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Design and structure optimization of a reconfigurable vibrating screen for the

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Conference Paper · June 2016

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 Design and structure optimization of a reconfigurable vibrating
screen for the mining and mineral processing industries

B. Ramatsetse1, K. Mpofu1, O. Makinde1, H.M. Campbell1, and C. Engelbrecht2

1Tshwane University of Technology

2 Vipro Vibrating Products (Pty) Ltd

Optimization of mining and mineral processing operations through the use of innovative
techniques is becoming more prominent on a daily basis. In order to achieve a required
separation of mineral particles into different sizes, appropriate technology in mining and
mineral processing equipment design is of paramount importance. Existing mineral
processing equipment is constrained by dedicated capacity. In today’s world, where
customer demand is sporadically fluctuating and changing dynamically and small-scale
mining industries are expanding rapidly, the need for appropriate cost-effective
beneficiation technologies to keep abreast with the ever-changing variations in volume is
becoming inevitable. An improved particle sizing device, called the reconfigurable
vibrating screen (RVS), has been proposed to overcome these limitations. The RVS is the
next line of beneficiation technology that was designed at Tshwane University of
Technology (TUT). This novel machine applies reconfigurable manufacturing principles
in order to ensure that varying volumes and varieties of mineral products are
beneficiated at any particular time when needed by the customers. In order to prove to
the mining community that the machine will perform effectively in industry, the RVS
machine has been designed and optimized to mimic how different mineral particle
aggregates are beneficiated into different size fractions depending on customers demand.
Three approaches were followed: (i) an industry survey and comparison of existing
conventional vibrating screens, (ii) a survey of new trends in vibrating screen machines,
and (iii) knowledge of mechanical design was used for calculations of the components of
the RVS. Stress simulation testing of the first generation of RVS machine revealed a
satisfactory performance, but this solution was, due to the control system cost of this
design, which entails hydraulic cylinders and their related power-pack, and there was a
need to optimize the design. The second generation of the RVS machine, which utilizes a
manual control system, is more cost-effective. The approach in modelling and
showcasing the use of the RVS in a closed loop system serves to demonstrate to the
mining community that the implementation and commercialization of the RVS machine
will ensure the production of varying volumes and varieties of mineral concentrates
demanded by the customers at any given time.

New technology and innovation in the Minerals Industry Colloquium

Emperors Palace, 9–10 June 2016
Southern African Institute of Mining and Metallurgy
125
INTRODUCTION

The development of vibrating screens and related methods of separation are some of the important
technology advancements in the mining and mineral processing industries. These machines are often
used to separate mineral particles into various sizes in order to meet customer requirements. They
consist of various components that ensure optimal functioning of the machine during its operation.
With the vast and ever-increasing demand for mineral particle concentrates, many manufacturers are
outlining new ways to optimize current equipment and processes in order to stay relevant to today’s
needs and requirements. There will be a direct negative influence on the mineral processing plant if
the reliability of a vibrating screen cannot meet the production requirements. Preliminary mechanical
design, medium-term manufacture, and equipment utilization are some of the factors that have been
identified as affecting the reliability of vibrating screens. This paper introduces the design and
structural optimization of the newly developed mining and mineral processing machine called the
reconfigurable vibrating screen (RVS) that can be utilized to sieve various mineral particles to
required size. Adopting ideas of reconfigurable manufacturing system (RMS) technologies originating
from Koren (2011) in the manufacturing sector, the proposed RVS is capable of responding to different
production demands in the mining and mineral processing industries. Currently, many mining and
mineral processing industries are facing the problem of fluctuating customer demand which is not
well addressed by conventional screening technologies. According to Park and Matunhire (2011),
when mineral demand changes, the actual mine production and the revenue generated are affected. A
good example of this is the recent economic downturn which started in 2008, resulting in a number of
mining operations closing down or cutting back on production. Most industries still prefer to order a
new vibrating screen machine that suits the current production requirements at a particular point in
time. Changing or replacing a vibrating screen every time the production demand changes can prove
costly and time-consuming. In order to address these problems, researchers have designed and
developed mining equipment such as portable/mobile vibrating screens that aims to eliminate the
time wasted during installation of equipment.

