electronics

Article
Brush-Holder Integrated Load Sensor Prototype for
SAG Grinding Mill Motor
Miguel Carrasco 1, * , Francisco Álvarez 2 , Ramiro Velazquez 3 , Javier Concha 1
and Francisco Perez-Cotapos 1
1 Facultad de Ingeniería y Ciencias, Universidad Adolfo Ibañez, Av. Diagonal Las Torres, 20700,
Santiago 7941169, Chile; javier.concha@edu.uai.cl (J.C.); iperez-cotapos@alumnos.uai.cl (F.P.-C.)
2 Prodin SPA, Condell 679. Providencia, Santiago 7501123, Chile; franciscoalvarez@prodin.cl
3 Facultad de Ingeniería, Universidad Panamericana, Josemaría Escrivá de Balaguer 101,
Aguascalientes 20290, Mexico; rvelazquez@up.edu.mx
* Correspondence: miguel.carrasco@uai.cl; Tel.: +56-22-331-12-69




Received: 2 October 2019; Accepted: 25 October 2019; Published: 27 October 2019


Abstract: One of the most widely used electro-mechanical systems in large-scale mining is the electric
motor. This device is employed in practically every phase of production. For this reason, it needs to be
inspected regularly to maintain maximum operability, thus avoiding unplanned stoppages. In order
to identify potential faults, regular check-ups are performed to measure the internal parameters
of the components, especially the brushes and brush-holders. Both components must be properly
aligned and calibrated to avoid electric arcs to the internal insulation of the motor. Although there
is an increasing effort to improve inspection tasks, most inspection procedures are manual, leading
to unnecessary costs in inspection time, errors in data entry, and, in extreme cases, measurement
errors. This research presents the design, development, and assessment of an integrated measurement
prototype for measuring spring tension and other key parameters in brush-holders used in electric
motors. It aims to provide the mining industry with a new, fully automatic inspection system that
will facilitate maintenance and checking. Our development research was carried out specifically
on the brush system of a SAG grinding mill motor. These machines commonly use SIEMENS
motors; however, the instrument can be easily adapted to any motor by simply changing the physical
dimensions of the prototype.

Keywords: electrical motor sensor; SAG grinding mill motor; inspection protocol; mining industry

1. Introduction
Although electric motors have been used in the mining industry for more than 75 years, it is
only in the last 15 years that large-scale mining companies have started to use systems and sensors in
their machinery for preventive maintenance, control, and management systems. The motors consist
of different parts, some of which, like the carbon brushes, require regular inspection. These conduct
the current to the motor blades, generating the magnetic field that causes the motor axle to rotate.
Despite their importance, the brushes seldom have integrated monitoring systems that allow their
state of wear to be checked, thus enabling maintenance staff to determine when they need replacing.
As far as we know, there are no automatic systems for assessing the state of the brush-holders and
the springs that maintain pressure on the brushes. These two components are vital for the correct
functioning of the motor since undue wear affects not only the brush but also the slip ring, which is a
key element of the motor and very expensive to repair. A fault in a slip ring is classified as catastrophic
as it implies dismantling the motor, which often costs millions of dollars.

Electronics 2019, 8, 1227; doi:10.3390/electronics8111227 www.mdpi.com/journal/electronics

Electronics 2019, 8, 1227 2 of 14

Unplanned stoppages in mine motors due to faults in brush systems occur periodically. Although
prediction methods have been developed based on model design and estimated parameters, there is
currently no way of accurately predicting the moment when they will fail [1–3]. Brush-holder systems
are generally referred to as black boxes because the only way of knowing what is happening inside the
machine is to stop it completely in order to check its components. To give an idea of the magnitude of the
losses, transporter belts move 4500 ton/h of ore at the cost of 0.8 USD/ton, which represents 3600 USD/h.
Stoppages on a primary belt can result in costs of approximately USD 500,000 per week. For a large
mining operation, the cost of a stoppage due to a fault in a SAG grinding mill is approximately
75,000 USD/h. This is because ore extraction and processing are done in series, meaning that a fault in
one machine will affect all subsequent processes. For this reason, the industry has sought to develop
plans to meet the need for increased environmental protection, and especially to improve its logistics,
concentrating on ensuring greater reliability in the productivity of machinery by improving equipment
availability. This is the focus of the present research.
Today, the mining industry has developed various types of sensors to detect mechanical faults,
but so far, no sensors exist for determining electrical faults in the motors used in operations, all of
which use carbon brushes for electricity transmission. Apart from this, inspection is very complicated
in many plants, leading to measurement errors due to the difficulty of positioning the measurement
devices correctly. With these circumstances in mind, this research presents an assessment of a prototype
brush-holder measurement and inspection device for electric motors that use carbon brushes for
electricity transmission.
This research presents a prototype for measuring the force exerted by the brush-holder spring on
the brush when it is inserted in its mounting, which simulates the real situation when the motor is
functioning. The device works with multiple integrated electronic and mechanical elements, together
with a monitoring system that allows the inspector to evaluate in situ whether the variables measured
comply with the manufacturer’s control standards or are outside the permitted range. In summary,
this research focuses on two main problems related with the brush-holder spring: (1) Brush spring
tension measurement; (2) inspector report generation by uploading this information to a mobile
application. Our proposed solution is not intended to act while the motor is functioning. Instead, it is
meant to assist the inspection process and facilitate the inspector’s work when checking the motor’s
parameters. In a high-risk environment like mining, inspection is a critical task since it ensures that
machinery and processes function correctly within standardized limits.

