Tire Monitor System

The mining industry in Chile has been under the media spotlight for some time but perhaps not for the best reasons. However, in the meantime, one Chilean mining support company, Bailac, has continued to grow and drive its business across South America. Bailac's expertise in tyre maintenance and management in the heavy mining industry stretches back over 85 years, and its success has increased dramatically in the last 10 years. This centres on the company's use of technology to deliver integrated services for the maintenance of off-the-road (OTR) tyres. By developing tools such as the UMAN® system, geared towards operational safety and prolonging the useful life of the tyres, Bailac has redefined the tyre service industry and forged a profile that has allowed the company to claim to be one of the best OTR maintenance companies in South America.

As industries across the world have striven for greater operating efficiencies and reduced costs, the mining industry has become increasingly sophisticated in its management of OTR tyres. There are hard commercial benefits for mine operators for monitoring tyre pressures. Tyres are a significant cost and small fluctuations in pressure and temperature can have a dramatic effect upon their working life. Benefits include a measurable increase in the useful life of the tyre, increases in the profitability of the mine because of reduced stoppages to shifts due to premature tyre failure and an increased availability of the fleet.

This desire to prolong tyre life has led to the development of UMAN, Bailac's new tyre management technology. By using internal pressure and temperature sensors, the system prevents tyres from operating outside the ranges of pressure and temperature recommended by the manufacturer, reducing damage to the tyre and maximising its useful life. The continual real-time monitoring of the pressure and temperature of the gas inside the tyre, coupled with alarms situated inside the cab or located remotely, provides warnings when a threshold value is exceeded that could indicate potential damage to the tyre and, consequently, the capacity for continuous operation of the vehicle during the shift in question. The monitoring process is displayed on an easy-to-read display inside the cab of the vehicle. It can also be displayed remotely using a WiFi-enabled PDA mobile device, and on computer screens through Intranet/Internet.

Alberto Bailac, Director of the Chile branch of Bailac San Ltd and the brains behind the UMAN concept, explains: "UMAN was developed to replace the traditional procedure for the control and monitoring of tyres, which is still in use in the vast majority of the mining companies in the world. This technique uses basic tools including manometers, and these give rise to a number of issues. Because it is a manual procedure, it cannot give warnings as soon as a tyre starts to operate in conditions that endanger its structural integrity. Control measurements are carried out daily or every few days, this time frame greatly exceeds the average time for damage to occur, which is around three hours. UMAN has been designed to provide real time monitoring of all tyres on a vehicle, including six-axle vehicles."

The testament to its efficiency is the number of mining sites that have UMAN installed. In Chile there are nine sites operating UMAN: Compañía Minera Doña Inés de Collahuasi (ANGLO AMERICAN XSTRATA), El Soldado (ANGLO AMERICAN CHILE), Mantoverde (ANGLO AMERICAN CHILE), SQM-Nva. Victoria (SQM), Minera Esperanza (ANTOFAGASTA Minerals), El Teniente (CODELCO – Corporación del Cobre de Chile), Mina Sur (CODELCO), Chuquicamata (CODELCO), Los Colorados ( Pacific Steel Company).

Within these sites, the variety and range of vehicles carrying UMAN is as varied as it is long: 34 Komatsu trucks 930E, two Komatsu loaders W900, two Caterpillar trucks 797B, seven Komatsu trucks 830E, eight Caterpillar trucks 777, nine Caterpillar trucks 785, three Le Torneau loaders L1850, four Caterpillar loaders 994 and five Toro 010 Sanvick Tamrock loaders.

Alberto Bailac continues: "The success of Bailac is down to our customers receiving a service of such a high standard that it enables them to increase their operational safety, prolong the useful life of their tyres and increase the time that their vehicles are available, and this increases the productive capacity of the mining shift in tons per hour. Another element of our value is that our customers can rely on Bailac to identify other tasks that require attention at the mine, which although these may not have a direct relationship with the extraction process, are critical activities that enable it to be carried out more efficiently."

At the heart of the UMAN system is the tyre pressure monitoring system (TPMS), which can facilitate the early detection of faults. The data provides historical analysis of the collected information (behaviour versus distances and loads, selection of tyres, maintenance schedules), and can be used to manage shift patterns and mine operations.

The UMAN TPMS includes the Tire Monitor System (TMS), which is manufactured by UK company AM Bromley. TMS delivers a solution for monitoring the internal pressure and temperature of a tyre, and Bailac relies on its quality, efficiency and effectiveness for accurate measurement of pressure and temperature in order to provide a competitive solution for the Chilean and international markets. The relationship that has blossomed between Bailac and AM Bromley is based on mutual understanding and the flexibility to react to the ongoing improvement of the product allowing new functions to support the mining customer. For that reason, in 2010, Bailac and AM Bromley signed a marketing agreement where Bailac became the exclusive distributor of its UMAN products at world level.

