Nobody can tell you why it keeps failing? We can.
A failure that comes back isn’t bad luck. It’s a design or application problem wearing a maintenance costume. We diagnose the root cause, in the crusher, and engineer a fix that makes the failure stop repeating.
Solutions
When the third replacement fails the same way
You’ve changed the part twice. You’ve tightened the maintenance interval. The supplier keeps shipping replacements, and the failure keeps coming back on the same schedule. At that point the part isn’t the problem; something upstream of it is, and finding it takes someone who understands the whole machine, not just the catalog.
Our lead engineers designed the original crushers. When they look at a wear pattern or a fracture face, they’re reading a machine they drew, and that changes what they can see.
Sound familiar?
“Why does my crusher keep burning bushings?”
Usually alignment, lubrication, or load, not the bushing. We trace which one.
“Why is my liner wearing unevenly?”
The wear pattern is a map of your feed and chamber. We read it.
“Why is my power draw climbing?”
Profile drift, packing, or setting creep. Each has a different fix.
“Why did the main shaft fail?”
Fracture analysis tells the story if you know the design loads. We do.
“Why does my main frame keep cracking?”
Cracking that comes back after every repair is a design problem. Our improved main frame designs have ended it at several mines, for many years and counting.
Each symptom links to a diagnostic article; the article proves we know the answer and the answer’s last step is a conversation with us. Enough to prove expertise, never the whole playbook.
How a root-cause investigation works
We listen to the machine's story.
Failure history, what changed, what you've already tried. Often the pattern is visible from the first phone call, at no charge.
We investigate on site.
Inspection, measurement, laser scanning, and a look at the failed parts themselves. In the machine, not from a desk.
We name the root cause.
In writing, in plain language, with the evidence. You'll understand exactly why it kept happening.
We engineer the fix and stay with it.
A redesigned part, a revised procedure, or both, and we track the machine after startup to confirm the failure is gone.
At Meadowbank, main frame cracking kept returning no matter how it was repaired. We engineered an improved main frame design that ended the problem; it has run for many years since. [ Confirm machine model, install year, and downtime avoided. ]
The people who designed the crusher
Complex problems get our most senior engineers: the ones with original design experience on 200 through 2,500 horsepower machines and decades of field investigations behind them.
Bring us the problem nobody can explain.
Describe what the machine is doing and we’ll tell you what we’d look at first. The full answer usually lives at your site, so let’s start there.
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