1.1. Technical Background

Recently, there has been a considerable increase in the use of sensors to detect mechanical faults in
mine equipment, and these have led to an enormous reduction in the number of catastrophic failures
in high-stress parts of static machinery. This has been achieved thanks to the miniaturization of
electronics. Nowadays, many mine process machines are now fitted with sensors to measure variables
such as temperature, vibrations, mechanical stresses, pressure, etc., in order to establish a control panel
that will indicate, to some extent, how the machine is working [4–7].
It should be noted that high power electric motors are found in all stages of ore transport and
processing, driving the machinery involved. This machinery includes loading shovels, off-road trucks,
transporter belts, grinding mills, crushers, etc., which are all electrically powered for reasons of their
size and application. The functioning of an electric motor requires the transmission of the electrical
current to the internal coils, where the magnetic fields are generated that cause the motor axle to rotate.
Carbon brushes are used to transmit the current from the fixed to the rotating parts through a slip ring
system (Figure 1a).
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Pressure
Wear
M+E

Mechanical

Pe
Electrical

3:2
SCALE
We Wear

(a) (b)
Figure 1. (a) Brush-holder and its components; (b) model for mechanical wear versus spring pressure.
94 Figure 1. (a) Brush-holder and its components; (b) model for mechanical wear versus spring pressure.
Although the brushes are considered to be wear-out elements and are tiny parts of the motor, the
95 In general, motors can only be inspected when they are stopped. The only way of assessing the
absence or malfunctioning of a brush will cause the motor to stop. These faults may occur, for example,
96 state of the brushes and other parts of the motor is by physical inspection carried out in situ by an
due to accelerated wear of the brushes, incorrect contact pressure, or non-uniform distribution of the
97 operator. Normally, inspection requires the use of various measuring instruments. For example, a
current, resulting in high temperatures, electric arcs, and damage to the internal insulation of the
98 dynamometer is used to measure the pressure of the brush spring, an internal caliper to take the
motor [8,9]. The continued existence of one of these anomalous situations may lead to a catastrophic
99 internal axial measurements of the brush-holder, and an external caliper to measure the length of the
failure of the motor, and consequently, to substantial economic losses.
100 brush. Although these measurements are important, the pressure of the brush mounting is
In general, motors can only be inspected when they are stopped. The only way of assessing
101 fundamental as it is related to the friction of the brush on the slip ring. Too high pressure will
the state of the brushes and other parts of the motor is by physical inspection carried out in situ by
102 accelerate the mechanical wear of the brush, while too low pressure will result in electric arcs,
an operator. Normally, inspection requires the use of various measuring instruments. For example,
103 producing a rapid deterioration of the electrical components in the ring, the brush, and even the
a dynamometer is used to measure the pressure of the brush spring, an internal caliper to take
104 brush-holder [8]. Correct measurement allows the inspector to check that the parameters of the
the internal axial measurements of the brush-holder, and an external caliper to measure the length
105 various pressure mechanisms are within the recommended ranges to produce uniform wear of the
of the brush. Although these measurements are important, the pressure of the brush mounting is
106 carbon brush, and therefore comply with the ranges established for maintenance programs. In
fundamental as it is related to the friction of the brush on the slip ring. Too high pressure will accelerate
107 general, the maintenance plan aims to find an optimum point at the intersection of the pressure and
the mechanical wear of the brush, while too low pressure will result in electric arcs, producing a rapid
108 wear curves for the contact point of the brush (We, Pe) (Figure 1b).
deterioration of the electrical components in the ring, the brush, and even the brush-holder [8]. Correct
measurement allows the inspector to check that the parameters of the various pressure mechanisms are
109 1.2. Existing Inspection Process
within the recommended ranges to produce uniform wear of the carbon brush, and therefore comply
110 withThe existing
the rangesinspection
establishedprocess is generally
for maintenance carried out
programs. Inby a teamthe
general, of two or more highly
maintenance qualified
plan aims to find
111 human operators,
an optimum due
point to the
at the high risk of the
intersection death in the and
pressure event of incorrect
wear curves foroperation and/or
the contact pointpermanent
of the brush
112 damage
(We , Peto the plant
) (Figure [9]. The job typically consists of adjusting the brush-holders and measuring the
1b).
113 spring tension. In order to do this, the motor must be stopped, blocked, and disconnected from the
114 1.2. Existing
power source. Inspection Process
This requires the inspection staff to block the control panel with padlocks, known as
115 LOTO-blocking [10], to ensure
The existing inspection processmaximum control of
is generally the machine
carried out by aandteamavoid
of two accidents.
or more highly qualified
116 human operators, due to the high risk of death in the event of incorrect operationby
Because of the danger for the plant, access to the motor requires strict control the operators.
and/or permanent
117 Only the items necessary for the inspection can be taken into the machine, and
damage to the plant [9]. The job typically consists of adjusting the brush-holders and measuring an inventory is takenthe
118 before
springentry andInafter
tension. orderexit.
to doLosing anything
this, the motor must insidebethe motorblocked,
stopped, can extend the inspection
and disconnected and
from the
119 maintenance time because nothing must be left inside, especially objects that may
power source. This requires the inspection staff to block the control panel with padlocks, known as affect the internal
120 parts such as coils[10],
LOTO-blocking andto rings,
ensurewhich are very
maximum difficult
control to machine
of the remove. andTo avoid
avoiddropping
accidents.or losing any
121 equipment,
Becausethe of
operator usually
the danger for keeps all his
the plant, toolstoattached
access the motorto his wrist by
requires a lanyard.
strict control by the operators.
122 Only the items necessary for the inspection can be taken into the machine, and(1)
Inspection and/or maintenance are usually divided into three stages: Measuringis and
an inventory taken
123 changing brushes, (2) regulation of the brush-holder(s), and (3) measuring
before entry and after exit. Losing anything inside the motor can extend the inspection and the working tension of the
maintenance
124 brush springs. The parameters generally measured are the pressure exerted on the brushes by the
Electronics 2019, 8, 1227 4 of 14