The RVS can be reconfigured to form a different scalable structure, depending on the demand, and
can also be reconfigured to perform different functions. Thus there is a need to optimize its
components to ensure optimal functioning during operation. Furthermore, this process of
optimization seeks to find optimum profiles and minimum weight design, subjected to von Mises
stress constraints under pressure loading. The target of this design development is to establish a
system of machine components that can be flexibly combined or reconfigured within one changeable
machine family. This will allow such machines to perfectly adapt to their applications.

The challenges that resulted due to demand fluctuations and also the techniques that are used to
optimize the mining and mineral processing machineries are discussed. The paper concludes with the
design and optimization methodologies used for the RVS and presents results acquired from the
optimization tools.

CHALLENGES THAT RESULTFROM DEMAND FLUCTUATION

Many research studies have been conducted on development of new machinery that will assist in
meeting high production targets. Often in industrial applications it is extremely difficult to design and
engineer in advance or forecast accurately how much screen area will be required to provide the
required screening action for a process flow of material (Kauffman, 1974). As innovation in mining
technology is gaining popularity, the application of reconfigurable and adaptable technologies
(Ramatsetse et al., 2015) is beginning to be accepted as one of the methods of increasing production.
Currently, similar machines are used for beneficiation of mineral particles; however, additional
problems were encountered mainly in times when the demand exceeds the throughput capability of
such machines. The challenges include breakdowns due to unforeseen contingencies which later lead
to shutdown in production. Furthermore, a problem such as installation time or replacement period
also has an effect on the production rate at which the plant can operate. To overcome these challenges,

126


Kauffman (1974) designed a mineral processing machine on modular basis so that a screen area of a
particular value may be obtained by grouping together standard size section modules in desired
numbers. The flow rates often change, as well as the type and consistency of material, and these
factors are not always accurately forecast. According to Wills (2006) high capacity and high efficiency
are often opposing requirements for any given separation operation.

Figure 1.Productivity pattern for RVS configurations.

A typical productivity pattern is shown in Figure 1; the machine needs to meet the requirement that
allows it to be changeable depending on the nature of the minerals. Furthermore, this figure illustrates
how various configuration of the machine can cater for unstable demand for products. For instance,
configuration 1 of the RVS machine, can be only produce X amount of mineral particle products, while
configuration 2 can only produce Y amount; and lastly configuration 3 of the RVS machine can only
produce Z amount in a given time interval.



 

Figure 2.Demand for mineral resources (Anon, 2006).

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Fluctuating mineral market conditions (Park and Matunhire, 2011), the high cost of purchasing and
maintaining machines (Makinde et al. 2015), as well as frequent breakdowns are some critical
problems limiting the competitiveness of mining industries globally. In addressing these problems,
the RVS machine can be reconfigured to make up production lost due to maintenance. Makinde et al.
(2016) showed how production can be recovered from a production halt due to maintenance using a
RVS machine. Figure 2 depicts a typical fluctuating mineral resource such as stone (e.g. granite) and
sand from the year 1905 to 2025 (projected). Thus there is a need for companies to think about
implementing innovations that will allow them to keep up with the ever-increasing customer
demands. The RVS machine is an effective and innovative solution to ensure that adequate amounts
of these mineral products are beneficiated to meet the demand at a reduced cost. One of the important
characteristics of the RVS is modularity, which will ensure that the machine can perform a wide range
of functions such as dry and wet screening, as shown in Figure 3.

