Leveraging the combined expertise of ACE and CPS, the team conducted manual stress and fatigue calculations alongside advanced digital Finite Element Analysis (FEA) to identify failure modes and refine the pulley design within strict site parameters.

The Challenge

A leading underground gold mining company in New South Wales was facing repeated and costly failures across several conveyor pulleys. These failures, primarily fatigue-related and catastrophic in nature, posed significant operational risks, threatened production continuity, and increased maintenance downtime.

The client sought an engineering partner capable of diagnosing the root causes of failure and providing a robust solution-all while operating within strict site parameters and regulatory constraints. Fenner Conveyors was engaged to deliver the solution.

The Solution

Fenner Conveyors leveraged the combined expertise of its engineering divisions-ACE and CPS— to deliver a tailored solution. The team conducted an in-depth engineering review of the existing pulley systems and identified the failure modes using a combination of:

• Manual stress and fatigue calculations
• Advanced digital Finite Element Analysis (FEA)
• These tools allowed Fenner Conveyors’ team to simulate the operational environment and accurately assess the mechanical loads on each pulley. The result was a refined and optimised design that addressed both structural integrity and fatigue resistance-without deviating from the operational requirements of the mine site.
• Fenner Conveyors successfully supplied four new Pulleys with approved manufacture standards.

The Results

The client validated Fenner Conveyors’ engineering approach and approved the proposed design. This led to:

• Successful procurement and award of purchase orders
• End-to-end management by Fenner Conveyors for the supply, manufacture, and assembly of the pulleys
• Reduction in downtime due to fatigue related failures
• Improved confidence in reliability and performance for future operations. Subsequent orders received for more pulleys
• Fenner Conveyors’ responsive engineering capabilities and collaborative approach enabled a critical issue to be resolved efficiently, delivering long-term value for the mine operator.