Metso Full portfolio CrusherMapper Condition Monitoring
CrusherMapper Condition Monitoring

CrusherMapper Condition Monitoring

Benefit from the next generation of condition monitoring for your gyratory crushers

Metso CrusherMapper™ Condition Monitoring is a unique service that allows your metallurgists and maintenance personnel to make informed decisions on reline scheduling and crusher operations to optimize maintenance operations.
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  • Improves safety
  • Prolongs maintenance intervals
  • Minimizes risk of unscheduled shutdowns
  • Optimizes shutdown times
  • Improves spares management
CrusherMapper Condition Monitoring

Metso CrusherMapper is a patented solution that has allowed some sites to nearly double their liner life. The resulting reductions in reline downtime represent significant savings in maintenance and reline costs, including labor hire, and reduced production losses.

  • 3D laser imaging condition monitoring to identify asymmetrical wear patterns
  • Measures the wear across the mantle and concave
  • Measurements of closed and open side settings (CSS and OSS) can be provided for every scan, giving remarkable control over product quality
  • Provides the most accurate condition information
  • Identifies cracks, high wear spots, and loose concaves
  • Helps prevent excessive gear wear
  • Laser scanning can be performed remotely by mounting the scanner on a deployment frame. Remote scanning eliminates the need for confined space entry.
ProcessBefore CrusherMapperWith CrusherMapper

Concave liner thickness measurement
  • Personnel need to be lowered into confined chamber for spot UTG measurements
  • Safety gear must be worn and safety procedures adhered to
  • 10 million thickness points captured by remote scanning
  • No entry or dump pocket clearance required
  • Automated, consistent, repeatable measurement
  • Reduced inspection downtime

Mantle thickness measurement
  • UTG accuracy susceptible to casting additives such as manganese
  • Only few arbitrarily selected points measured
  • Color-coded 3D model and indepth report indicating accurate wear patterns, cracks, and hotspots
  • Automated, consistent, repeatable measurement

Measure open and closed side settings
  • Alfoil/lead ball
  • Manual tape measurement in confimed crushing chamber
  • Automatically calculated from scan data

Monitor condition of spider-arm
  • Suspended over crusher opening to carry out spot UTG measurements
  • Thickness calculated from scan data ±3mm
  • No safety issues

Schedule reline
  • Manual spot measurements
  • Reliable forecasting
  • Optimization with tonnage-based wear tracking

  • Detailed wear report
  • One-on-one consultation follow-up
  • 3D model and software
  • Database package of site’s wear history

The scan is conducted within an hour and can be scheduled to coincide with your planned shutdown.

Metso CrusherMapper software automatically selects and reports on the highest wearing zone, protecting operators against the impact of unpredictable wear zones and ensuring that high wearing areas are always captured.

The wear report is written by a metallurgist or engineer, followed by recommendations in a one-on-one consultation. Sites are also encouraged to download the 3D models and reports from their scan, using the integrated CrusherMapper software. They can then conduct a virtual inspection of the crusher and review any particular point in detail.

Metso case studies
How others have improved profitability and reduced risks?
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