REVIEW OF TECHNIQUES USED TO OPTIMIZE EQUIPMENT IN MINING AND MINERAL

PROCESSING INDUSTRIES

There are numerous designs of mineral processing machines, but in all these designs, the concept of
reconfigurability has not been fully investigated. One of the few studies in this field is that by
Ramatsetse et al. (2013), who developed a basic framework to assist in the development of a RVS; the
study also included the mechanisms needed for different processes or configurations. According to
Makinde et al. (2013) some mining technologies and machinery should be purchased for the purpose
of producing reconfigured or adaptable machineries of high efficiency, productivity, and adaptability.
In light of this, there are various techniques employed to optimize designs, which include, MATLAB®
optimization. Li et al. (2015) used a particle swarm optimization (PSO) algorithm to search for the
optimal parameter for a vibrating screen in order to improve the design and manufacture. Wang
(2012) used MATLAB® optimization Toolbox to establish an optimal mathematical model when
considering the productivity per unit power for a linear vibrating screen as the objective function. It
was affirmed that this tool solves practical optimization problems in initial design conveniently and
efficiently and provides new ideas in optimization design of products. Baragetti, (2015) proposed a
new structural solution for high-loaded vibrating screens, which was aimed at increasing the
structural and functional performance through modification of the mechanical system. Csizmadia et
al. (2011) determined the optimal vibration parameters of vibrating screens using analytical methods.
They further optimized the vibration parameters by firstly modelling interparticle collision on a
vibrating screen using the discrete element method. Yan et al. (2010) established a mathematical model
of linear vibrating screens when considering the minimum power consumption per unit output of the
machine using the MATLAB® optimization technology. Structural failure due to impact of material on
the screen structure must be minimized for better performance and extended screen life. Thus
predicting of the stresses before the actual application is essential for the overall analysis. According to
Mular et al. (2002), finite element analysis is the latest design technique used to analyse the distribute
on of operating stresses on screen components and structures under vibration and material loading,
and can be used to fine-tune vibrating screen designs by altering the stiffness of the screen structure in
order to minimize the modal frequency of the screen. Yue-min et al. 1999 simulated a new vibrating
screen with a hyperstatic net-beam structure using the finite element method (FEM). By optimizing
the structural stiffeners on the side plates, the structural strength was increased and the natural
frequency of bending deformation was enhanced. Nianquin et al. (2010) studied the stress distribution
of an ultra-heavy vibrating screen under static loading using the finite element analysis software
ANSYS®. The results from the study showed weakness in the structure; therefore further
improvements were incorporated to strengthen the structure and extend the life of the machine.
Similarly, Chen-Yu et al. (2011) studied the selection of the working frequency of large vibrating screen
using ANSYS® and were able to generate a theoretical guidance for selecting an acceptable working
frequency. Li et al. (2013) analysed the modal and harmonic response of the beam structure using
ANSYS®, enabling the fatigue life and reliability of the screen to be improved. Yantek et al. (2012)
conducted a study on estimating the level of sound reduction by adding rib stiffeners to weak points
of the screen structure using finite element analysis. The results showed that adding stiffeners has

128


little impact on sound level, but enhances the structural stability of the machine. Wolny et al. (2010)
used finite element analysis to obtain the state of stress distribution generated on the screen separator.
In contrast to the other studies, strain gauges installed on the screen were used to verify the stress
from the numerical analysis. All these studies indicate that the ANSYS® optimization tool can be used
to optimize the RVS machine parameters, since it incorporates robust problem-solving techniques to
enhance the results required to make improvements. The following section highlights the important
systems and subsystems of the RVS machine in order to identify the critical areas that require
optimization.

DESCRIPTION OF THE RVS MACHINE

The design relates to a new improved RVS for use in classifying materials such as bulk granular and
particulate materials and wet slurries. The RVS uses a simple theory of reconfigurability to increase its
capacity and productivity. The innovative design improves mineral particle screening through the
inbuilt geometric screen structure, which ensures alteration of the screen surface structure so that
adequate amounts of mineral concentrates can be screened even with unforeseen contingencies such
as machine downtime due to breakdown and other failures (Makinde et al.,2016). At its initial position
the RVS operates same way as the conventional vibrating screen. As the production of mineral
particles increases the screen is able to adjust itself to the required capacity. As the machine expands,
interconnected side plates slide against each other to extend outwards by means of two hydraulic
cylinders at opposite ends of the screen. At its maximum configuration the screen exceeds the
capabilities of a conventional screen with the same specifications. The RVS, also known as the multi-
functional processing machine, addresses the three most important principles of RMS –as scalability,
modularity, and integrability. The RVS is made up of major systems and subsystems, which can be
further classified into mechanical and control systems:

The frame. Is a solid structure responsible for holding all components of the screen. Its advantage is
a flexible and changeable structure that can extend or stretch and contract in the x and y directions
to ensure easy gyration of the reconfigurable vibrating screen.

Suspension system. This is attached to the main frame of the screen and its main function is to
generate the upwards and downwards isolation movement.

Side plates .These are mounted by bolts on the side of the screen frame. The side plates are
responsible for containing the mineral particles within the apertures of the screen. They are welded
to the spring supports to aid effective vibration and maintain the whole structural balance.

