A Novel Condition Monitoring Technique for Mining Ground Engagement Tools via Modal Analysis

Ground engaging tools (GETs) are critical consumable components on mining excavators, and their timely replacement is essential to prevent risks and excessive downtime. This paper presents a monitoring method utilising the modal properties—natural frequencies and mode shapes. The method is applied in a test case to show how the GETs on an excavator bucket could be monitored. Modal analysis and dynamic analysis are conducted with ANSYS to verify the effectiveness of the proposed method. The finite element analysis models are validated by experimental vibration experiments. The results demonstrate a strong correlation between changes in natural frequencies and the conditions of the teeth on the excavator bucket, when comparing the intact to the worn-out condition. In conclusion, the presented method offers a promising approach for real-time monitoring of the GETs on mining excavators and similar equipment. It will contribute to efficient maintenance interventions and enhancing operational efficiency and safety.