Reliability and safety in the harshest environments: Powertrain solutions for modern mining
In the rugged and harsh environments that epitomise the mining industry, the last thing an operation wants is to question equipment reliability. Whether working deep underground or in expansive open-pit sites, extreme heat, corrosive dust and remote locations constantly push mechanical systems to their limits. In this high-stakes environment, failure isn’t just inconvenient, it’s a significant financial and operational risk.
From gearboxes to braking systems, every component must perform reliably under continuous stress. With operations often running 24/7, even a short period of downtime can cost millions in lost production. This makes selecting the right components, and backing them with intelligent monitoring, absolutely vital.
Regal Rexnord understands these challenges and delivers more than just products. With industry-leading gearboxes and advanced Svendborg Brakes SOBO® iQ systems, Regal Rexnord empowers mining operators with a comprehensive, integrated powertrain solution designed for maximum uptime, safety and performance.
Reliability matters more than ever
Gearboxes lie at the heart of mining conveyors and hoists, handling immense torque, absorbing shock loads and operating around the clock under adverse conditions. A failure here is not just a component issue; it can bring an entire operation to a halt. Downtime costs are substantial, and in remote mining operations repairs are often complex, time-consuming and expensive. To avoid these risks, operators need to select gearboxes that deliver proven durability, smart design and flexible integration.
However, mining environments pose some of the toughest challenges to mechanical systems. The gearboxes chosen for these applications must be up to the task. There are a number of important factors mining operators should consider when selecting a gearbox:
- Load capacity: Gearboxes must handle enormous static and dynamic loads, sometimes far beyond rated capacities due to impact loads during operation. Oversizing, while conservative, isn’t always efficient. For this reason, Regal Rexnord gearboxes are engineered with high service factors and robust torque-handling capabilities to meet both expected and peak loads without compromise.
- Environmental resistance: Mining often means dust, water ingress, extreme temperatures and corrosive chemicals. Gearboxes must be built with reinforced seals, protective coatings and corrosion-resistant materials. Some installations may also benefit from auxiliary cooling systems, and Regal Rexnord offers units that support integrated or external cooling to maintain thermal stability and extend service life.
- Efficiency: High-efficiency gearboxes not only reduce energy consumption but also minimise heat generation. This is crucial in hot environments where heat management directly affects operational uptime and gearbox longevity.
- Maintenance access and serviceability: Even the best gearboxes need maintenance. Regal Rexnord gearboxes are designed for ease of service with modular components, easy access points and a readily available supply of spare parts. Quick turnarounds on maintenance fit with planned outages and enhance operational predictability.
- System compatibility and flexibility: New gearboxes must often be integrated into existing infrastructure. Regal Rexnord offers gearboxes with adaptable mounting options, multiple ratio configurations and digital integration support, making them easier to deploy without major modifications. This ensures not just mechanical fit, but also seamless integration with existing control systems and monitoring technologies.
Conveyors and hoists: The core of mining movement
Nowhere are these powertrain demands more pronounced than in conveyors and hoists, two of the most critical applications in modern mining. Conveyors can span miles across undulating terrain, while hoists must operate over large distances with absolute safety and precision. In both cases, gearboxes must deliver constant, controlled motion and brakes must stop safely, every time.
Regal Rexnord offers high-performance gearboxes and brakes tailored specifically for these applications. They provide rugged, long-life operation and feature design options to support high shock loads, vertical drive alignment and integrated braking systems.
Revolutionising conveyor safety
Reliable motion is only half the equation, controlled stopping is just as essential, especially on long, heavy downhill conveyors. This is where Svendborg Brakes and the SOBO iQ braking system come into play.
First introduced in 1998, the original SOBO system set a new standard for safe braking. Today’s SOBO iQ builds on that legacy with advanced IIoT-enabled hydraulics, smart controls and real-time data acquisition. It is not just a brake; it utilises a braking intelligence platform designed to optimise safety, uptime and equipment lifespan.
Key features of SOBO iQ include:
- Precise braking control for smooth deceleration and reduced belt tension.
- Rollback prevention to eliminate uncontrolled movement during power failure.
- Overspeed detection and correction to proactively address system anomalies.
- Remote monitoring and diagnostics via the Universal Control (UC) case.
- Cloud-enabled predictive maintenance to reduce manual inspections and extend system life.
Global impact: Chilean copper mine
An excellent working example is in Chile, where one of the world’s largest copper mines faced a common yet complex challenge – managing high-speed, long-distance downhill conveyors transporting ore from mountainous elevations to the processing plants.
Using Svendborg’s SOBO braking systems, the mine achieved:
- Controlled deceleration across kilometers of conveyor belt.
- Emergency braking during power loss with no rollback or spillage.
- Improved energy efficiency through regenerative braking.
- Lower maintenance costs via predictive diagnostics.
This success story highlights the real-world benefits of integrating intelligent braking and monitoring into critical conveyor systems.
Raising the bar for mining safety and uptime
In mining, equipment reliability is more than an engineering goal, it’s a business imperative and a safety standard. Gearboxes and brakes are the foundation to this mission, especially when supported by technologies like SOBO iQ and market-leading predictive maintenance solutions.
With Regal Rexnord, mining operators gain a trusted partner delivering rugged gearboxes, intelligent braking and real-time monitoring – all designed to withstand the world’s harshest conditions while optimising safety, efficiency and profitability.
Beyond these examples, the Regal Rexnord portfolio of brands offer industry-leading solutions for clutches, couplings, bearings, drive chains and motors; in fact all the powertrain solutions required to keep your operation moving safely and reliably.
Safety, reliability and intelligence – that’s Regal Rexnord in mining.