Screen mesh. This component is attached to the screen frame and its function is to separate different
sizes of mineral particles.

Torsion bar. This is the connecting bar between two side plates subjected to twisting stress caused by
applied torque during screen operation. The torsion bar consists of two interlinked shafts and two
coupling flanges which are bolted on each side of the screen.

Vibrating motor. This generates the vibrating motion in order to separate finer mineral particles.

There are some technical aspects that differentiate the conventional vibrating screens, such as inclined,
grizzly, horizontal, resonance, dewatering, banana, high-frequency screens, and the proposed RVS
machine. Some of the technical aspects such as the medium of separation and the operating
mechanism of conventional screens are highlighted in Table I.

129
 Table I. Types of vibrating screens used in mining and mineral processing industries (Makinde, 2015)

Type Medium of separation/operating mechanism Separation target

1 Inclined Vertical circular or elliptical vibration that is Coarse or fine mineral particles
mechanically induced by rotation of separation between 4mm – 8mm
unbalanced wheels or flywheels attached to a
single drive-shaft

2 Grizzly Grizzly gaps inclined at approximately 20° Very coarse mineral particles
and set at a fixed distance between 250mm and 500mm

3 Horizontal Linear or an elliptical vibration produced by Finer mineral particles up to 500μm

a triple-shaft vibrator

4 Resonance Dynamically balanced frame which has the Separation of finer particle sizes
same natural frequency as that of vibrating than horizontal screens
screen body.

5 Dewatering Inclined slight up-hill for dewatering wet Complete moisture removal or
particles drainage of wet mineral particles

6 Banana Linear stroke vibrator as well as variable Efficient sizing operations.

slope of around 30–40°at the feed end of the Efficiency is three to four times
machine, reducing to around 0–15° in greater than conventional vibrating
increments of 3.5–5° for effective separation screens (Meinel, 1998)
(Beerkircher, 1997)

7 Modular Multiple independent screen cloth or panel High-tonnage separation

modules arranged in series to produce a
large screen unit, which is powered using an
electric vibrator.

8 High-frequency Frequencies of up to 3600 r/m. Equipped Particle separation between 45–

with an electric motor or electrical solenoids 100μm

9 RVS Dimension can be varied depending on Separation of particles between 45–

customer demand for processed mineral 100μm, depending on the type of
particles. The length and the width of the mineral.
machine are adjustable and modular.

It is also essential to compare the productivity throughput of conventional vibrating screens with the
proposed RVS machine. At full capacity the RVS can produce the same amount of mineral
concentrates as the conventional vibrating screen. Its advantage lies in the fact that there will be no
stockpiles stored for future use, alternatively there will be no need to acquire another beneficiation
machine in the case of increased demand.

DESIGN METHODOLOGY

130


In order to design a mechanical structure for any machine, it is important to understand what is meant
by ’mechanical design’. This can be defined as ’the creative decision-making process for specifying or
creating physical devices to fulfil a stated need’. In the case of RVS, the need being addressed is the
fluctuating demand for mineral concentrate products. In light of this, the authors specified a set of
design criteria that suit the problems that the RVS is addressing. Figure 3 shows a proposed design of
a new RVS concept with its additional modules. Through configuration the concept is able to achieve
a variable production output. Additional Modules
Agitation
module
Mobility
module
Side plate
module
Control
module

Screen mesh
module

Suspension
module

Hydraulic
module
Spray
nozzles

Figure3. Schematic diagram of the proposed RVS concept and additional modules.

Table II include some of the major components of the RVS and the material specification for each
component depending on its function and application.

Table II. RVS components and material specifications.

Part No Description Quantity DRG No.-Remarks

required
1 Side plate 2 VSDS-216-610-1220-0.22-07
2 Back plate assy 2 VSDS-216-610-1220-0.22-08
3 Drive beam 1 VSDS-216-610-1220-0.22-09
4 Panel support bar 2 VSDS-216-610-1220-0.22-10
5 State 1 liner 2 VSDS-216-610-1220-0.22-11
6 Single suspension 2 VSDS-216-610-1220-0.22-12
7 Double suspension 2 VSDS-216-610-1220-0.22-13
8 Rear bolt on section state 2 assy 1 VSDS-216-610-1220-0.22-04
9 Front bolt on section state 2 assy 1 VSDS-216-610-1220-0.22-03
10 Back plate liner 2 VSDS-216-610-1220-0.22-11
11 Panels 1 MULTOTEC
12 VV10B/4 2 VENANZETTI
13 Hex bolt M12×35 LG.C/W 14 GR. 8.8
Cleveloc nut and th. washer
14 CSK. CAP screw M12×35 LG.C/W 18 GR. 8.8
Cleveloc nut and th. washer
15 Hex bolt M16×40 LG.C/W 16 GR. 8.8

