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Crusher GET ejection protection

Under certain circumstances a crusher can eject ground engaging tool (GET) bits. The GET pieces can get stuck in the crusher and can be ejected under immense pressure. In some cases they only get stuck and has to be removed – see the attached link for an example of how to remove such a piece of steel

This object can then fly through the air and could seriously injure or kill anyone that happens to be in the way. To reduce this major hazard, an ejection frame can be fitted over the crusher chute. However, care should be exercised as, although the GET ejection protection frame would prevent the ejection of the GET tool, it can trap this piece of steel inside the crusher and chute and may lead to damaged equipment. For this reason the frame must be fitted with impact sensors to alert the operator of an ejection event

Dynamic Engineering Consultants recently completed such a crusher GET ejection protection frame. The example below shows a GET ejection frame for a jaw crusher.

Crusher GET ejection protection frame

In order to remove the GET items from the chute, the frame has been equipped with a hydraulic ram that will enable the frame to be opened easily. The “gate” part of the frame is also locked in place by means of hydraulically activated pins.

The above is one specific example but Dynamic Engineering Consultants can design a system that is specific to our clients application. Give us a call or contact us today to discuss your specific requirements .

Conveyor Magnet Structure

Below is an example of a conveyor magnet structure Dynamic Engineering Consultants designed for one of our mining clients. The structure accommodated a permanent, self cleaning belt magnet setup on anm existing stacker conveyor. To facilitate transport and installation, the structure was design as bolted rather than fully welded.

The conveyor magnet structure was mounted on four concrete footings and secured with chemical anchors. The structure is equipped with a chute that directs the tramp metal to a forklift-removable bin. The design complied with all the relevant Australian standards i.e. AS4100 (–4100-1998) and AS1170 (wind loading)–1170-dot-2-2002

A Conveyor Magnet Structure suspends an electro- or permanent magnet above a conveyor belt and extracts tramp metal from the ore on the belt to provide protection to downstream equipment. In most cases a conveyor may already have a magnet installed at the head end of the conveyor. However, in some cases, for various reasons, this may have been omitted. Installing a belt magnet at the head end of the conveyor is in many cases the preferred option, but may not be always possible. In some cases the head end are not being able to accommodate the higher loads from the magnet and in other cases the limited access at the head end of the conveyor would be unfavourable. In this case our client opted to install the structure on a lower part of the conveyor where it could be supported from ground level.

Do you have a similar application? Give the team at Dynamic Engineering Consultants a call today or send us and e-mail via the “contact us” page on this site We have the ability to design and draw your new structure (including shop drawings) to your exact requirements, whilst remaining compliant to the relevant australian standards.

Self cleaning permanent magnet structure

Civil and Structural Facility Audits

Dynamic Engineering Consultants performs civil and structural facility audits to help you ensure that you provide a safe working environment for your employees. These audits are typically divided into three phases: site visit, compile report and lastly individual repair procedures.

Phase 1 Site visit

The audit consists of a site visit in which our engineers do a detailed inspection of our client’s facilities. The time for the inspection depends on the size of the facilities and the severity of any problems encountered. The report and site visit is compiled by an experienced civil/structural engineer that is a Chartered member of Engineers Australia.

Site visit

Phase 2 Compile report: Outcome of civil and structural facility audits

A detailed report is compiled back at base. This report will include photos, a description the problems and will group problems together in terms of severity. The report will also provide a clear direction as to which areas must receive attention first and the time in which it should receive attention. This will give the client direction on what areas to fix first to avoid safety hazards or production loss.

Phase 3 Repair procedures

If required by our client, we will also help with the specific repair procedures for the problems encountered.

You can book civil and structural facility audits or inspections by contacting us via the details listed on our contact page.

Mill Maintenance Monorail

Dynamic Engineering Consultants can assist with your mill maintenance monorail project in accordance with AS1418. We will take care of all the civil, structural and mechanical aspects of your monorail installation project. Because of this, the final product will be tailored specifically for your application. From a cost point of view, a recent project also revealed that our project was only a fraction of the cost of our closest competitor in this area.