time because nothing must be left inside, especially objects that may affect the internal parts such as
coils and rings, which are very difficult to remove. To avoid dropping or losing any equipment, the
operator usually keeps all his tools attached to his wrist by a lanyard.
Inspection and/or maintenance are usually divided into three stages: (1) Measuring and changing
brushes, (2) regulation of the brush-holder(s), and (3) measuring the working tension of the brush
springs. The parameters generally measured are the pressure exerted on the brushes by the spring
mechanism, the internal measurements of the brush-holder, and the state of the slip ring. From this
information, together with a visual inspection, the inspector produces a report on the state of the motor.
If there is any parameter that does not conform to the standards, the part is changed, or the assembly
is regulated.
The measurement protocol used today includes paper forms for recording the measurements of
each part inspected. Unfortunately, this process is slow, complicated, and subject to errors because
it places a high burden on the human operator in terms of information collection and recording,
leading to possible errors in measurement, reading, or even data entry into the form. Furthermore,
these formal inspection plans generally refer to major maintenance, and it is therefore difficult to design
a mechanism for assessing the state of the machine over time. A historical record of the data could
help in designing models for fault prevention and traceability control [11,12].

1.3. SAG Grinding Mills

The electric motors used in SAG grinding mills are enormous. They possess multiple contact
points since they have to drive very heavy machinery that is around 12 m in diameter and a capacity
bigger than 100,000 tpd (ton per day) [13]. To do this, they use a combination of brush-holder pairs,
each with independent springs distributed in different chambers around the mill. Each contact point
corresponds to a different phase of the motor when current is transmitted from the brushes to the
coils, and each must be inspected, photographed, and calibrated if necessary. Due to the large size
and physical dimensions of the motor, and the confined spaces in which maintenance is carried out,
the time required for inspection is increased by the need for the operator to move about inside the
structure in each phase of the process
Although the brushes depend on the configuration of the motor, the industry typically uses
brushes configured in pairs. The dimensions of the brushes of the SAG grinding mill used in this
research are 50.00 × 25.00 × 16.00 mm. They must be subject to a constant pressure of 7.84 N/cm2 ±
0.05 N/cm2 . Because of the small dimensions of the brushes and brush-holders, and the spaces in the
inspection chamber, proper use of measuring instruments becomes a complex task, subject to errors in
handling and operation.

2. Materials and Methods

To address the problems described above, this research presents the development of a new
integrated monitoring instrument with a control software prototype. Specifically, we present a new
sensor to measure the force applied by the spring mechanism, combined with a wireless caliper for
taking the axial measurement of the mounting. The process is orchestrated by a control software that is
already used for inspecting a motor with brushes of equivalent dimensions to those used in the SAG
grinding mill (Figure 2a). The process is controlled by a mobile application that is implemented in App
Inventor [14], which collects the information from the sensors by wireless connection and stores the
data for each inspection point in a phase called the “online process”. There is also an automatic report
generation process (ARG), designed as a desk application, that uses the stored information to generate
a report from the automatically read data.
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Brush-holder
Brush-holder

Carbon
Carbon

Slipring
Slip ringsystem
system

(a)
(a) (b)
(b)

164
164
Figure 2.2.(a)
Figure2.
Figure
Brush
(a)Brush
(a)
arrangement
Brusharrangement in
arrangementin the
inthe motor
themotor of aa SAG
motorof
of SAG grinding
grinding mill,
a SAG grinding
mill,Codelco,
Codelco,Chile,
mill, Codelco,
Chile, (b)SAG
Chile, (b)
SAG grinding
(b) SAGgrinding
grinding
165
165
mill CODELCO,
millCODELCO,
mill CODELCO,Chile.Chile.
Chile.

166 Various small-sized

Varioussmall-sized components
small-sizedcomponents
components were were designed
were designed
designed and and integrated
and integrated
integrated to to create the
the system. They They are
166 Various to create
create the system.
system. They are are
167 incorporated
incorporated in
in aa sensor
sensor thatthatisisinserted
insertedinin the
the brush
brush mounting
mounting in in brush-holder
the the brush-holder of theofmotor.
the motor.
The
167 incorporated in a sensor that is inserted in the brush mounting in the brush-holder of the motor. The
The proposed system
168
168 proposed
proposed system
system hashas
has
transmission
transmission
transmission
modules,
modules,
modules,
sensors,
sensors,
sensors, and
and
and a battery
aa battery
battery system toallow
system
system to
allow efficientsensor
to allow efficient
sensor
efficient sensor
169
169
charging/discharging.
charging/discharging. Below, Below,we we present
present the
the details
details ofof each
each of of the
the application’s
application’s sub-systems
charging/discharging. Below, we present the details of each of the application’s sub-systems and the
sub-systemsand andthethe
170
170
new automation protocol with its
new automation protocol with its components.
new automation protocol with its components.
components.