131
 Cleveloc nut and th. washer
16 CSK. CAP screw M12×45 LG.C/W 4 GR. 8.8
Cleveloc nut and th. washer
17 Hex bolt M12×70 LG.C/W 8 GR. 8.8
Cleveloc nut and th. washer

DESIGN ANALYSIS

According to Uthman (2011), design analysis is the process that is carried out in order to determine all
the parameters necessary for the selection of appropriate grade and size of materials. The parameters
for major components of the machine were calculated separately using formulae from various
literature sources. . The first most important step was to determine the load carried by the suspension
due to the weight of the material flowing on the machine as shown by Equation [1]. Since the aperture
size is one of the factors that influence the efficiency of the mineral processing machine, it is very
important to determine how much aperture area that is needed to achieve a certain production
requirement. The function of the vibrating screen frame is to support all components and mainly for
supporting a series of inter-connected screen meshes which are placed on different screen decks,
where the top deck has screen panels with larger aperture sizes and lower deck panels have small
aperture sizes.

Figure 4.Schematic representation of RVS during design analysis.

Using the method employed by (Rao et al., 2014), the vibrating motor for the RVS machine was
selected, when taking into account the weight parameters of the machine and its products.

 
 [1]





The maximum load ( ) carried by each suspension is assumed to be the sum of both the product
weight () and the weight of the machine () divided by the number of suspension mounts.


 ! " 































































































































































[2]
 

132


The formula from (Gupta, 2006) has been used where A0 is the Open area expressed in percentages, LA
is Aperture length in mm and Dw is diameter of mesh wire as shown by Equation [2].


 [3]

It is essential to calculate the critical buckling load Pcr and the critical axial stress Qcr of the square
tubing bar used for designing the frame as shown by Equation [3].

 [4]

The volume (V) of the screen can also be calculated by multiplying the length (L), the breath (B) and the height
(H) of the screen as shown by Equation [4].


 [5]
!   "

To design the torsion bar, it is highly necessary to determine the angle of tilt ( ) which represent the
torque (T) applied to the torsion bar of length (l), outside diameter (D) and inside diameter (d) as
shown in Equation [5].

  [6]

Capacity ( ) is defined as the amount of mineral products a separation process can handle, and is
therefore considered important when the number and size of units needed are taken into account. FB
represents the basic capacity, while the area of the screen is express by (A) and Correlation factors is
expressed by ( ) of the machine as shown in Equation [6].

DRIVERS FOR CHANGE FROM FIRST TO SECOND-GENERATION RVS MACHINE

The need for a cost-effective solution that will be suitable for commercialization and also for market
conditions and requirements inspired the change of design from first generation to the second
generation. Development of the first-generation RVS machine focused mainly on the reconfigurability
concept, thus satisfying the characteristics of RMS as outlined by Merhabi (2012). These characteristics
include scalability, integrability, convertibility, and modularity. The second-generation machine was
inspired by the features that were incorporated in the first generation; however, in addition to these
features, the market requirements formed the basis for consideration in order to reduce the cost
drastically.

First-Generation RVS

This concept consists of two torsion bars to ensure stability of the structure during configuration. It
also uses a hydraulic mechanism to ensure the automatic extension and retraction of the screen
structure. As one screen mesh module is added, the screen area is increased and a similar
configuration can be repeated throughout the entire process. However, the construction and
maintenance costs are high, since control is by means of a hydraulic system, which is very expensive,
and also poses a risk to operators, due to the oil leakages that might arise, and finally the vibrating
motor, which also comes with a significant cost. Also, the instability of the machine at different
configurations poses a problem since the resultant motion is not in line with the centre of gravity at
different configurations.

