It is also giving indicators around the overall performance of the processing cycle.

The prototype screen, designed and developed in Australia by Shenck Process, is undergoing site trials.

Shenck believes the prototype could change the way vibrating screens are developed and operated.

A standard screen condition monitoring system comprises two sensor nodes, including six degree of freedom microelectromechanical system accelerometers, a high-resolution accelerometer and a temperature probe.

On the prototype screen four additional sensors have been fitted - one on each corner.

Schenck Process senior research and development engineer Doug Teyhan said the measurement regime for the additional sensors included spring amplitude and mean compression.

That allowed the estimation of tonnes and load bias to determine if the feed was presented square to the screen or favouring a side, and the determination of spring operating characteristics and cumulative fatigue damage.

"We are looking into the development of a predictive failure program to improve overall productivity and efficiency and significantly reduce the possibility of unplanned downtime," Teyhan said.

Failure prediction has traditionally been determined by running components to the point of failure and assessing a mean time to failure based on a known operating history.

The data generated by the prototype screen is being used to estimate the operating stress of the screen at the most aggressive fatigue areas and assessing the cumulative damage of those areas based on the measurement of non-ideal operating characteristics.

Using a cumulative damage system that counts machine cycles and also trend characteristics that can adversely affect vital component life expectation, the plan is to make the machine monitoring system a lead measure in predicting the potential for component failure.

The expanded monitoring system will also provide input into machine development of the next generation of vibrating screens by filling in the unknowns in the design process with real-time field data.

Teyhan said not only would customers get increased screen availability and performance, they might also be able to make improvements to the processing cycle.

"And from a screen operation point of view, the additional data is bringing to light characteristics not previously known," he said.

"It is highlighting transient feed characteristics - not visible using traditional condition monitoring techniques - that impact the loading of the screen and affect machine life expectations.

"We also believe there are potential industry wide benefits, through new design parameters and possible changes to machine construction techniques and materials."

To optimise the greater range and scope of data the screen is generating, Schenck is collaboratively investigating and assessing other performance variables.

Getting on top of those could potentially control of the variability in the feed rate and make for more consistent performance and improved overall cycle efficiency.