Dynamic Engineering Consultants can assist with:

Initial Consultation phase to determine requirements
Civil and Structural Design
3D Modelling and Drafting
Fabrication Quality Assurance

A typical design would include a discussion with the maintenance team in which their requirements are recorded and noted. After this initial consultation we can produce 3D models for discussion / approval. From there we complete the detailed structural design and drawings. The extent of the drawing range from GA drawings down to shop drawing level. This is all performed in-house.

Below are some examples of completed designed monorail systems.

mill monorail system
3D model of mill maintenance monorail system
Actual mill monorail (discharge end)
Actual mill monorail – as installed (discharge end)
Typical monorail GA drawing

For simpler (straight) monorails no 3d modelling may be required, and we can skip directly to the detail design calculations.

Contact us to discuss your specific needs. To see how we can assist you with your maintenance needs, visit our Maintenance page.

Load Rating of Equipment and Structures

Sometimes there is a need to retrospectively certify existing structures or equipment. This is done by determining their load rating and Dynamic Engineering Consultants can assist you to do this. In broad terms, the procedure to do this is broken up in the following steps:

  1. Measure up existing structure or model from drawings
  2. Determine grade of materials of construction
  3. Model in 3D or use SPACE GASS structural analysis
  4. Apply loads and load cases in accordance with the relevant Australian Standard. Latest versions of the Australians can be purchased here.
  5. Iteratively calculate the load that would lead to compliance with the standards
  6. Record load rating in a calculation report
  7. Perform actual load testing if required
  8. Provide nameplate/marking of structure.

Examples of structures on which Dynamic Engineering have applied this process are: monorail structures, maintenance stands, job cranes, platforms, winches etc.

Below a fabricated welding rotating jig is shown. The next picture shows the 3D model, ready to be analysed with Finite Element Analysis by applying loads and constraints to find the highest stresses and deflections.

Load roller frame
Welding Rotation Jig
Rotating Welding Jig MOdel
Welding Rotation Jig 7.5T

Do you have similar equipment which needs to be certified? Please contact us to discuss how we can assist you. If you like to know more about our certification services, please click here.

Modular Minesite Washbay Vehicle Ramp Design

Dynamic Engineering Consultants recently completed a 5T capacity Modular Minesite Washbay Vehicle Ramp Design for one of our clients. The client requirements were:

1) Constructed from large welded assemblies that can be transported easily and that would minimise construction time on site – modular.

2) Galvanised surface treatment.

3) Open sections to make it easy to monitor corrosion and damage.

4) Capable of handling certain site vehicles.

5) Fully compliant with the relevant Australian Standards.

6) 5T capacity.

7) Incorporated vehicle wheel guides (safety).

The final design for this ramp is shown below. It complied with all of the above requirements and is currently installed at a few minesites around WA. It was constructed in four large sections that was bolted together on site with splice plates and was also attached to the concrete with mechanical anchors. The all-important feedback that was received from our clients are very positive. The ramp was easy to transport, easy to install, had a quality construction and was easy to use. It is an example of a simple design that just works.

3D model 5T capacity vehicle ramp

3D model 5T capacity vehicle ramp

Photos of the Modular Minesite Washbay Vehicle Ramp Design during construction and testing:

Actual ramp during construction

Actual ramp during construction


Washbay vehicle ramp

Actual ramp during testing

Contact us to discuss your specific minesite requirements.

Hopper Structural Design Certification

A hopper collects ore, which typically falls from an overhead conveyor or is dumped by a belt feeder into the bin. This causes dynamic loads and stresses, which need to be taken into account when designing the hopper. Dynamic Engineering analysed our client’s proposed design with Finite Element Analysis. We found that it would require strengthening in order to reliably withstand the imposed forces. With relatively cheap modifications, a more robust design was implemented – saving our client on future repair and maintenance costs.

