How to Maintain Peak Performance in Critical Mining Assets

Braemac
May 21
4 min read

Global mining operations are undergoing a fascinating transformation. Driven by digitalization, rising demands, market turbulence, and tighter regulations, mining organizations are rethinking their strategies to tap new levels of efficiency, innovation, and long-term growth.

From automotive to agriculture and healthcare, modern mining is a central piece of a wide range of industries. As the pressure to perform intensifies, organizations are recognizing that maintaining peak performance in critical mining assets is no longer optional – it’s a strategic imperative.

To stay ahead, mining operations must move beyond traditional models and embrace smarter, data-driven approaches and cutting-edge technologies that enhance equipment reliability, minimize downtime, and maximize productivity.

Top 3 Ways to Maximize Mining Operation Uptime

Increasing productivity isn’t just about keeping machines running, it’s about designing smarter, more resilient operations that can adapt in real time to complex, high-risk environments. Modern mining operations must move beyond traditional maintenance models to embrace future-ready technologies for deeper insights, faster response, and greater control over physical assets.

Here are three proven strategies mining organizations are using to minimize unplanned downtime, extend equipment life, and drive operational excellence:

High-Speed Data Collection

Integrating high-speed data collection initiatives is crucial to addressing the immense volume of data modern mining operations generate. In scenarios involving safety incidents, quality deviations, or compliance checks, high-speed data collection enables sub-second logging and processing to provide operators with immediate actionable insights when they’re most needed.

Customer Sensor Integration

Standard platforms often fall short of meeting the demanding and varied requirements of mining environments. From corrosive conditions to intense vibration, custom sensor integration empowers operators to monitor exactly what’s needed. These specialized sensors help address niche challenges—such as tracking chemical reactions, particle flow, or detecting gas and air leaks—while maintaining seamless compatibility with centralized control systems.

Real-Time Control

Fast feedback loops enable measurement-based control strategies that respond instantly to emerging issues. Whether it’s shutting down a machine before a bearing fails or adjusting process parameters on the fly, real-time control minimizes risk, reduces downtime, and ensures safer, more efficient operations. This proactive approach extends asset life and improves throughput, without compromising safety.

Enhancing Mining Operations in the Real World

Today, forward-thinking mining organizations are setting new industry standards by implementing high-impact strategies like high-speed data collection, customized sensors, and increased actionable insights to deploy advanced systems that optimize performance, reduce downtime, and improve safety in even the harshest environments.

Machine Health Monitoring Solutions

Slurry pumps, dewatering pumps, and ventilation fans are the lifelines of any mining operation. Resonate Systems’ health monitoring solutions deliver real-time asset insights by continuously tracking vibration, temperature, and alignment to enable early fault detection and maximize uptime.

Designed for ruggedized deployments, these systems offer both wire and wireless installation, integrating seamlessly with SCADA and control systems to support predictive maintenance insights.

Distributed Instrumentation in Titanium Production

Icon Technologies has developed a robust instrumentation system for the TiRO process, a next-gen titanium production method. Built on NI’s CompactRIO Systems and LabVIEW software, the system integrates 12 distributed IO controllers and over 400 analog and digital points to enable high-speed, deterministic control and monitoring. Supporting both ongoing R&D and 24/7 commercial-scale production, this solution effectively meets strict operational standards.

Velocity of Detonation (VOD) Measurement for Blasting

Source: Gamma Engineering — **Source:** *Gamma Engineering*

Gamma Engineering’s SpeedVOD system is a breakthrough in blast performance measurement. It uses cost-effective coaxial cable and TDR technology to capture the velocity of detonation across multiple boreholes. Combined with GPS time synchronization and an extensive data system, SpeedVOD enables superior quality control and operational efficiency.

Acoustic Imaging for Leak Detection

Source: SM Instruments — **Source:** *SM Instruments*

The BATCAM 2.0 from SM Instruments is an ultrasonic and acoustic sound camera designed for quick identification of air or gas leaks in mining environments. Featuring 112 precision microphones and powered through NI hardware, it delivers real-time visual feedback for conditions often undetectable by the human ear.

Compact, rugged, and accurate, this tool enables onsite personnel to respond immediately to leaks to reduce energy loss, improve safety, and ensure compliance.

Enabling Innovation with Braemac Solutions

At Braemac, we specialize in embedded solutions and connected technologies that can help mining operations take critical asset performance to the next level. With a deep understanding of industrial challenges and a future-focused approach, our comprehensive portfolio delivers best-in-class solutions to fully immerse the mining sector in Industry 4.0.

Available through Braemac, NI’s CompactRIO Systems allow developers to combine high-speed data collection, custom sensor integration, and real-time control within a single, ruggedized solution.

Purpose-built for industrial control and monitoring, CompactRIO synergizes high-performance processing capabilities, sensor-specific conditioned I/O, and a closely integrated software toolchain to support mission-critical applications. Ideal for applications and use cases requiring real-time data management and control, CompactRIO systems feature a controller with a processor running a Linux Real-Time OS and a chassis that contains a user-programmable FPGA. It supports industrial I/O modules from both NI and third-party vendors.

Ready to enhance your mining operation with scalable, intelligent solutions?

Contact us at info@Braemac.com to learn how Braemac can help you implement cutting-edge technologies that drive smarter decisions and measurable results.