Winder Controls (Pty) Ltd - South Africa

We are excited to share this video showcasing the supply, installation and commissioning journey of a drum replacement on one of the world's largest mechanically coupled Blair multi-rope winders situated at the GOLD FIELDS South Deep Gold Mine, South Africa. #engineering #excellence #teamwinder #worldclass

As the year comes to a close, we want to express our heartfelt gratitude for your trust and partnership throughout 2024. Your continued support inspires us to continue striving to deliver excellence every step of the way. In the spirit of the festive season, please note that our offices will be closed from Friday, 13th December 2024, and will re-open on Monday, 6th January 2025. During this time, our team will take a well-deserved break to recharge and spend time with loved ones. For critical matters, our Services Manager, Mr. Henry Kapp, will be available to assist: 📱 071 863 7126 📧 Henry.Kapp@winder.co.za Thank you for choosing us as your partner. We wish you a Merry Christmas, a joyful holiday season, and a prosperous New Year filled with success and new opportunities. #SeasonGreetings #MerryChristmas #HappyNewYear #WinderControls

Collaboration: Stronger Together At Winder Controls, we believe that the whole is greater than the sum of its parts. This philosophy guides both our internal practices and the relationships we build with our clients and stakeholders. By working together, sharing expertise, and combining our strengths, we create solutions that drive innovation and deliver exceptional results. Collaboration is at the heart of everything we do, and it’s what empowers us to achieve more, together. #Collaboration #StrongerTogether #InnovationInAction #WinderControls

At Winder Controls, integrity is fundamental to our operations. We are dedicated to conducting our business in a professional and ethical manner, prioritizing the well-being of our all interested parties including our company, clients, employees, local communities and the environment in which we operate. We believe that maintaining high ethical standards fosters trust, enhances collaboration, and contributes to a positive and sustainable business environment. Together, we strive for excellence while upholding our commitment to integrity in all that we do. #WinderControls #Integrity #CoreValues #EthicalBusiness #Trust #Excellence

Case Study: Monitoring of a Compromised Drum Hub with SAMS The Sentinel Analysis Monitoring System (SAMS), developed by Winder Controls, showcases its efficacy in ensuring the structural integrity of hoist drums through continuous monitoring. Here's how SAMS was pivotal in addressing a critical situation: Scenario:   - Hoist Operation: The hoist was operating at a depth of approximately 3000 meters, carrying a payload of 30 tonnes at a speed of 18 m/s.   - Issue Identified: Significant cracks were detected around the hub of one cheek of the hoist drum, aligning with the end of its fatigue life.   - Immediate Challenge: With the mine under production pressure and long lead times for new drums, a solution was necessary to ensure continued safe operation. Solution: Structural Repairs:    - Cracks were repaired using metal stitching.    - A stiffener ring was installed to prevent the cheek from detaching from the hub, though it obstructed visual inspection. Implementation of SAMS:    - Real-time Monitoring: SAMS was installed to track strain on the stiffener ring.    - Data Utilisation: Intelligent algorithms processed the data, providing insights into drum condition and guiding maintenance schedules.  Operational Benefits:    - Extended Drum Life: The mine safely prolonged the drum's operational life.     - Efficient Maintenance: Maintenance and periodic inspections were efficiently planned based on real-time data patterns.     - Reduced Downtime: Continuous monitoring helped in minimising unexpected halts, ensuring consistent production. Conclusion: SAMS enabled the mine to maintain operational safety and efficiency, even under challenging conditions. By monitoring compromised structural elements in real time, it allowed for proactive maintenance, reducing the risk of failure and extending the lifespan of critical components. For further details on SAMS, contact: info@winder.co.za SAMS exemplifies how advanced monitoring can revolutionize the maintenance of aging infrastructure, ensuring safety and reliability.

Case Study: Using SAMS for Finite Element Analysis Validation in Multi-Layer Rope Hoists Problem Overview: In multi-layer rope hoists, rope tension decreases as the conveyance nears the shaft top. The added layers cause the hoist barrel to deflect, altering the tension distribution in lower layers. This creates a complex, non-linear problem for estimating rope pressure, traditionally addressed using the Atkinson-Taylor method. However, this method's assumptions can lead to inaccuracies:    - Overestimations lead to excessively thick barrels, increasing mass and inertia.    - Underestimations risk premature drum failure due to inadequate design. Solution Approach: The Sentinel Analysis Monitoring System (SAMS), designed by Winder Controls, provides real-time strain monitoring. SAMS validates rope tread pressure estimations by analyzing the strain and deflection patterns of the drum barrel under operational conditions. Key Findings: Fatigue Life Insights:       - Barrel Fatigue Cycles: One cycle per hoisting operation for drum winders.       - Hub Fatigue Cycles: One cycle per drum revolution. Deflection Patterns:        - Observable deflection changes occur with each additional rope layer, providing critical input data for accurately assessing and validating hoist drum stiffness calculations. Applications of SAMS Data:    - Safe Operation Assurance: Monitors drum integrity when defects or end-of-life conditions are detected.    - Design Validation: Ensures the hoist drum's design aligns with operational demands and expected stress.    - Risk Mitigation: Supports the development of additional safety measures to address potential failures. Conclusion: SAMS enhances the accuracy of finite element analysis (FEA) models, ensuring safer and more efficient hoist operations by providing critical insights into the dynamic behavior of multi-layer rope hoists. This reduces the risk of design failures and optimizes the balance between drum thickness and operational safety. #WCS #Engineering #HoistOperations #CriticalInsights

