Project number
25058
Organization
Capstone Mining Corporation
Offering
ENGR498-F2024-S2025
Capstone Copper is an open pit mine that operates 24/7. It serves as a key contributor to Arizona’s copper production by processing 22 million tons of ore annually. Conveyor belts transport this ore to various phases of processing within the mine. Failure of these conveyance systems leads to excessive downtime and major economic loss. To minimize these failures, the team designed a system which will monitor the conveyor belts that deliver mined ore from the primary to a secondary crushing facility.
The team determined that the key areas of concern – the ones that produce the highest economic loss and downtime – are the belt and the driving pulleys. The team simulated the belt’s status of abnormal side travel, temperature gradients, and the quality of the belt’s surface. They then designed and built a proof-of-concept small-scale conveyor with a range sensor and an infrared temperature sensor integrated with two microcontrollers. An intuitive graphical user interface in the system allows
operators to view the real-time condition of the belt and sends an alert when conditions indicate a failure. Operators can also access a historical data log.
The team determined that the key areas of concern – the ones that produce the highest economic loss and downtime – are the belt and the driving pulleys. The team simulated the belt’s status of abnormal side travel, temperature gradients, and the quality of the belt’s surface. They then designed and built a proof-of-concept small-scale conveyor with a range sensor and an infrared temperature sensor integrated with two microcontrollers. An intuitive graphical user interface in the system allows
operators to view the real-time condition of the belt and sends an alert when conditions indicate a failure. Operators can also access a historical data log.