Client Overview
An Australian instrumentation manufacturer specialising in real-time process analysers and automated sampling systems for the mining sector. Their technologies are used across alumina, nickel, and base metal operations, where ruggedness, uptime, and process accuracy are critical. Sampling systems are often installed in harsh environments with exposure to high humidity, abrasive slurries, and corrosive vapours.
The Challenge: Reliable Motion in Harsh Mining Process Conditions
The customer required a reliable and compact motion solution to drive linear sampling probes used for mud level profiling and slurry density measurement. The system needed to operate continuously in process areas with limited access for maintenance.
Key requirements included:
- Precise and repeatable motion for accurate depth control
- Reliable operation in high-temperature, dust-laden, and moisture-prone environments
- Integration with onboard control systems for speed, position, and diagnostics
- Low power consumption from a 24 V DC plant supply
- Minimal mechanical wear and extended service intervals
Powerbox Solution: A Compact Brushless DC Motor Drive Package
Powerbox supplied a Dunkermotoren BG series brushless DC motor, selected for its high efficiency, long brushless lifespan, and compact form factor. The motor was integrated into the sampling equipment as part of a custom drive assembly.
The motion package included:
- A high-torque brushless DC motor with integrated electronics
- A custom gearbox, engineered for continuous-duty cycles and environmental sealing
- A sealed motor housing, compliant with IP67, for protection against process dust and humidity
- Pre-assembled and tested units, supplied ready for mechanical integration and electrical connection
The Outcome: Improved Sampling Accuracy and Reduced Maintenance
The solution delivered meaningful performance improvements in a demanding mining application. With reliable, repeatable motion and a rugged brushless design, the system helped improve sampling consistency while reducing the maintenance burden typically associated with traditional alternatives.
This gave the customer a more dependable and efficient sampling solution for harsh process environments, particularly in installations where uptime, limited access, and low-voltage power requirements are key considerations.
- Improved sampling accuracy, with reliable probe control and consistent positioning
- Reduced maintenance, with brushless design eliminating service intervals associated with traditional geared motors or pneumatics
- Increased operational uptime in areas where physical access is restricted
- Lower power draw and minimal thermal footprint, ideal for use with low-voltage process power
Why Powerbox: Industrial-Grade Motion Technology with Local Support
By combining Dunkermotoren’s industrial-grade motion technology with local engineering and support, Powerbox delivered a motion solution that met the unique challenges of the mining industry.
With proven performance in demanding field conditions and full integration support, Powerbox enabled the customer to enhance sampling performance and reduce operational overhead in their analyser product line.