Methodology for SAMS: Structural Evaluation of Hoist Drums The Sentinel Analysis Monitoring System (SAMS) integrates advanced monitoring technologies to evaluate and maintain the structural integrity of hoist drums. The methodology involves several key steps and benefits, ensuring that the hoist operates safely and efficiently. The diagram provides an overview of sensor locations within the drum, which are strategically placed to capture critical data. Methodology:    1. Sensor Placement and Data Collection:        Strategic Sensor Locations: Sensors are placed at critical points within the drum to capture strain and stress data        Non-Destructive Testing (NDT): Used in conjunction with sensors to assess the structural integrity without compromising the drum's function        Data Transmission: Wireless nodes collect and send real-time data to the cloud, enabling continuous monitoring   2. Data Integration and Analysis:        Finite Element Analysis (FEA): Simulates the drum's behaviour under operational loads, validated against real-time data from SAMS        Monitoring Algorithms: Convert raw data into actionable insights by processing it into easily interpretable metrics like stress levels and deflection patterns    3. Continuous Monitoring and Maintenance:        Cloud-Based Alerting: Configurable alerts notify operators of potential issues, supporting proactive responses        Early Detection of Issues: Alerts operators to potential problems before they lead to significant failures, enabling preemptive maintenance Key Benefits: Early Detection: Identifies wear and defects at an early stage, improving safety and reliability Data-Driven Insights: Ensures decisions are based on accurate, real-time data, enhancing operational efficiency Simplified Evaluation: Streamlined processes allow for quicker assessments and interventions Informed Decision-Making: Enables proactive risk mitigation and ensures operational decisions are well-founded Stiffness and Structural Insights: Continuous assessment of drum stiffness provides valuable information for:        Managing defects.        Assessing end-of-life conditions.        Implementing additional risk mitigation strategies.        Validating design changes or new installations. SAMS enhances operational safety and efficiency by ensuring the hoist drums are maintained in optimal condition, reducing downtime, and extending the life of the equipment. #WCS #EngineeringExcellence #Safety #Efficiency #HoistDrums #Monitoring #WeLoveWhatWeDo

Maintaining Excellence: Recertification Achieved We are proud to announce the successful recertification of our ISO 9001:2015 Quality Management System! This significant achievement underscores our unwavering dedication to excellence across every facet of our operations—from design and engineering to manufacturing, installation, and servicing of mine winders and associated equipment. This milestone is a testament to the hard work and commitment of our incredible team, who continuously strive to uphold the highest quality standards. We remain dedicated to delivering excellent engineering solutions that ensure reliability for our valued clients and stakeholders. Thank you to everyone who contributed to this success. Here's to continuing our journey of quality and innovation!

In South Africa, many hoists in operation today are between 20 to 100 years old, with a number of these featuring drums of cast construction. These machines, with their often undocumented histories, have become crucial components in mining operations. The advent of advanced and meticulous annual inspections has brought to light a range of issues with these hoists. Magnetic Particle Inspection (MPI) is frequently employed to identify potential concerns, including casting defects, fabrication issues, and fatigue-related indications. These inspections often reveal conditions that prompt questions about the continued fitness of these hoists for service. With recorded data from these inspections, the challenge lies in determining the appropriate course of action. Some indications may require no intervention, while others may necessitate monitoring or urgent action. This is where Winde Controls is well positioned to assist by means of high-level technical analysis, along with the implementation of our Sentinal Analysis And Monitoring System (SAMS). SAMS leverages real-time strain measurements from critical locations on the hoist drum. The data gathered is processed through an advanced algorithm that simplifies complex information, making it actionable for stakeholders. By analysing deviations from standard patterns, SAMS provides targeted alerts about potential issues, ensuring that only pertinent information is highlighted for timely attention. This approach allows for informed decision-making, enhancing the safety and reliability of hoists in service. Integrating SAMS offers a proactive solution to managing the health and performance of aging hoist systems. Ensuring timely interventions and maintaining operational integrity is not just a necessity but a commitment to safety and efficiency. For more information contact info@winder.co.za #EngineeringExcellence #HoistSafety #StructuralMonitoring #SAMS #IndustrialInspection #ReliabilityEngineering #WinderControls #WeLoveWhatWeDO

At Winder Controls, we take structural integrity seriously. Our Sentinel Analysis and Monitoring System (SAMS) is an advanced, online condition monitoring tool specifically designed to assess and evaluate the performance of hoist drums. This system leverages wireless strain measurements, monitored at critical locations, and processed by intelligent algorithms, providing mine engineers with essential data to track changes in structural integrity of a drum. SAMS offers comprehensive insights into structural conditions, making it ideal for: - Detecting concerning defects in hoist drums - Addressing end-of-life concerns for aging equipment - Supporting risk mitigation strategies where required Key Features of SAMS: - Real-time evaluation of structural integrity through wireless strain data - Automated analysis, taking into account repeated strain changes and varying load conditions - Easy-to-understand dashboard for live data tracking and insights For mines seeking enhanced reliability and safety in their operations, SAMS offers the perfect solution to detect early signs of failure and optimise performance. For more information on SAMS contact info@winder.co.za #EngineeringExcellence #ContinuousImprovement #WinderValues #WinderControls #WeLoveWhatWeDo