrocyclones are one of the key technologies for the classification...

C28056Surface Alloying Of Centrifuge Baskets And Sieve Bends Screen Surfaces To Increase The Service Lifetime

The main objective of this project was to improve the wear resistanc...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C33066Washability And Distribution Of Sulfur And Trace Elements For Different Size And Density Fractions Of Raw Coals

Based on the hypothesis that the levels of sulfur and other toxic tr...

C34060In-Situ Investigation Of Coke Structure Formation Under Stamp Charged Coking Conditions

Stamp charged cokemaking has emerged as an effective technique to im...

C34062Improving The Classification Of Microstructure Distribution In Coke CT Images Using Deep Learning And Lineal Path Calculations

This project builds on a number of earlier projects that have helped...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C28076Selective Absorption Of Methane By Ionic Liquids (SAMIL)

This third and final stage of this project was the culmination of a ...

C29069Low-Cost Catalyst Materials For Effective VAM Catalytic Oxidation

Application of ventilation air methane (VAM) thermal oxidiser requir...

C23052Novel Stone Dust Looping Process For Ventilation Air Methane Abatement

This multi‐phase project is concerned with the mitigation of m...

Mine Site Greenhouse Gas Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community

NERDDC

National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook

NERDDC