Development of a Remote Vibration Analysis Service for Mining Equipment : A Case Study at Metso

Abstract

This thesis presents the development of a remote vibration monitoring service for mining equipment, conducted as a case study at Metso. The project addresses the limitations of traditional on-site vibration analysis — such as high operational costs, safety risks, and limited data availability — by integrating existing vibration sensors with Metso’s connectivity module and a containerised software stack. The system enables secure, automated acquisition and transmission of vibration data from mining equipment, particularly grinding mills, operating in harsh environments.

The implemented solution demonstrated significant improvements in efficiency, safety, and diagnostic capabilities. Key challenges, including network configuration, data formatting, and sensor integration, were resolved through iterative development and collaborative teamwork. While some limitations remain — such as vendor specific sensor compatibility and the need for expert intervention — the project lays a strong foundation for a more practical and intelligent condition monitoring service. Future work will focus on enhancing diagnostic tools and incorporating machine learning for automated fault detection.