Below the 3D model is shown:

Final hopper design

Final hopper design

Finite Element Analysis was used to find the stresses:

FEA analysis of hopper

FEA analysis of hopper

Our client was able to make significant monetary and time savings by using our expertise as opposed to using one of the larger engineering consulting companies. All our work complies with the relevant Australian Standards.

Most organisations need a trusted partner who will help them navigate through today’s ever changing business environment. Dynamic Engineering Consultants has built up a reputation for providing cost effective world-class engineering support in very quick turnaround times. This makes us the ideal partner for small to medium sized clients that need more flexibility from engineering contractors. Contact us to discuss your requirements.

Radiation Source Cradle Design and Supply

A radiation source cradle was designed to assist plant metallurgists to easily and safely move radiation sources (gauges) around inside a process plant.

Aluminium cradle

Due to the weight of the source the cradle was designed to that it can be carried by two people. To keep the weight to a minimum, the cradle’s design called for aluminium for its construction. To make it multi functional (to move different sizes of radiation gauges) it was fitted with spacers, which could be moved into place very easily. It was also furnished with a stainless steel nameplate that contained information regarding the load rating and use.

Below is the CAD model of the cradle showing the smaller gauge in place. Rod spacers are used to ensure the gauge is safely secured. These rods are designed for easy fitting and removal.

Radiation Cradle

Concept radiation source cradle

The design was finalised with Finite Element Analysis where the stresses and deflection were determined to ensure that it was below the permissible values according to Australian Standards.

The picture below shows the stresses in the cradle:

Stresses in cradle

Below the deflection is shown:

Deflection plot

After our client has approved the design, the cradle was fabricated and shipped to site, ready for use.

Radiation Source Cradle

Fabricated radiation source cradle

Do you require custom made cradles? Please contact us to see how we can assist you.

Project Management and Expansion Projects

Dynamic Engineering Consultants has wide experience with project management and can assist you with your small to medium projects. This includes management up to approx $AU 3mil total project cost. We are able to assist our clients with project schedule development, mechanical and civil estimates as well as client representation when dealing with EPCM contractors.Whether it is a new project or you are looking to expand an existing one, Dynamic Engineering can help you.

As part of this services we can assist with the following:

1) Scope of works development

2) Layout drawings

3) Project schedule development

4) Detail foundation design and drafting

5) Detail structural design and drafting

6) Detail mechanical design and drafting

Below are some examples of the projects we have done recently:

project management

Dust Extractor Foundation being poured

Dirty air duct supports awaiting ducting

Dust extractor installation (Dust extractor by Luhr filter)

project management

Photo of the completed project site

During expansion Dynamic Engineering can help you with complying with WorkSafe requirements.

Nothing matters more to us than making sure that you are completely satisfied with the results we deliver. Your goals are our goals too. We focus on exceeding expectations and making sure that you have been provided with the service and support that you expect. Please contact us to discuss your next project.

Kibble systems (Back up ball charging)

After being mined, mills use small steel balls to grind ore smaller for further processing. To load and unload these steel balls, kibble systems are used. This provides a safe and easier way to charge mill chutes or inlets. Dynamic Engineering can design kibble systems to suit your unique mining operation.

An example of such a back up ball charging system is given below:

After consultation with our client, the system is designed to ensure it is suitable for the application and in accordance with Australian Standards. The kibble is analysed with finite element analysis to check the stresses and deflections so that the design can be strengthened for a long work life.

An example of a stress plot can be seen below:

kibble systems

Finite element model and stress analysis

Below are some photos of the fabricated kibble being used on site. First the kibble is being charged with mill balls. Its size and design makes filling the kibble an easy task.

Kibble being charged

Then it is moved into position and the balls are discharged into the system:

Kibble discharge system in use

We take into account mine site structural constraints to find the best solution for moving the kibble in place and utilise existing equipment where possible. Contact us to discuss your specific mine site requirements.