Rodolfo Zalavari, Project Engineer for Bailac explains: "Delivering reliable data from the tyres is key to the development and marketing of UMAN. When it came to selecting the technology provider, we found that AM Bromley had the sensors and the kit for storing information on pressure and temperature, but would it work in the mines of Chile? After conducting on-site tests, we were able to verify that TMS could be integrated into UMAN, and was able to deliver measurements under diverse environmental and operational conditions, such as operating in extreme temperatures including snow, operating at sea level and at an altitude of 5000 metres, and operating on tyres covered with steel chains. Fortunately, the R&D period was not very long – AM Bromley was the second supplier of TPMS sensors that we tried, and the results speak for themselves.”

Because the Bromley TMS sensor transmitter is mounted on the inner wall of the tyre, one of the main challenges faced was whether Bromley’s TMS receiver inside the driver's cab would be able to read the RF signals through the steel mesh in the tyres, or through tyres covered in steel chains. However, after exhaustive tests, the results were successful and the system proven to work.

"Following the successful trials and implementation, Bailac developed a new version of UMAN which was launched in October 2010. From that moment the company began an aggressive plan of consolidation and penetration of the Chilean and international markets, with the expectation that during the remainder of 2010 a total of a further 50 vehicles will be fitted with our system. In 2011 we expect to extend across a significant number of mining sites in Chile, and to consolidate international business, with a plan to penetrate mining markets such as those of Australia, South Africa, Peru, Colombia and Bolivia." added Zalavari.

The mining companies that rely on UMAN have seen positive changes in their operational management. This includes redirecting the work of maintenance staff to tasks of greater overall value and avoiding the risks of accidents when bringing samples to the site, because these are now carried out in an automatic manner by the system. The workers have an awareness at an early stage of the tyre condition that could endanger their integrity, and the companies see an increase in the performance of the tyres of at least 10%.

Alberto Bailac concludes: "Bailac is fortunate to possess a great deal of knowledge about tyres and about their usage in the heavy mining industry. Thanks to the aptitude and flexibility of AM Bromley, we have been able to develop a series of improvements aimed at the automation of current manual operations that will clearly differentiate UMAN from its competitors. Because of this, in October 2010, AM Bromley developed a new generation of sensors that correspond to the first stage of improvements agreed between the engineering departments of both companies. The future of the Tire Monitor System and UMAN, in our opinion, could progress to the point where it acts not only to gather information, but also take corrective action in real time."

Bailac has developed a substantial footprint in South America and currently has five repair and retreading plants, strategically located over the length of Chile, as well as a plant in Utah, in the USA. These plants are supported by more than 600 specialists working on-site in the mines, and this has enabled the company to service tyres and tyre-related needs of large mining companies across the regions.

Part of Bailac’s marketing strategy is to cover the majority of the Chilean market with its UMAN solution, not only providing the relevant hardware and software, but also supplying information management services for the operational and administrative areas of each mining company. On an international basis, the company is targeting mining operations in the following countries Peru, Colombia, Bolivia and Brazil, Australia, Russia and South Africa.

Singleton Birch have had Tire Monitor System (TMS) installed on their brand new Volvo L350 wheeled loader, now operational at their Lincolnshire chalk quarry, in order to improve tyre management and reduce costs of operation.

Singleton Birch took delivery of the large Volvo L350 in February direct from the new Volvo Construction Equipment facility in Immingham. Prior to its delivery to the Melton Ross quarry Earthmover Tyres (Wakefield) Limited, who have been working with Singleton Birch on tyre supply and service for the past 12 years, installed TMS to the loader whilst it was at the Volvo depot.

The Goodyear 875/65 R33 tyres on the wheeled loader were fitted with the small battery powered pressure sensors, the receiver and the operator interface were fitted inside the cab. The system provides the driver with real time information on the status of the pressures in each tyre and an alarm alerts the driver of any issues such as low pressure or high temperature.

Mark Sacker, Quarry Manager at Singleton Birch is focused on increasing productivity and reducing costs, running the new Volvo machines complete with the tyre pressure monitoring system will help ensure that the tyre pressures are kept at optimal levels.

Mark says: "There have always been issues with tyres on 4 wheel loaders, they are extremely hard working and it is critical to run them at the correct pressure to maximise tyre performance. In fact, we run the tyres at slighter higher pressure than normal, something we have found to be advantageous. The service we have received from Earthmover Tyres (Wakefield) over the years has been very good and now, with the addition of TMS, we have the complete tyre management programme."

Singleton Birch produces high calcium lime and the only natural hydraulic lime in Britain at their Melton Ross Quarries in North Lincolnshire. They have been quarrying Lincolnshire Chalk for nearly 200 years, producing up to 400,000 tonnes of lime and over one million tonnes of chalk annually, the products are supplied to many industries such as steel, building, chemical and environmental.