171 2.1.
2.1.Starting
StartingthetheMobile
Mobile Application
Application andand Visual
Visual Record
Record
171 2.1. Starting the Mobile Application and Visual Record
172 The
Themobile
mobile application
application (APM)
(APM) has has been
been designed
designed to to facilitate information collection
facilitate information collection during
during
172 The mobile
inspections. It application
stores the values(APM)
and has been
sends them designed
directly totothefacilitate
APM, information
which allows collection
the user to during
control
173 inspections. It stores the values and sends them directly to the APM, which allows the user to control
173 inspections.
all the It stores
sensors. The the values
first process andof sends
the them directly
application is thetouser
the APM,
openingwhichthe allows
software. the The
userAPM
to control
then
174 all the sensors. The first process of the application is the user opening the software. The APM then
174 all
asksthe sensors. The first process of the application is the user opening the software. The APM then
175 asksthe
theuser
userto toread
readaaQR QRcode
code [15]
[15] located
located atat aa strategic
strategic point beside the
point beside the brush
brush mounting
mountingthat thatthethe
175 asks the user to read a QR code [15] located at a strategic point beside the brush mounting that the
176 operator is going to inspect. The data previously entered and stored in
operator is going to inspect. The data previously entered and stored in the QR code, which contains the QR code, which contains
176
177
operator
information is going
informationon onthe
to inspect.
thestation,
The data
station,mill,
mill,and
previously entered
andinspection
inspectionpoint,
point,are
andby
read
are read by
stored
the in theThis
APM.
the
QRiscode,
APM. This the
is the
which contains
starting point
starting pointfor
177
178 information
the
forinspection
on
the inspection
the station,
process, mill,
and all
process, and
and inspection
additional point,
information
all additional
are read
is incorporated
information
by the APM.
together
is incorporated
This is
with the
together
the starting point
brush-holder’s
with the brush-
178
179 for the inspection
location (Figure 3).process, and all additional information is incorporated together with the brush-
holder's location (Figure 3).
179 holder's location (Figure 3).
Bush-Holder Sensor Calliper Sensor
Online Process Activation and
Bush-Holder Sensor Activation
Calliper Sensor
Online Process sensorand
Activation
Data
and sensor
Activation
Data
reading Transmission
Data reading transmission
Data
Process sensor and sensor
reading Transmission reading transmission
Process
Data
APM mobile application platform
Data
APM mobile application platform
User
QR code Data SCA sensor Force Caliper Sensor Measurement
initialization Visual record
User reading confirmation activation visualization activation visualization
APM QR code Data SCA sensor Force Caliper Sensor Measurement
initialization Visual record
reading confirmation activation visualization activation visualization
APM

APP 1 1
Mining Company
APPUser Chuqui_1
Lecture #1 1 Lecture #1 1
Mining Company
User
test Machine 2.45#1
Lecture N/cm2 50.91#1
Lecture mm
Chuqui_1
Password
test AE201-S 2.45 N/cm2
normal 50.91 mm
-
Machine normal
******
Password
SAG
AE201-S
23E-PAR normal
+ - +
-
normal
******
Accept Read
SAG
23E-PAR
Confirm Accept Insert Save
+ Insert
- Save
+
180 Accept Read Confirm Accept Insert Save Insert Save

180
181 Figure 3. Inspection by mobile application
Figure 3. application APM.
APM.
181 Figure 3. Inspection by mobile application APM.
183 the inspection point. This information is important, especially if damaged and/or worn parts need to
184 be changed or replaced. The information is stored temporarily in the memory of the mobile device
185 and later uploaded to the cloud when an Internet connection is available. In general, the motors have
186 two or more brush-holders at the same point, so measurements of both are taken until the inspector
187 can physically
Electronics check whether the measurements are normal or out of the correct range.
2019, 8, 1227 6 of 14

188 2.2. Mounting Sensor (SCA)

Once all the above parameters have been accepted, the application asks the user to photograph
189 The mounting sensor (SCA) is made of Acrylonitrile Butadiene Styrene (ABS), simulating a real
the inspection point. This information is important, especially if damaged and/or worn parts need to
190 brush of similar dimensions and mechanical properties (density 1020 Kg/m3, elastic module: 2e+0009
be changed or replaced. The information is stored temporarily in the memory of the mobile device and
191 N/m2). Its function is to measure the force applied by the spring mechanism on the SCA when the
later uploaded to the cloud when an Internet connection is available. In general, the motors have two
192 latter is fully inserted into the brush-holder. Our prototype uses the Honeywell FSS Low Profile micro
or more brush-holders at the same point, so measurements of both are taken until the inspector can
193 sensor fitted in the head of the sensor. It makes tangential contact with the slip ring of the motor in
physically check whether the measurements are normal or out of the correct range.
194 order to sense the force exerted indirectly on the pressure spring (Figure 4).
195 The system
2.2. Mounting Sensor is (SCA)
energized when it is inserted into the mounting because it has a button that makes
196 contact with the internal walls of the brush-holder. When this happens, the micro-controller and the
197 The mounting
Bluetooth antennasensor (SCA) is made
are energized, of Acrylonitrile
allowing Butadiene Styrene
wireless communication (ABS),
between simulating
the sensor and athe
real brush of similar dimensions and mechanical properties (density 1020 Kg/m 3 , elastic module:
198 mobile device programmed with the APM. The application is provided with the antenna connection
2 Its function is to measure the force applied by the spring mechanism on the SCA when
199 2e+0009
numbers N/m to ).facilitate the process. The process is therefore transparent and direct for the user, with no
200 theneed
latter
to pair devices. into the brush-holder. Our prototype uses the Honeywell FSS Low Profile
is fully inserted
micro sensor fitted in the head of the sensor. It makes tangential contact with the slip ring of the motor
in order to sense the force exerted indirectly on the pressure spring (Figure 4).

