Tyler Calvert, Application Engineer Svendborg Brakes

Anything can happen within the depths of a mine. While safety in the mining industry has increased significantly throughout the years, mining is still an inherently dangerous and risky field – especially in the world of copper. Mitigating those risks is of upmost importance, from employee safety protocols to advancements in technology that make the equipment safer and easier to run – advancements such as soft braking systems for mine conveyors.

Soft braking systems and other technological advancements not only enhance safety, but also increase efficiency and productivity in mining operations. Additionally, continuous monitoring and maintenance of equipment plays a critical role in preventing accidents and ensuring miners’ well-being.

The Evolution of Soft Braking Systems

In 1998, Svendborg Brakes™, a Regal Rexnord® company, introduced the first generation of the popular SOBO® (SOft Braking Option) controller, a groundbreaking solution tailored to meet the specific demands of the mining industry. This initial model revolutionized the way mining conveyors operated globally, offering smooth, controlled braking that set new standards in the field. As technology and industry requirements evolved, Svendborg Brakes continued to innovate. Later versions of the SOBO controller moved from Pulse Width Modulation (PWM) to Pulse Frequency Modulation (PFM), and now a combination of both is utilized for even more precise control. These enhancements significantly improved the performance of low-torque/ low-volume hydraulic brakes and optimized oil flow. This was crucial for maintaining long controlled braking in the case of a power failure, ensuring operational safety and reliability.

The landscape of mining operations has dramatically changed over the years, with conveyor OEMs developing larger and more complex systems. These advanced conveyors are designed to deliver enhanced strength and capacity, driving the need for more sophisticated braking solutions. Mine operators now require systems that are not only faster and more intelligent but also more intuitive to use. Responding to these industry shifts, Svendborg Brakes unveiled the SOBO iQ. This system integrates cutting-edge advancements in brake technology, hydraulics, and control systems, setting a new benchmark in the industry and meeting the increasingly challenging demands of modern mining operations.

Inside the SOBO® iQ

Managing the start-up, deceleration, and stopping of heavy conveyor loads is critical. When dealing with equipment this size, safety is paramount. The mining industry focus on safety is continuing to become more and more stringent to protect both the miners and the integrity of the mine. The unique SOBO® iQ soft-braking controller is specifically designed to enhance safety and durability in mining conveyor applications. It ensures controlled start-up and braking, significantly reducing torque peaks and thereby preventing damage to both the conveyor belt and its mechanical components.

The controller adjusts the braking torque using preset speed ramps, along with real-time feedback on speed and system pressure. It offers various braking profiles tailored to different operational scenarios. Additionally, the SOBO iQ is equipped with sophisticated features such as independent overspeed monitoring, rollback prevention, and gear monitoring, all integrated within the control box.

The SOBO iQ features a dual-loop PI control (pressure/speed) with an internal pressure control loop, a first in braking systems. This advanced control mechanism adjusts pressure not just based on speed but also on deceleration, delivering just the right amount of torque for a safe, controlled stop. This system features a unique threestate digital modulation, previously unseen in braking technology, and can support up to four Hydraulic Power Units (HPUs) with defined torque sharing. For enhanced usability, the system offers remote access and a touchscreen interface for easy setup and monitoring.

The controller supports various communication ties and protocols, allowing users to effortlessly modify parameters such as defining parking sequences or presetting stop times. The SOBO system also can provide additional dynamic braking functionality. For instance, if a motor’s Variable Frequency Drive (VFD) loses control due to material overload, causing the conveyor to exceed its normal speed, the SOBO system can trigger an overspeed alarm to the main Programmable Logic Controller (PLC). The PLC can then decide whether to initiate a full SOBO stopping ramp or simply reduce the conveyor speed to normal levels, at which point the brakes would disengage automatically, allowing the conveyor to continue operation.

Given the significant hazards associated with mine conveyors, especially on long, inclined, or declined sections that are often unmanned due to their location and terrain, the installation of an intelligent soft-braking system like the SOBO iQ is essential. It manages the starting and stopping of conveyors under varying load conditions, enhancing safety and efficiency in challenging mining environments. Some key highlights of the SOBO softbraking controller include:

• Controlled braking that is independent of load and load position.
• Options for braking based on time, distance, or deceleration.
• Adjustable brake ramps and curves.
• Compensation for variable friction factors.
• Controlled start-up.
• Real-time monitoring of brake sequence timing.
• BUS communication with customer PLC systems.
• Emergency braking functionality.