"We are delighted that the kit is continuing to help Singleton Birch to optimise the performance of the tyres and the loader." reported Darran Stone of Earthmover Tyres (Wakefield). "We have been the UK distributor of the TMS since May 2009 and, following the success of the Hillhead show last month, the UK is recognising the benefits of the system and we are installing an increasing number of kits. It is not just information for the drivers but also the logged data held in the system that can be used to identify any potential issues such as a machine with periods of operation with low pressure which can lead to early failure of the tyre. TMS can assist in preventative management which, in turn, can save tens of thousands of pounds."

Wakefield based Earth Mover Tyres is exhibiting the tyre pressure and temperature monitoring system TMS at Hillhead, stand R5.

The system has been well received throughout South America and has been proven in the most extreme conditions in the mines of the Atacama Desert. Monitoring the pressure and temperatures of the tires in the huge earthmoving machines is vital to the performance and safety of the tyres. TMS can help improve fuel efficiency, reduce wear and predict imminent problems, allowing companies to schedule tire maintenance – losing access to a machine because of unplanned maintenance caused by an unexpected problem with a tire can significantly affect a company’s productivity.

In the UK it has proven its worth by preventing a bearing failure in an Terex TS40 Motor Scraper. Fitted as part of a tyre management programme the alarm built into the TMS in the driver's cab sounded and the tyre pressure and temperature data downloaded from the TMS unit showed that the air temperature in the tyre was reaching the predetermined threshold and triggering the alarm. All known sources of the problem were checked but unable to identify any defect with the tyre or the system the vehicle was returned to service. The tyre monitoring system triggered the alarm once more and finally a faulty wheel bearing was identified as the cause of the tyre heating, transferring heat to the hub/rim and then causing the air temperature inside the tyre to heat up and trigger the tyre monitoring system alarm. The repair was able to be scheduled and downtime minimised.

Earthmover Tyres is a tyre maintenance and fitting company dedicated to the OTR earthmover market and who have found fitting TMS sensors both easy and quick when undertaken as part of a tyre replacement program. TMS is designed and manufactured by AM Bromley of Buxton, Derbyshire and is specifically designed for use in OTR tyres. The TMS system sends information wirelessly from a sensor inside each tyre to a receiver mounted in the vehicle. The receiver is connected to an operator interface in the cab of the vehicle to display real time information to the driver. The operator interface can also be connected to a laptop for historical data viewing and alarm configuration via TMS Manager, a PC application.

Technical advisers from A M Bromley will be on hand on stand R5 at the Registration Pavillion at Hillhead to discuss all aspects of the system.

Ferrybridge Power Station has ordered more TMS systems to be fitted to new tyres about to be fitted to their remaining Terex T40 scrapers by Earthmover Tyres of Wakefield, taking the total number of TMS sets installed at Ferrybridge to five.

Following the success of TMS in preventing the expensive downtime of one of the scrapers through an overheating bearing, which was detected by the system as an increase in temperature and pressure in the tyre, the power station operators have ordered systems to be fitted to the latest batch of tyres.

"These tyres are sourced from the US and are quite hard to find, it seemed a sensible option to fit the TMS when we fit the tyres to the scrapers. This installation will mean that all of the power station's scrapers can be monitored using TMS." explained Darran Stone of Earthmover Tyres.

A M Bromley has secured an Innovation Support Grant from East Midlands Development Agency (emda) which will enable the company to commence manufacturing their new, externally mounted tyre pressure monitoring system for numerous OTR applications.

The existing Tire Monitor System, an OTR TPMS, is proven technology and is widely used in mining and construction applications around the world. This includes the extremes conditions found in the enormous Chilean mining and quarrying industry. However, in certain circumstances it cannot be used in its current format.

Sales Director Mandy Bromley explains: “Several customers have requested an externally mounted option of the existing sensor transmitter that can be connected directly to a large bore valve for use in applications where fitting an internal sensor is not possible or practical. An example of this would be where an inner tube may be used such as tyres used on Reach Stackers.”

An effective TPMS can help decrease downtime and operating costs by giving accurate tyre pressure and temperature data. It helps improve fuel efficiency, increase tyre life and keep equipment on the move. The TPMS consists of low powered wireless transmitting pressure sensors that are installed inside the tyre and a receiver and operator interface unit mounted in the cab displaying the tyre pressures and alarms for up to six wheels. The unit also has a real time log feature so that data can be downloaded and analysed at a later date.

Mandy concludes: “Following successful trials of the prototype canister we needed to move into volume production of the external canister housing. Following several meetings with the iNets team from Loughborough University we have now been awarded a grant towards the cost of producing the mould tool that will see this new product available from June 2010”