Pressure
mechanism
Brush

Current
circulation

Brush-Holder
Spring

Slip ring

Figure 4. Diagram of the brush inside the brush-holder, in contact with the slip ring.
201
202 The system is energized
Figure 4. Diagramwhen it is
of the inserted
brush insideinto the mountinginbecause
the brush-holder, it hasthe
contact with a button that makes
slip ring.
contact with the internal walls of the brush-holder. When this happens, the micro-controller and the
203 BluetoothTheantenna
prototypeare energized,
sensor was allowing
configuredwireless
usingcommunication
the Olimexino between the sensor and the
85S micro-controller mobile
because it is
204 device
smallprogrammed with the
with low battery APM. The application
consumption (300 μA) and is provided with
can operate in the antenna
a wide connection
temperature numbers
range (−45 °C
205 to to
facilitate
+85 °C)the process.
[16]. The process
According to the flowis therefore transparent
chart of the program,and direct
shown in for the user,
Figure 5a, thewith no need to
micro-controller
206 pair devices.serial communication with the antenna and then begins to read the force sensor. The sensor
activates
207 Thethe
takes prototype
movingsensor
averagewasofconfigured
the last 100 using the Olimexino
readings every 10 85S micro-controller
ms to reduce measurementbecause errors,
it is small
since
◦ C to
208 with low battery consumption (300 µA) and can operate in a wide temperature
variations may occur at the start of the readings while the mechanical system is stabilizing (Figure range (−45
209 +855c).
◦ C) [16]. According to the flow chart of the program, shown in Figure 5a, the micro-controller

210 activates serial

Once thecommunication with the has
average measurement antenna
been and then begins
determined, theto read the
digital valueforce sensor.
is sent TheBluetooth
to the sensor
211 takes the moving
antenna average
by serial of the last 100
communication readingsestablished
previously every 10 ms to reduce
between themeasurement errors, and
mobile application sincethe
212 variations maySMD
sensor. The occurRN42
at theantenna
start of the readings
receives the while
value the mechanical
from system is stabilizing
the micro-controller and sends (Figure
it on to5c).the
 Electronics 2019, 8, x FOR PEER REVIEW 7 of 14

213 APM linked to the sensor. This process occurs through the application while the sensor is inserted in
214 the brush-holder
Electronics as often as is necessary for the operator to determine if the value found is within
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215 company’s expected tolerances (Figure 5b).

Microcontroller Lipo
Bluetooth RN42 Capacitor
Olimexino 85S Battery
module initialization
initialization
Synchro

Serial

50 mm
communication link
Olimexino

Lipo
Olimexino Processing

Charger
Sensor reading loop
Button

Bluetooth
data Bluetooth
FSS
transmission
Sensor

(a) (b)

(c)
Figure 5. (a) Data processing in the mounting sensor (SCA); (b) real prototype of SCA sensor; (c) data
216 Figure 5. (a) Data processing in the mounting sensor (SCA); (b) real prototype of SCA sensor; (c) data
processing Olimexino SCA sensor.
217 processing Olimexino SCA sensor.
Once the average measurement has been determined, the digital value is sent to the Bluetooth
218 The SCA sensor uses a Honeywell FSS force sensor, with a sensitivity of 0.1 mV/gram. This type
antenna by serial communication previously established between the mobile application and the sensor.
219 of sensor is appropriate for these applications, which require high sensitivity to small changes in the
The SMD RN42 antenna receives the value from the micro-controller and sends it on to the APM
220 force exerted longitudinally. A capacitor connected in parallel to the sensor is used to filter anomalous
linked to the sensor. This process occurs through the application while the sensor is inserted in the
221 signals generated when the sensor is inserted into the mounting. Electric power is provided by a Lipo
brush-holder as often as is necessary for the operator to determine if the value found is within the
222 110 mA battery, managed by the Sparkfun Lipo Charger Basic plate, and activated by a contact button
company’s expected tolerances (Figure 5b).
 Electronics 2019, 8, 1227 8 of 14

The SCA sensor uses a Honeywell FSS force sensor, with a sensitivity of 0.1 mV/gram. This type
of sensor is appropriate for these applications, which require high sensitivity to small changes in the
force exerted longitudinally. A capacitor connected in parallel to the sensor is used to filter anomalous
signals generated when the sensor is inserted into the mounting. Electric power is provided by a
Electronics 2019, 8, x FOR PEER REVIEW 8 of 14
Lipo 110 mA battery, managed by the Sparkfun Lipo Charger Basic plate, and activated by a contact
223 button
locatedlocated
on theon theof
side side
theofSCA
the SCA sensor.
sensor. ThisThis means
means thatthat
thethe sensor
sensor is isswitched
switchedon ononly
only when
when itit is
is
224 inserted into the mounting. With the electricity consumed by the circuit, the sensor can
inserted into the mounting. With the electricity consumed by the circuit, the sensor can operate for operate for 8 h8
225 continuously
hours continuouslybefore before
the battery is completely
the battery discharged
is completely (Figure(Figure
discharged 6). 6).

226
227 Figure 6.
Figure 6. SCA
SCA mounting
mounting sensor
sensor circuit.
circuit.

