A copper and nickel mine in Michigan’s Upper Peninsula was experiencing recurring monthly crusher blockages that led to costly downtime and repairs. The root cause was traced to a loss of visibility inside the crusher after the installation of dust control equipment. Without a clear view into the crusher, the site was forced into a reactive maintenance approach whenever blockages occurred.
The Challenge
At this mine, monthly instances of crusher blockage were creating avoidable downtime and repair costs. A recent dust control installation had reduced visibility into the crusher, making it difficult for operators to identify buildup before it became a problem.
As a result, the mine could no longer proactively monitor developing issues and instead had to respond only after a blockage had already occurred.
Why Predictive Maintenance Was Difficult
The obvious solution was to regain visibility inside the crusher so buildup could be identified early and prevented. However, implementing a camera-based monitoring system in this environment came with several major challenges.
First, the crusher area was extremely dusty and difficult to access without shutting operations down.
Second, any camera installed near the crusher would need to withstand occasional impact from debris and rock while also functioning in complete darkness.
Third, the system would need to perform reliably in extreme temperatures, including conditions as low as -40°C.
Finally, the installation area did not allow for added infrastructure such as water tanks, pumps, or routed air lines. In a high-impact environment like this, adding more hardware would have reduced reliability and increased maintenance demands.
Overcoming the Monitoring Challenge
To solve the problem, the site selected the ToughEye-3100 as the best-fit solution.
ToughEye cameras use active self-cleaning technology designed to remove abrasive dust, mud, oil, grease, and salt without requiring fluid top-ups, air supply, or routine upkeep for the life of the camera.
For this particular mining application, the chosen model also included:
- its own integrated lighting
- a powerful thermal subsystem
- the ability to operate in total darkness
- performance in temperatures down to -40°C
The camera also needed to survive possible impacts from rock and debris. ToughEye units had already demonstrated durability in punishing industrial conditions, including deployment near blast drill bits and on haul trucks, which helped support the decision. Its single-piece, standalone construction also contributed to simpler installation and improved reliability.
Implementation
ExcelSense staff provided the customer with the documentation and training needed to properly install, configure, and operate the ToughEye system.
Installation and commissioning were completed in a single afternoon.
Results
After deployment, the mine was able to identify buildup and unwanted debris before they caused clogs. This helped eliminate unscheduled maintenance and avoid unnecessary production downtime.
Primary and secondary crushers are among the most critical points in the mining process, and the cost of downtime in these areas is often extremely high. Yet these are also some of the hardest areas to visually monitor because of dust, debris, and poor visibility.
With the ToughEye system in place, the site gained a consistent, clear view of the crusher and was able to move from reactive response to more proactive monitoring. Just as importantly, the system achieved this without requiring regular maintenance or ongoing upkeep.
Conclusion
This case shows how reliable visual monitoring can play an important role in predictive maintenance, even in some of the harshest mining environments.
By restoring visibility into the crusher without adding complex support systems or maintenance burden, the site reduced the risk of blockages, prevented unnecessary downtime, and improved operational reliability.
For operations dealing with crusher buildup, poor visibility, and difficult environmental conditions, this type of rugged monitoring solution can offer a practical path to better maintenance outcomes.
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