Thermal Video Monitoring in Mines: Catch Problems Before They Catch You by Surprise

Written by Heidi Schmidt, Global Sales Manager, Opticom Tech

Mining operations run on one fundamental truth: downtime costs money – a lot of money. Massive equipment, constant motion, and harsh conditions combine to create an environment ripe for mechanical wear and tear.

Traditional maintenance schedules help, but they often miss the subtle warning signs that something is about to fail.

This is where thermal video monitoring comes into play. This predictive maintenance solution is designed specifically to catch issues early and help avoid expensive downtime and catastrophic failures.

Why heat matters in mining equipment

Mining relies heavily on large, complex machinery – haul trucks, conveyors, crushers, loaders, and drilling equipment – all essential and all subject to relentless use. These heavy-duty machines operate under tremendous mechanical stress, generating substantial heat as their parts move and interact.

While some heat is normal, abnormal heat buildup can indicate friction, lubrication issues, electrical faults, or even impending mechanical failures.

When heat generation moves beyond safe thresholds, it becomes an early indicator of a potentially serious issue. Left undetected, minor overheating can escalate rapidly into major equipment breakdowns, production halts, and even safety hazards for your team.

How thermal monitoring works

Thermal monitoring uses infrared technology to detect temperature variations on equipment surfaces from afar. Cameras equipped with thermal imaging technology can continuously monitor equipment in real-time, providing visual heat maps that clearly highlight areas experiencing abnormal temperature spikes.

Rugged thermal cameras offer continuous surveillance, capturing temperature fluctuations with precision, even in challenging mining environments. By translating heat variations into clear, actionable images, maintenance teams can identify potential problems immediately and proactively intervene before a minor issue becomes a full-blown failure.

Built into Opticom Tech’s thermal monitoring camera system is the ability to configure alerts for heat abnormalities. Set each area’s acceptable temperature range and get alerted to any readings outside of that. Choose text or email alerts, integrate warnings directly into your existing smoke/fire alert system, and see warnings on your video monitoring screen. These alerts give you the opportunity to investigate and rectify before heat becomes dangerous.

Preventive vs predictive maintenance: What’s the difference?

Traditional preventive maintenance follows a fixed schedule, inspecting and servicing equipment at regular intervals, regardless of actual condition.

Predictive maintenance, on the other hand, leverages real-time data and insights—such as those provided by thermal imaging—to detect and address issues precisely when needed.

A Deloitte study on predictive maintenance showed that it can reduce facility downtime by up to 15 per cent and increase labor productivity by up to 20 per cent.

By shifting from preventive to predictive maintenance, mining operations become more efficient, safer, and significantly more profitable.

Key benefits of thermal monitoring for mines

Numbers and stats look good on paper, but what can thermal video monitoring actually do for mines? Let’s take a look at some of the benefits:

1. Early fault detection

Thermal cameras catch temperature anomalies early, identifying issues like worn bearings, overheating motors, loose electrical connections, and faulty gearboxes long before they cause critical equipment failure.

This helps you fix minor problems during scheduled downtime rather than reacting to catastrophic breakdowns.

2. Reduced downtime

Every minute your mine stands idle represents lost revenue. Proactively addressing problems means fewer unexpected stoppages.

Mines using predictive thermal monitoring have reported significant reductions in unscheduled downtime, directly boosting productivity and profitability.

3. Improved safety

Mining operations present inherent risks. But you can mitigate some of them. Thermal monitoring significantly enhances worker safety by alerting maintenance crews to potential hazards like overheated electrical components or mechanical failures, reducing the risk of dangerous equipment malfunctions and workplace injuries.

4. Lower maintenance costs

Predictive maintenance is cost-effective. By accurately diagnosing issues before they escalate, you avoid costly emergency repairs, extend equipment life, and optimize spare parts inventory management.

How thermal monitoring fits into your mining facility

Thermal monitoring can be effectively applied across various mining equipment types, including:

• Haul trucks and loaders: Thermal imaging can quickly identify issues in engines, transmissions, and hydraulic systems to reduce expensive downtime.
• Conveyor belts: Hot spots caused by worn rollers, misaligned belts, or overheated motors can be pinpointed quickly, avoiding extensive belt damage.
• Crushers and mills: Excess heat in bearings or gearboxes signals potential failures. Early detection prevents unscheduled outages.
• Electrical panels: Overheated connections can lead to costly and dangerous electrical fires or equipment damage. Continuous thermal surveillance provides timely alerts for immediate action.

How to get started with thermal monitoring in mining

There is no one-size-fits-all solution for choosing and installing your thermal monitoring system. However, based on our experience at Opticom Tech working with mining facilities, this is a good place to start:

• Identify critical machinery: Prioritize equipment where failure poses significant operational or safety risks.
• Select ruggedized video equipment: Choose thermal cameras built for the harsh environments typical of mining operations to ensure reliable, consistent monitoring.
• Integrate with maintenance processes: Establish protocols that trigger immediate inspection and maintenance action when issues are detected.
• Train your team: Make sure your staff knows how to interpret thermal imaging data and take timely corrective actions.

Wrapping things up

Mining operations face plenty of uncertainties, but equipment performance shouldn’t be one of them. Not sure how to mitigate this risk through thermal monitoring?

Work with an experienced mining video monitoring partner like Opticom Tech who can help mines make sure video monitoring equipment fits their needs and their budget. A partner helps make sure you don’t overspend on needlessly complex cameras in areas where you don’t need them but, at the same time, you have all the important monitoring features wherever they are needed.

For more information, visit www.opticomtech.com.