228 2.3.
2.3. Wireless Internal Caliper
229 Another
Another basic
basicphase
phaseof ofthe
theinspection
inspectionprocess
processconsists
consistsofofanalyzing
analyzing thethe internal
internalmeasurements
measurements of
230 the brush
of the mounting.
brush mounting. TheThevibrations caused
vibrations by anbyincorrect
caused gap between
an incorrect the brush
gap between and the
the brush brush-holder
and the brush-
231 cause
holderundue
cause wear
undueinwearbothin pieces, leadingleading
both pieces, to motor malfunctioning
to motor and incorrect,
malfunctioning premature
and incorrect, wear
premature
232 of the brush, mainly due to changes in its angle within the mounting. Normally,
wear of the brush, mainly due to changes in its angle within the mounting. Normally, the inspector the inspector takes
233 internal measurements
takes internal measurementsof the mounting, which must
of the mounting, whichbemustdonebefordone
each for
paireach of brushes
pair ofand recorded
brushes and
234 manually. The tolerance
recorded manually. The of the fit between
tolerance of the fitthe brush and
between the the
brushmounting
and theismounting
E10 (ISO-286),
is E10allowing
(ISO-286),a
235 maximum
allowing aplay of 0.075play
maximum mm ofbetween
0.075 mmthe pieces.
between Thistheexplains
pieces. the
Thisimportance
explains the of the precision of the
importance the
236 sensors
precision andof the
the correct
sensorshandling of instruments.
and the correct handling of instruments.
237 To
To facilitate
facilitate inspection,
inspection, we we used
used aa wireless
wireless caliper,
caliper, integrated
integrated with
with the the application
application inin the
the same
same
238 way
way as as the
the SCA
SCA sensor
sensor described
described above.
above. The Kroepling
Kroepling digital
digital internal
internal measurement
measurement caliper
caliper was
was
239 used,
used, which has has aa keyboard
keyboardthat thatallows
allowsdirect
directhandling
handlingbybythe the user
user ononthethe sensor.
sensor. TheThe procedure
procedure for
240 for taking the axial and tangential measurements of the brush-holder consists
taking the axial and tangential measurements of the brush-holder consists of inserting the caliper intoof inserting the caliper
241 into the brush-holder
the brush-holder and and pressing
pressing the OKthe button
OK buttonof theof sensor
the sensor
when when
it is itinisthe
in the
rightright position
position for
for the
242 the reading.
reading. ThisThis
allowsallows
the the inspector
inspector to to send
send thetheinformation
informationtotothe theapplication
applicationand and toto view thethe
243 permitted
permitted tolerances.
tolerances. As with the SCA sensor, sensor, this
this process
process must
mustbe be carried
carriedout outinineach
eachofofthe
themotor’s
motor's
244 brush-holders
brush-holders (Figure
(Figure 7).7)
 Electronics 2019, 8, x FOR PEER REVIEW 9 of 14
Electronics 2019, 8, 1227 9 of 14

Krœplin Caliper
Electronics 2019, 8, x FOR PEER REVIEW 9 of 14
Battery
Lipo Charger
Krœplin Caliper
Battery
Lipo Charger

USB
Caliper
USB
Caliper
HUB
HUB

LedLed Bluetooth
Bluetooth
Switch Arduino
Arduino MiniMini
Pro Pro
Switch
245 245
246 246 Figure
Figure7.7.Real
Realmodel
Real of Caliper
model of CaliperUSB
USBHub.
Hub.

247 247 The circuit

The circuit
circuit associated
associated
associated with with
with thecaliper
the the
calipercaliper enables
enables the
the application
the application
enables to the
to read
application read
to thefrom
data
read datadata
the from
the the the
instrument
from
248 248 instrument
once the user
instrument once once
acceptsthe user accepts
the accepts
the user reading.the the reading.
Wereading.
used a USBWe used a USB host
host akeyboard
We used keyboard
USB hostreader reader
to read
keyboard to read
the data
reader the data
sent
to read thebydata
the
249 sent by the caliper through a USB connection. The data are then processed by an Arduino Pro Mini
249 caliper
sent bythrough a USB
the caliper connection.
through a USBThe data are then
connection. The processed by an
data are then Arduino Pro
processed Mini
by an micro-controller
Arduino Pro Mini
250 micro-controller and retransmitted to the Bluetooth antenna. The system has a 500 mA battery, which
250 and retransmitted
micro-controller
251 andtoretransmitted
the Bluetoothtoantenna. The system
the Bluetooth antenna.hasThe
a 500 mA has
system battery,
a 500which supports
mA battery,
supports the continuous functioning of the instrument for at least 24 hours. Because it uses a LiPo
the
which
251 continuous
supports
252 functioning
thethe
battery, continuous of the instrument
system hasfunctioning
a charging and
for at
of managementleast
the instrument 24 h. Because
forand
circuit at least it uses
24 hours.
an on/off
a LiPo battery, the system
Because8) it uses a LiPo
switch (Figure
252 has a charging
battery, and management
the system has a chargingcircuit and an on/offcircuit
and management switchand
(Figure 8). switch (Figure 8)
an on/off

253
254 Figure 8. Caliper USB Host Controller and data sensor circuit.

253
254 Figure 8. Caliper
Caliper USB
USB Host
Host Controller and data sensor circuit.
 Electronics 2019, 8, 1227 10 of 14

