MANNHEIM, Germany – In the demanding world of mineral extraction, where operational efficiency and safety are paramount, Pepperl+Fuchs has released a compelling new application overview showcasing how robust sensor technology is transforming the automation of mining yard machinery. As mining companies strive to optimize stockpile management, the integration of modern sensing solutions is proving critical for ensuring reliable material inflow and outflow, even in the harshest environments.

The Challenge: Harsh Environments and Precision Demands
Automated stackers and reclaimers are the backbone of mineral logistics, yet they operate under extreme conditions—heavy dust, grime, and constant vibration. To address this, Pepperl+Fuchs highlights a suite of rugged sensing solutions designed to enable fully reliable automation of yard operations, ranging from travel positioning and boom monitoring to safe movement control.

Precise Machine Positioning via RFID and Rotary Encoders
Accurate positioning is the foundation of smooth stacking and reclaiming. The featured solution combines RFID tags fixed along the travel path with RFID read/write heads mounted on the moving machinery. This is complemented by a multi-turn absolute rotary encoder that provides continuous position feedback.

RFID tags are installed at preset intervals (typically every 10 to 15 meters). When the read/write head detects a tag, it cross-references the stored position data with the rotary encoder’s value to confirm the machine's exact location within the yard. These rugged RFID components, rated IP67, ensure reliable reading and high repeat accuracy despite the aggressive conditions of a mine. Additionally, the Pepperl+Fuchs RFIDControl software simplifies commissioning, device access, and offers seamless PLC integration options.

Collision Protection with Ultrasonic Sensors
Uneven stockpiles and limited visibility in mining yards create significant risks of boom collisions. Ultrasonic sensors are deployed to continuously monitor the machine’s travel path and detect material build-up in danger zones. If a collision is imminent, the system triggers immediate corrective actions, preventing costly damage and enhancing on-site safety.

Boom Monitoring and Inclination Sensing
Efficiency and safety are directly linked to boom angle. Tilt sensors provide real-time data on the boom's position, allowing operators to optimize material placement and proactively address issues during operation. This results in more stable workflows and consistent handling performance.

Predictive Maintenance with IO-Link
To minimize downtime, Pepperl+Fuchs emphasizes condition monitoring through IO-Link technology:

• IO-Link Vibration Sensors: Detect changes in vibration and acceleration to identify potential issues such as imbalance, misalignment, or excessive wear.
• IO-Link Multi-turn Absolute Rotary Encoders: Measure wheel rotation angle, speed, and direction for precise navigation and control feedback.
• Tilt Sensors: Ensure components remain within specified angular ranges to guarantee stability and prevent accidents.

Defining Operational Boundaries with Inductive Sensors
Rugged inductive sensors (IP67 rated) serve as reliable limit switches to define travel boundaries, preventing over-extension or accidental movement. They also detect the motion of critical machine parts, ensuring operations stay within preset parameters, thereby extending equipment lifespan.

Industry Perspective
"In the mining industry, some machines simply cannot stop running. With the right sensors, operators gain higher precision, safety, and reliability. Pepperl+Fuchs has demonstrated this effectively in practice," said Daniela Bomfim Alves, Market Coordinator at Pepperl+Fuchs Brazil.

The Road Ahead for Mining Automation
By integrating RFID, ultrasonic, inclination, IO-Link vibration, rotary encoder, and inductive sensing solutions, mining operators can achieve a new level of reliability in yard machinery automation. This holistic approach not only improves equipment availability and optimizes workflows but also significantly boosts material handling efficiency—key drivers for competitive and sustainable mining operations.

About Pepperl+Fuchs
Pepperl+Fuchs is a global leader in the development and manufacture of electronic sensors and components for industrial automation. With a commitment to innovation and quality, the company provides solutions that enable smarter, safer, and more efficient industrial processes worldwide.