Second-Generation RVS

The second-generation RVS concepts are less easy to configure compared to the first generation. Since
the screening is controlled by a vibrating motor while the reconfiguration is controlled manually, the
control system is relatively cheap compared to the first generation. Also, this design has fewer
complex moving parts. The major advantage is having the centre of gravity on the line of resultant

133
motor force in all size configurations, as well as balanced suspension positions in all possible screen
size configurations. The concept makes use of a different type of suspension system (Rosta
suspension). Damping is by means of natural rubber, which is inserted at each joint in the Rosta
suspension, with a natural frequency that avoids resonance during starting and stopping.

OPTIMIZATION METHODOLOGY

Optimization is a tool originating from mathematics that involves determining the minimum and the
maximum values from defined functions when subjected to a set of constraints. This tool is often used
by engineers and system designers to find set of design parameters that will yield the best possible
results. In design, optimization of machine components is a fundamental step towards a quality
product with fewer cost implications. This tool is often used to optimize vibrating screen designs,
frequency (Csizmadia et al., 2011), productivity (Wang et al., 2012), in order to allow smooth and
efficient operation. Figure 5 depicts a flow chart of a typical optimization process followed during the
design phase of the RVS machine.

Figure 5. Optimization process.

The RVS machine was optimized using ANSYS®. The process begins with a set of design variables,
which are then subjected to set of constraints to ensure validity of the model being optimized.
ANSYS® then uses the harmonic responses and stress distributions from the model, which are critical
to determine where the model will withstand those specified forces during operation. While the
constraints are not satisfactory, the design variables are changed and the procedure is repeated until
the constraints are satisfactory. Based the general knowledge of RMS, the RVS machine problems were
analysed and redesigned in an optimized fashion in order to ensure effective reconfiguration.

134


 Table III. The stress distributions of RVS machine.

Case index Design Stress distribution

First generation

  
 

Second generation

DESIGN OPTIMIZATION FOR MANUFACTURABILITY

The components of the RVS machine were further optimized for manufacturability, using design
theory and practical experience. The optimization was performed to ensure compliance with the
design for manufacturing without compromising the RVS specifications as well as customer
requirements. In design for manufacturing, design principles needs to be considered in order to
ensure that the cost to produce the RVS and the degree of difficulty during manufacturing are
minimized. The reduction of the number of parts and also the features required to produce those parts
is considered as the best possible approach to reducing the manufacturing cost of the product.

Two different design optimization approaches were taken, by defining a set of finite ‘restricted’ and
‘unrestricted’ design domains. Manufacturability of the optimized structures was considered. It is
essential to perform a post-optimization process prior to manufacturing to ensure ease of production.
Both sets of optimized solutions were then compared to ascertain whether the ‘restricted’ design
domain solution resulted in superior performance characteristics compared to the ‘unrestricted’
design domain solution, which could only be manufactured by conventional manufacturing
processes.

135
 Figure 6. Optimization results.

Potential Improvements Towards Fabrication

After assessing all the design components, it was necessary to consider design for manufacturability
of the RVS machine in order to develop an improved screen with a reasonable cost and minimal
defects. The following are some of the potential improvements that arose during the final optimization
phase

•
The suspension bracket was modified from using three structural ribs to a single rib
positioned in the middle of the suspension plate
•
The beam plate, which experienced high stress during the FEA analysis, was modified by
bending the top section at angle for more rigidity and stability
•
The machine height was also reduced significantly to allow a shift in centre of gravity
•
The beam plate was modified from being a single independent plate to being part of the beam
structural unit.

The optimization results for the RVS are shown in Table IV, and the optimal mass values of various
components are shown in Table V.

Table IV. Stress analysis values for the RVS machine.

Unloaded Granite
(Mpa) (Mpa)
Drive beam assembly 9.35 9.95
Side plate assembly 5.5 6.1
Suspension brackets 2.8 2.9
Back plate assembly 16 14.2
Stringer 9.39 15

