Specialised services can prevent unanticipated downtime
ZF’s Ralf Matke explores the impact of unexpected downtime and how specialised services can prevent it.
The mining industry faces numerous challenges, including health and safety concerns, geopolitical risks, fluctuating demand and the need for constant technological innovation. These challenges necessitate robust and reliable equipment to ensure continuous operation and minimise downtime. Industrial gearboxes in mining equipment must withstand harsh conditions and heavy loads.
The importance of specialised services
Specialised services for gearboxes are essential to address unexpected malfunctions and minimise downtime. These services include rapid damage analysis, availability of spare parts, well-trained technicians, and a global network of service points. Quick repairs or replacements help maintain mining operations’ efficiency and productivity.
Service is crucial for smooth operations in an open pit mine. Preventative maintenance and overhaul of drive units require close planning and coordination between the operator and supplier. In the event of unplanned incidents, a service organisation must respond quickly and efficiently.
Introducing ZF Industrial Drives
ZF Industrial Drives’ gearbox portfolio covers all mining applications, from raw material extraction to final processing. This includes crawler excavators, draglines and stationary equipment such as apron feeders, mills and crushers. As the only full liner for drive technology on the market, ZF Industrial Drives offers a comprehensive range of large gearboxes with torques from 100,000Nm to 7.2 million Nm.
With over 20,000 planetary gears proven in the mining industry for more than 30 years, the company has the expertise to provide reliable service. Downtime is costly for operators, with potential losses running into thousands of dollars per hour. The worst-case scenario is unplanned downtime, which requires a quick reaction and solution to avoid high costs for replacement components and production downtime.
“Service begins with the awarding of the order for a new gear,” says Mark Patzak, head of Industrial Gearbox Service in Witten. “Robustness and reliability of the new gear are top priorities for trouble-free operation of the machines, whether stationary or mobile. Experience, analyses, and feedback from the field are already flowing into the development of new generations and product updates.”
ZF is setting standards with its transmissions. The Redulus4F series features a significant increase in output torque by up to 40% to 80% compared to previous series, resulting in higher robustness and service life of the components. The same results of increased performance and robustness are evident in mobile drives.
“Despite the highest reliability and robustness in dealing with extreme conditions in mining operations, even our transmissions reach their limits,” continues Mark Patzak. “Whether unplanned or at the end of the calculated service life, competent, reliable service is essential.”
Preventative maintenance
To optimise maintenance intervals, ZF uses its proven condition monitoring system ProVID, which offers access to information on the current condition of transmission components whenever needed. Maintenance and overhauls, previously carried out according to fixed plans, are now initiated, planned and carried out variably at the best possible time. ProVID also enables early detection of possible damage, allowing for a response long before a damage event occurs. By planning a repair and providing necessary components early, unplanned downtime is avoided.
When speed is crucial
The advantage of a service organisation geared to the mining industry’s needs is evident in the case of a sudden, unexpected malfunction, where speed is crucial. Qualified contacts on-site for rapid damage analysis, worldwide short-time field service availability based on a global partner network, and well-trained service technicians on-site are basic offerings from ZF Services.
Close contacts and cooperation between the organisation onsite and specialists at headquarters enable quick repairs or even transmission replacements. Alternative repairs are carried out at ZF service points or authorised partners in the regions, equipped and certified according to ZF standards for industrial gearbox sizes.
The company uses a global gearbox pool to keep common gearboxes and spare parts in stock for the fastest delivery in the event of a failure. The components are “ready for pick-up”, guaranteeing immediate availability and minimising downtime.
A professionally reconditioned exchange gearbox is a cost-effective and ecological alternative to using a new one. The products are in “like new” condition in terms of function, reliability, and service life, giving them a second life. This commitment to sustainability and responsibility for the future is underlined by knowledge and innovations.
Reducing downtime, saving money
Today’s modern service offers more than just maintenance or replacement of a gearbox. Suppliers such as ZF bear responsibility for its products throughout their entire life cycle and beyond. Supported by modern condition monitoring and forward-looking planning, downtimes can be minimised, saving money and resources – the key to sustainable and customer-focused service.
For more information, visit: www.zf.com