3. Results
This section presents the assessment of the properties of the sensor and the SCA sensor calibration
Electronics 2019, 8, x FOR PEER REVIEW 10 of 14
system. A physical–mechanical analysis has been prepared to assess their application in industry.
255 The details are given below.
3. Results
256 3.1. Analysis
This sectionof Mechanical
presents the Properties
assessment of the properties of the sensor and the SCA sensor
257 calibration system. A physical–mechanical analysis has been prepared to assess their application in
In order to test whether the geometry of the sensor is sufficiently robust not to be deformed by the
258 industry. The details are given below.
stresses applied by the spring mechanism, we carried out a modal analysis using the Finite Elements
Method (FEM) [17], based on a 3D design and simulating the ABS material. The object was to show
259 3.1. Analysis of Mechanical Properties
that the SCA did not have any play in the mounting, and thus had the same measurement as a brush in
260 itsInplace.
orderTheto test whether2014
SolidWorks the geometry
Software was of the sensor
used is sufficiently
for the analysis, whichrobust not to static
included be deformed
analysisbyusing
261 the ABS
stresses applied
material. Forbythethe springwe
fixings, mechanism,
consideredwe four carried out aControl
Roller/Slip modal conditions
analysis using thewalls
for the Finitethat
262 Elements Methodwith
make contact (FEM)
the[17], based on amounting
brush-holder 3D design soandthatsimulating
movementthe was ABS material.
only possibleThe object
radial wasring,
to the
263 to show that in
as occurs thereality.
SCA did Wenotalsohave
fixedany
theplay
face in theis mounting,
that and thus
in contact with had the
the force same
sensor in ameasurement
radial direction
264 as a(details
brush in inits place.9a).
Figure The SolidWorks 2014 Software was used for the analysis, which included static
265 analysis Theusing ABS material.
external loads are For the fixings,
applied we considered
in the center of the upper four
faceRoller/Slip
of the SCA,Control conditions
distributed evenly for
over a
266 the rectangle
walls thatofmake
0.5 mm contact
by 1.5 with
mm. theThisbrush-holder
represents themounting so that
pivot contact movement
of the was onlywith
spring mechanism possible
the base
267 radial to the
of the SCA.ring,
Theasforce
occurs in reality.
applied Wecorrect
for the also fixed the face of
functioning that is in contact
a brush withdimensions,
with these the force sensor in
according
268 a radial
to thedirection (details in
manufacturer’s Figure 9a). is 7.84 N. For the meshes, we used 21,870 high order quadratic
specifications,
269 The external
elements with loads
36,446are applied
nodes. Thein the center
mesh selectedof was
the upper face of solid
the standard the SCA,mesh distributed evenly over
with four Jacobian points.
270 a rectangle of 0.5 mm by 1.5 mm. This represents the pivot contact of the spring
In this simulation, we found that the maximum deformations obtained from the analysis were mechanism with the
271 base0.003
of the
mmSCA.(FigureThe9b),
force applied
proving thatfor
thethe correct functioning
mechanical design of theofSCA a brush with these
is sufficiently dimensions,
robust not to suffer
272 according to the
significant manufacturer's
deformation while specifications,
under pressureisby7.84 theN. For the
spring meshes, we
mechanism. Weused 21,870a high
also show order
section profile
273 quadratic elements with 36,446 nodes. The mesh selected was the standard solid
of the deformations obtained from the analysis in the internal parts of the sensor, using a colored scale mesh with four
274 Jacobian points.the degree of internal displacement (Figure 9c).
to highlight

Strain constraints Finite Element Mesh Displacement

URES (mm)
Tensor 0.003

0.003

0.002

0.002

0.002

0.002

0.001

0.001

9.838e-4

7.379e-4

4.919e-4

2.460e-4

0.000e+0

(a)
Figure 9. Cont.
 Electronics 2019,
Electronics 2019, 8,
8, x1227
FOR PEER REVIEW 11 11
of of
14 14

Front view Longitudinal view Cross-Section view

URES (mm)
0.003

0.003

0.002

0.002

0.002

0.002

0.001

0.001

9.838e-4

7.379e-4

4.919e-4

2.460e-4

0.000e+0

(b)

Static deformation tensor Nodal Stress analysis

ESTRN von Mises (N/m2)

3.484e-4 9.792e+5

3.194e-4 8.976e+5

2.904e-4 8.160e+5

2.613e-4 7.344e+5

2.323e-4 6.528e+5

2.033e-4 5.712e+5

1.742e-4 4.896e+5

1.452e-4 4.080e+5

1.162e-4 3.264e+5

8.715e-5 2.449e+5

5.812e-5 1.633e+5

2.909e-5 8.168e+4

5.881e-8 9.262e+1

Scale 1030.1 Scale 1030.1

(c)

Figure 9. (a) Model restrictions and displacements generated by mechanical stresses; (b) section
275 Figure 9. (a) Model restrictions and displacements generated by mechanical stresses; (b) section
profile subject to mechanical deformations; (c) simulation of sensor deformation through FEM
276 profile subject to mechanical deformations; (c) simulation of sensor deformation through FEM modal
modal simulation.
277 simulation.
3.2. Calibration of SCA Sensor
278 In this simulation, we found that the maximum deformations obtained from the analysis were
279 0.003For
mmsensor calibration,
(Figure a mechanical
9b), proving system connected
that the mechanical design oftothe
a PCE
SCAprecision dynamometer
is sufficiently with
robust not to a
280 screen
suffer significant deformation while under pressure by the spring mechanism. We also show a sectionby
read-out was used. Because the force exerted on the sensor varies, the voltage generated
281 the SCAofsensor
profile was recordedobtained
the deformations along with
fromthethe
value measured
analysis in thebyinternal
the dynamometer.
parts of the Each reading
sensor, usingwas
a
282 taken
coloredwith a 10-s
scale pause for
to highlight each
the forceofincrement
degree to allow the sensor
internal displacement (Figurereading
9c). to stabilize. As shown in
283 3.2. Calibration of SCA Sensor
284 For sensor calibration, a mechanical system connected to a PCE precision dynamometer with a
285 screen read-out was used. Because the force exerted on the sensor varies, the voltage generated by
Electronics 2019, 8, 1227 12 of 14
286 the SCA sensor was recorded along with the value measured by the dynamometer. Each reading was
287 taken with a 10-second pause for each force increment to allow the sensor reading to stabilize. As
288 shown
Figure in10,
Figure 10, theshow
the results results show
high high precision
precision and stability
and stability in the calibration
in the calibration tests donetests done
in the in the
laboratory
289 laboratory
(R = 0.995).
2 (R2 =The0.995).
SCAThe SCA
sensor sensor
was was designed
designed to receiveto receiveload
a higher a higher load
but this butnot
does thisoccur
doesinnot occur as
practice
290 in the
practice as the forces are smaller than 15 N. Based on this result, the reading procedure
forces are smaller than 15 N. Based on this result, the reading procedure integrated into the software integrated
291 into the SCA
of the software
sensor ofconverts
the SCAthesensor
voltageconverts theusing
to a force voltage to a forceequation:
the following using thef following equation:
orce = voltage × 414.48,
292 𝑓𝑜𝑟𝑐𝑒 = 𝑣𝑜𝑙𝑡𝑎𝑔𝑒
a linear × 414.48,bya the
model generated linear model generated
least-squares method.by the least-squares method.