136


 Table V. Optimal design mass values

Parameter Description Optimal

design
mass (kg)
P1 Side plate 16
P2 Back plate assy 5.2
P3 Drive beam (torsion bar) 30.9
P4 Panel support bar 2.8
P5 State 1 liner 6.6
P6 Single suspension 4
P7 Double suspension 7.8
P8 Rear bolt on section state 2 assy 15.1
P9 Front bolt on section state 2 assy 14.9
P10 Back plate liner 4
P11 Panels (screen mesh) 80
P12 VV10B/4 24
P13 Hex bolt M12×35 LG.C/W -
Clevelocnut andth. washer
P14 CSK. CAP screw M12×35 LG.C/W -
Clevelocnut andth. washer
P15 Hex bolt M16×40 LG.C/W -
Clevelocnut &th. washer
P16 CSK. CAP screw M12×45 LG.C/W -
Clevelocnut andth. washer
P17 Hex bolt M12×70 LG.C/W -
Clevelocnut andth. washer
O2 Geometrical mass C1 120.1
Geometrical mass C2 150.1
Geometrical mass C3 165.6

DETAILED COMPARISON OF THE CONVENTIONAL VIBRATING SCREEN MACHINE AND

RECONFIGURABLE VIBRATING SCREEN MACHINE

Table VI compares the productivity rates of the conventional vibrating screens and the RVS machine.
When demand increase or the current vibrating screen experiences a high production loss owing to
breakdown or maintenance, to the extent that the current production capacities of the conventional
screens (Table VI) at 40, 50, 70, 80, and 150 t/h results in under-production, most of the industries are
forced to either increase the material feed rate in order to increase the production rate of the
conventional screens or mark-up the production loss, which in most cases increase the wear rate of the
machine; or purchase another beneficiation machine that could mark-up the productivity rate of this
machine in meeting the production target, which thus increases the company’s operating cost.
However, with the RVS machine, the increased demand can be met or the production loss can be
marked-up by reconfiguring the machine. For example, if a company needs to increase production
from 594 604.8 t/a to 900 000 t/a, according to Makinde et al.(2016),’instead of the company
purchasing more vibrating screen machines to beneficiate the mineral particles to meet this demand
(which thus increases the company’s operating cost), they just need to reconfigure the RVS machine
used in their mining company from the 1st configuration with dimension 2500 mm × 1500 mm to the
5th configuration with dimension 4700mm × 2500 mm (as depicted in Table VI) for 2months, 25 days,
12 hours, 33 minutes and 13 seconds in order to meet the demand’. From another perspective, if the
vibrating motor of the RVS machine breaks down and is inoperative for 32 hours, the RVS machine is
reconfigured from its 1st configuration to the 5th configuration for 14.8 hours in order to mark-up the
production rate required to recover the production loss. Another benefit of the RVS machine over the

137
conventional screens is that the RVS machine can be switched from dry operation to wet operation by
equipping the RVS machine with water spray nozzles and water pump modules. Furthermore, screen
panel modules of aperture sizes 20, 15, 5, 2.63, 1.94, 1.24, 0.55 and 0.09mm etc. can be utilized for
screening gravel, coal, diamonds, and gold of different grain sizes depending through the geometric
transformation of these screen panel modules on the RVS machine in meeting customers’ demand.

Table VI. Comparison of conventional screens with the reconfigurable vibrating screen (RVS)

RVS Conventional
RVS Conventional
productivity vibrating screen
configurations vibrating screen
productivity
dimensions (t/h) dimensions
(mm×mm) (mm×mm) (t/h)
2500×1500 68.82 1200×3000 40
3000×1800 101.25 1500×4500 50
3500×2000 130.5 1500×4800 70
4000×2000 165 1800×5400 80
4700×2500 217.62 2100 150

CONCLUSIONS
The RVS machine represents a significant advancement in the mineral processing environment and in
future mining. The design and the optimization of this machine have been successfully completed as
presented in this paper. In the later stage of this design project we intend using very low
environmental load material to optimize the RVS machine. The reconfigurability approach will allow
the RVS machines to adapt faster and easier to any mining conditions than the conventional machines.
Utilizing this concept to the fullest extent plus designing components using rigid design rules leads to
families of modular machines built from the same pool of field-proven interchangeable components.
For small mining or processing operations, changing the entire machine every time the demand
changes will be a thing of the past. Small and medium mining industries that currently want to run
small-scale mineral concentrate production using cost-effective beneficiation will be able to afford a
small-scale and portable RVS machine at a reasonable price. Another major advantage of this
technology is that the machine can be reconfigured to perform different applications, e.g. processing of
aggregate and concentrates. The RVS includes a mechanism that can accommodate or meet any
change in production demand, in order to increase output without running the plant continuously.
Future work will include the development of the RVS prototype and performance evaluation of the
machine during operation in a real mining environment. The results from the performance evaluation
could be further compared with results from the ANSYS® software in order to further optimize the
RVS machine.