Integration of IIoT Condition

Monitoring in SOBO® Systems Svendborg Brakes™ has integrated remote IIoT and data mining technologies into its braking systems, offering a sophisticated solution that enables real-time monitoring and predictive maintenance. It is compatible with all versions of the closedloop control SOBO® systems, including the advanced SOBO® iQ. Additionally, dedicated IIoT technology allows for connectivity with alternative control systems. The necessary hardware includes the in-house developed Svendborg Brakes Gateway or the SOBO iQ braking system, paired with a high-security Cloud gateway to ensure a secure Cloud connection.

This system gathers vital data on braking operations and component status, including system pressure, the current state of the brake and its piston, as well as brake fluid level and temperature. This data is then analyzed in the Cloud, where advanced analytics assess the condition of the brakes and generate predictive insights to optimize maintenance schedules. By analyzing actual usage and wear data, the system provides early warnings for necessary servicing or component replacement.

End users can access these actionable insights through a user-friendly condition monitoring platform, offering an immediate and comprehensive view of the braking system’s status. This enables precise scheduling of maintenance activities, allowing mines to transition from preventative to predictive maintenance strategies. Such a shift significantly reduces the time and costs associated with manual inspections and maintenance, particularly beneficial in the remote and isolated locations typical of mining operations. Additionally, it enhances the service life and uptime of braking components while minimizing the risk of unexpected failures. The system also prioritizes maintenance tasks based on time criticality, further enhancing operational efficiency. Svendborg Brakes’ IIoT solution also includes security features to prevent unauthorized access or tampering with the system, such as alerts for any unauthorized attempts to open the cabinet door.

For scenarios requiring a non-permanent condition monitoring solution, such as during commissioning or troubleshooting, Svendborg Brakes also offers the Universal Control (UC) Case. This handy, lightweight case makes it easy to access data remotely, allowing technicians to step in and manage maintenance online.

The UC Case is user-friendly, designed to be operated by technicians with general training. It efficiently uploads data to the Cloud, allowing for comprehensive analysis of the braking system. This can lead to up to a 90% reduction in service costs compared to the expenses involved in dispatching technicians to the site. The UC Case effectively replicates the capabilities of a service technician onsite because there is a remote technician on the other end of it. This tool not only optimizes maintenance processes but also adds substantial value by improving service response times and reducing operational costs. The UC Case is one of many IIoT offerings from within the Regal Rexnord Perceptiv Intelligent Reliability Solutions portfolio.

From Theory to Terrain: SOBO Systems in Action in a Chilean Copper Mine

In the field, Svendborg Brakes™ SOBO® systems have been proven to handle the large daily throughputs common in mining applications, while also ensuring safety and efficiency.

In a large copper mine in Chile, Svendborg was tasked with equipping three downhill conveyors with advanced braking systems. These challenging conveyors, essential for transporting 5,000 tons of copper ore per hour, stretch up to 1600 meters in length and operate at speeds of 5.5 meters per second.

Svendborg’s solution included the robust BSFH 520 caliper disc brakes, innovative SOBO controllers, and custom-engineered hydraulic power units, capable of managing all three conveyors at once. This solution not only ensures precise and reliable stopping power but also offers controlled deceleration to prevent damage to the conveyor system. The brakes, designed to apply up to 182,160 Nm of torque, allow for a smooth and controlled stop over 50 seconds, enhancing both safety and durability. This system also includes monitoring features for critical conditions such as oil level and temperature, ensuring minimal downtime and optimal performance.

In case of power outages, the system’s emergency protocols activate automatically, stopping the conveyor within 40 seconds to protect both the equipment and its cargo. This efficient use of generated energy not only supports the mine’s operations but also contributes to its energy sustainability goals.

Reflecting on SOBO’s Impact and Vision for the Future

As part of the Regal Rexnord family, Svendborg’s leadership in controlled braking systems technology, combined with their dedicated teams of on-staff service technicians stationed in major mining centers, is unparalleled in the industry. Since its introduction in 1998, along with its evolution to the SOBO iQ, Svendborg Brakes SOBO systems offer controlled and gradual braking essential for the high loads and speeds of mining conveyors and has significantly improved safety and efficiency in the mining industry.

Globally, SOBO systems are installed on some of the largest mining conveyors, showcasing their reliability and effectiveness. These advancements support the mining industry’s shift towards more automated and optimized processes, significantly boosting productivity and safety in challenging mining environments.