Velapulsar - IIoT Wear Monitoring, Predictive Maintenance, and Tracking in Mining Industry

Velapulsar - IIoT Wear Monitoring, Predictive Maintenance, and Tracking in Mining Industry

IoT Embedded Systems Software Development Cloud Computing Tracking Monitoring

Overview

Velapulsar is an advanced wireless sensor platform engineered to monitor the mechanical integrity of Ground Engaging Tools (GETs) used in heavy industrial equipment. Originally developed for electric-rope shovels in oil-sand mining, Velapulsar ensures real-time detection of detachment events, significantly reducing downtime, equipment damage, and associated maintenance costs.

Motivation

Ground Engaging Tools, like shovel adapters and teeth, experience severe mechanical stress, leading to potential structural failures. Detached GETs can cause extensive damage to downstream equipment, creating costly production halts. Traditional manual inspection is unreliable, necessitating an automated, sensor-based solution.

Velapulsar addresses these issues by integrating resilient wireless sensors directly within GET components, providing proactive, reliable, and continuous monitoring under extremely challenging conditions.

Core Technologies and Innovations

Rugged Wireless Sensor Nodes (SeN)

  • Robust sensor nodes embedded within metallic components (adapters and teeth).
  • Capable of withstanding harsh conditions including vibrations, mechanical shocks, extreme temperatures (−40°C to 85°C), and exposure to dirt and moisture.

Reliable Wireless Communication

  • Utilizes LoRa™ technology to establish highly resilient, low-data-rate communication links.
  • Proven effective even within non-hermetic metallic enclosures where RF signals typically face significant attenuation.

Multi-Sensor Integration

  • Combines capacitive, inductive, and magnetic force sensors to reliably detect detachment.
  • Features additional sensors such as vibration, temperature, and battery voltage monitoring, providing comprehensive data about operational health and conditions.

Real-Time Alert System

  • Upon detecting a GET detachment, the system immediately alerts equipment operators and remote monitoring stations, pinpointing the exact location of the event.

System Architecture

The Velapulsar platform consists of two primary components:

  • Sensor Node (SeN): Embedded sensors directly within the GETs, continuously collecting data.
  • Sink Node (SiN): Centralized node that communicates wirelessly with SeNs, processes data, and forwards alerts via 4G-LTE to backend monitoring systems.

Field-Validated Performance

Velapulsar has undergone extensive field validation, demonstrating:

  • 100% detection rate of complete detachment events.
  • Reliable wireless communication in operational environments (up to 25 meters with strong attenuation conditions).
  • Rugged design tolerating extreme mechanical stress and temperature fluctuations during operational tests in active mining environments.

Applications & Benefits

Velapulsar’s robust platform is ideal for various industrial sectors including:

  • Mining operations (oil sands, metal ore extraction)
  • Construction equipment monitoring
  • Agricultural machinery wear and damage detection
  • Industrial equipment reliability assessment and predictive maintenance

The technology significantly improves operational efficiency by reducing unplanned downtime, minimizing repair costs, and enhancing overall safety.

Publications and Technical Papers

  • “Wireless Sensing for Ground Engaging Tools”
    Read the Paper

  • “A Wireless Sensor Platform for Industrial Non-hermetic Metallic Enclosures”
    Read the Paper

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