ACKNOWLEDGEMENT

The financial assistance of the Manufacturing Engineering and Related Services SETA (MerSETA),
National Research Foundation (NRF), Technology Innovation Agency (TIA), and Tshwane University
of Technology (TUT) is acknowledged. The assistance of Vipro Vibrating Products (Pty) Ltd is also
acknowledged. Opinions expressed and conclusions arrived at in this article, are those of the authors
and are not necessarily to be attributed to the institutions mentioned above.

138


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 Boitumelo Ramatsetse

Doctoral Student
Tshwane University of Technology

Mr. Ramatsetse Boitumelo is one of the emerging researchers, who currently pursuing his doctoral
studies in the department of Industrial Engineering from Tshwane University of Technology (TUT),
South Africa. He currently specializes in Mining Machinery Design. He has been opportune to write
papers related to development of reconfigurable vibrating screens, which were submitted, approved
and published in South African Institute of Industrial Engineers (SAIIE) and South African Institute of
Mining and Metallurgy (SAIMM). His experience includes working with the South African Mining
Machinery Industries, which led to coming up with then design, analysis and the development of a
novel beneficiation machine called ‘Reconfigurable Vibrating Screens’, which tends to cater for
variations in mineral demand due to change in mineral concentrates demand, which in the long run
tends to take the global mining industries to its peak due to the highly technical features that this new
machine possesses. He recently filed a provisional patent for his invention.

Prof. Khumbulani Mpofu

Research coordinator
Tshwane University of Technology

Prof. Khumbulani Mpofu is a specialist in Advanced Manufacturing, Expert Systems, Artificial

Intelligence, Robotics and Mechatronics. He is currently the Head of Department (HOD) at the
Industrial Engineering Department at Tshwane University of Technology. He already graduated
masters students and PhD students in the area of control systems, reconfigurable systems, knowledge
based systems and production systems. He is continually endeavouring to acquire unequalled
managerial acumen in both the technical and the business aspects of his engagements. Through the
experience of independent research, Prof. Mpofu has grown to have initiative, work with a team at a
local institutional level, at the national consortium level and international level this has also grown his
interpersonal skills immensely. He also established international collaborators. He is an effective
player, self-starter, systematic thinker and worker, passionate about his responsibilities, a perseverant
individual who is results oriented.

141
 Olasumbo Makinde

Doctoral Student
Tshwane University of Technology

Mr. Olasumbo Ayodeji Makinde was born in Ibadan, Oyo State, Nigeria. He completed his B-Eng.
Degree in Mining Engineering in Federal University of Technology, Akure, Nigeria in 2011 and served
his country from 2011 to 2012 in Ulysses Private College, Nigeria. During his undergraduate days, he
has being opportune to undergo field work activities in Dangote Cement Factory, Obajana, Kogi State,
Nigeria where he learnt a lot about drilling, crushing and mineral processing operations in the quarry.
He is an Associate Member of Association of Entrepreneurs and Technologist in Nigeria. He is
currently doing his PhD Degree programme at Tshwane University of Technology, Pretoria in the
department of Industrial Engineering and intends to specialize fully in Reconfigurable Manufacturing
Systems (RMS). He has written different papers circumventing around RMS in order to suggest
directions for technology and manufacturing development in South Africa.

Prof. Harold Moody Campbell

MerSETA chair
Tshwane University of Technology

Prof. Harold Campbell is a coordinator for MerSETA chair at Tshwane University of Technology. The
main focus of his duties is to “identify and support skills for technology gaps that will improve the
competitiveness and sustainability of South African manufacturing value chain”. He already
graduated Masters Students in the area of Neural Networks, Stochastic process, knowledge
management and operation management.

142


 Christie Engelbrecht

Engineering Manager
Vipro Vibrating Products (Pty) Ltd

Mr. Christie Engelbrecht is an Engineering Manager at Vipro Vibrating Products (Pty) Ltd, who
currently holds a B.Eng. Degree in Mechanical Engineering from University of Pretoria (UP). His
experience includes the design of structures for fine mechanical systems, structural analysis design of
structures for mine machinery, Engineering Management etc.

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