14
y = 414,48x
R² = 0,9953
12

10

8
Newtons

0
0 0,005 0,01 0,015 0,02 0,025 0,03
Volts
293
294 Figure
Figure 10.10. Sensor
Sensor calibration
calibration curves
curves andand
an an estimate
estimate of Force/Voltage
of Force/Voltage conversion.
conversion.
4. Discussion
295 4. Discussion
Our research presents the development of two offline motor measurement systems: (1) A wireless
296 Our research presents the development of two offline motor measurement systems: (1) A
SCA sensor that simulates a brush and has similar mechanical properties, and (2) a caliper which has
297 wireless SCA sensor that simulates a brush and has similar mechanical properties, and (2) a caliper
been fitted with a wireless transmission module. Both systems are controlled by a monitoring software
298 which has been fitted with a wireless transmission module. Both systems are controlled by a
that is operated by the inspector. It allows the spring forces and the internal measurements of the
299 monitoring software that is operated by the inspector. It allows the spring forces and the internal
brush-holder to be recorded on a mobile platform by wireless Bluetooth technology. The software
300 measurements of the brush-holder to be recorded on a mobile platform by wireless Bluetooth
assesses in real-time, whether the values recorded are outside the standard range or present normal
301 technology. The software assesses in real-time, whether the values recorded are outside the standard
parameters. Once the measurements have been collected, a report generation software is applied using
302 range or present normal parameters. Once the measurements have been collected, a report generation
the data stored over one or more days of the inspection.
303 software is applied using the data stored over one or more days of the inspection.
In order to assess the mechanical and physical capacities of the SCA sensor, the force parameters
304 In order to assess the mechanical and physical capacities of the SCA sensor, the force parameters
were measured using a mechanical system calibrated with a force sensor, and the wear and stress
305 were measured using a mechanical system calibrated with a force sensor, and the wear and stress
parameters were measured using the Finite Elements Method (FEM). The results confirm that the
306 parameters were measured using the Finite Elements Method (FEM). The results confirm that the
mechanical design of the sensor allows it to correctly measure the spring tension by indirect means since
307 mechanical design of the sensor allows it to correctly measure the spring tension by indirect means
the maximum deformation of the SCA sensor under the stress applied is 0.003 mm. The errors in spring
308 since the maximum deformation of the SCA sensor under the stress applied is 0.003 mm. The errors
tension measurement caused by elastic deformation of the component can therefore be considered
309 in spring tension measurement caused by elastic deformation of the component can therefore be
as negligible. Future research will be to design a test brush that can be used while the machine is
310 considered as negligible. Future research will be to design a test brush that can be used while the
operating to sense its internal conditions, e.g., temperature, voltage, humidity, and vibrations.
311 machine is operating to sense its internal conditions, e.g., temperature, voltage, humidity, and
312 vibrations.
5. Conclusions
Over the last five years, large-scale mining has seen a sustained reduction in profit levels worldwide.
For this reason, mining companies are developing new maintenance and control units for inspection
processes in order to avoid unplanned stoppages and catastrophic failures. Today, the industry is
Electronics 2019, 8, 1227 13 of 14

focusing more on avoiding damage to components than replacing parts and pieces in order to reduce
costs and increase the sustainability of their machinery. The inspection of electric motors is a central
point of this policy. Unfortunately, current inspection processes are inefficient because they rely on
inspector training, which is inevitably subject to human error. Motor inspections are associated with
physical, acoustic, and mechanical restrictions. This research has to be planned with extreme care,
control, accuracy, and efficiency because the loss of elements inside the motor can result in high
operating costs for the companies, in the order of 75,000 USD/h or more, depending on the nature of
the fault.
This research presents a newly developed sensor, a new inspection protocol, and a software that
orchestrates the system in order to improve the current inspection protocol in electric motors of SAG
grinding mills. The proposed system will allow for the automation of tasks that are currently done
manually, such as inspection, data collection, parameter evaluation, and report generation. The new
inspection protocol is a support tool available to the inspector that will significantly reduce human
error, increase measurement accuracy, allow online data storage, reduce inspection times, and facilitate
monitoring and control of the various components by allowing traceability of the points inspected.
This software can be incorporated as a KPI in mine management systems, since it allows managers
to assess the availability levels of machinery, and reduces maintenance times, increasing availability
for use.

Author Contributions: Conceptualization, M.C. and F.Á.; methodology, M.C.; software, J.C. and F.P.-C.; validation,
F.Á. and R.V.; formal analysis, F.Á.; investigation, M.C. and R.V.; resources, M.C., F.P.-C.; writing—original draft
preparation, M.C. and R.V.; writing—review and editing, M.C. and R.V.
Funding: This research was funded by Innova Chile, CORFO, grant number 15VIP-44025.
Conflicts of Interest: The authors declare no conflict of interest.

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