I met with Alberto Bailac, grandson of founder Pascual Bailac, and was delighted both with the results the combined technologies were achieving and the strength of the partnership between our two family-owned companies. Alberto spends all his time and energy saving his customers money and promoting the highest possible standards of safety and care. It’s fantastic because it’s everything we believe in and as a result our relationship is going from strength to strength.

Bailac had always offered a comprehensive range of tire services to the mining industry and we’d worked with them since 2006 but it was Alberto’s vision to create a tire monitoring system capable of evaluating and analysing the pressure and temperature of the Off The Road Tires (OTRs) that was realised with the launch of the innovative UMAN product in 2010.

Under blue skies and in blistering heat at the El Soldado copper mine north of Santiago Rodolfo Zalavari, UMAN Project Engineer, told me how delighted he’s been with the take-up of the system. The mine is owned by Anglo American who has a mixed fleet of mine haul truck and they’ve been operating UMAN since 2010. At the time of my visit more than 30 vehicles had already been fitted with the system with more installations due imminently. An indisputable success.

Bailac uses a combination of our internal and external TMS sensors, the data from which is transferred to the UMAN unit so drivers can be made aware of any fluctuations in pressure or temperature outside the ranges recommended by tire manufacturers. The tire pressure and temperature information is also relayed from trucks and loaders via a mine-wide WiFi network direct to the Anglo American Service & Contract Manager who can see at a glance any issues likely to arise and implement corrective measures quickly and efficiently.

The visit reminded me of the magnitude of the job OTRs do in the mining environment, the extreme conditions in which they operate and the scale of the disruption caused if tires fail. Seeing with my own eyes the real and immediate impact our collaboration with UMAN has had at El Soldado reminded me why we spend so much time and energy developing tire pressure sensing technology.

Flying home I was sad to leave the Chilean weather and generous hospitality behind, but I couldn’t wait to get back to our product developers and find out what I’d missed while I was away…..

Find out more about our pioneering TMS system go to www.tiremonitorsystem.com

Maintaining the right inflation pressure of off-road tires is the single most important factor in maximising their use and longevity. As businesses continue to reduce their expense base, taking good care of their tires can represent a significant cost saving and sound business practice.

Product Highlights

The TMS System integrates tire pressure sensors – both internal and external – with a data management system that means drivers and managers have direct access to key tire performance information via cab interfaces and PC programmes while their vehicles are in service.

The addition of the TMS Sensor Reader means that vehicle managers have on-site access to performance-critical information about any vehicle, providing reassurance they’re fully operational and working to maximum capacity.

Director Mandy Bromley recalls:

“Our customers told us that the type and amount of information our system generates was hugely beneficial in helping them keep their vehicles on the road. They just wanted to be able to access it on site too. We set to work developing the TMS Sensor Reader and now they can do exactly that. ”

When pointed at a tyre fitted with a TMS Sensor, the TMS Sensor Reader will identify the sensor’s unique code and instantaneously relay tire pressure, temperature and battery status information to the operator. Its features include a robust enclosure, backlit display and recharge time of 1-2 hours.

Regular Vehicle Checks

The problems associated with poor tire performance include vehicle down time, accelerated wear, tire failure, fuel inefficiency and expensive repairs. These can be minimised by a regular vehicle checking regime and this is where the TMS Sensor Reader comes into its own, giving vehicle managers an easy, cost-efficient tool – literally at their fingertips – that can tell them how well their vehicles’ tires are performing.

Large Fleet Maintenance

The TMS Sensor Reader is particularly beneficial to operators of large fleets as it will pick up the unique sensor identification code for any given vehicle, meaning a large number of vehicles can be checked on-site in the same shift. Drivers and managers can identify potential problems at the earliest opportunity and take decisive, preventative action.

Used in conjunction with the detailed historical data captured by TMS Manager and the analysis and visual reporting provided by TMS Log Graph, the system provides the complete set of tools needed to ensure businesses get the bet return possible on the investment they make in their tires.

TMS Service

Hot on the heels of the TMS Log Graph, the launch of the TMS Sensor Reader re-emphasises TMS’s willingness to listen to and design solutions that its customers both want and need.

TMS offers an after-sales support service across all its products, for clients in all locations.

For more information see www.tiremonitorsystem.com

The innovative TIRE MONITOR SYSTEM (TMS) ® already offers an impressive range of sensor devices designed to keep costs low and productivity high. At a time when companies are experiencing increasing fuel costs and pressure on profits it makes sense to investigate the TMS proposition to drive efficiencies by optimising tire – and therefore vehicle – performance.

Manufactured independently by AM Bromley, the TMS System provides visible, real-time data to drivers and managers that ensure a strong return on the investment they make in their tires, for as long as possible.

The day-to-day benefits of TMS’s blend of innovative electronics with smart software includes the minimisation of vehicle down time,  the avoidance of accelerated wear, reduction in tire failure frequency,  maximisation of fuel efficiency and the reduction of costly repairs associated with poor tire pressure maintenance.

Added Value

The initial TMS range launched in 2005 and was well-received and is now used by thousands of off road vehicles across the world. With a commitment to continued service excellence and product quality, AM Bromley listened to customer needs, which has resulted in this exciting new product launch.

Director, Mandy Bromley explains:

“We’re always striving to add value to our proposition so we talked to our clients and soon realised that a tool that provided meaningful analysis of key tire maintenance information would be of significant benefit to them.  I’m extremely proud that in launching TMS Log Graph we’ve responded to a real need. “

TMS Log Graph

The revolutionary software generates visual reports of tire performance data logs from all vehicles fitted with a TMS, prompting managers to take appropriate action at the earliest opportunity. Its use demonstrates a serious commitment to protecting the investment made in their vehicles’ tires and ultimately to company productivity.

The user-friendly tool saves time that would otherwise be spent analysing data in-house and is free for existing customers to download at www.tiremonitorsystem.com/downloads.

TMS Internal Sensor

The TMS Internal Sensor is now one of the most robust products on the market and can withstand the most challenging of physical environments, including dust and temperature changes. And re-fitting has been made easier too with the incorporation of a unique rubber toggle system that detaches the sensor from the application patch offering a high degree of versatility few products can offer.

Meanwhile TMS Manager – used by managers to monitor individual tire performance – has been updated with improved software to make better sense of the data supplied by vehicle sensors.  The latest version is available for customers to download at www.tiremonitorsystem.com/downloads.

TMS Service

TMS has long been committed to providing leading-edge technical solutions in tire performance optimisation but the launch of TMS Log Graph and key enhancements to the TMS Internal Sensor range goes a step further – it demonstrates their willingness to consult with clients, understand the issues that are important and tailor design accordingly.

TMS offers an after-sales support service across their entire product range and what’s more they actively encourage their clients to use it.

For more information go to www.tiremonitorsystem.com

A 64-vehicle INNOVIA people mover fleet serves 10 stations on 8 kilometres (5 miles) of dual-lane elevated guideway at Dallas Fort Worth airport.

The image shows the INNOVIA on the test track in Pittsburgh where Bombardier Transportation tried and tested TMS before it was launched.

As industries across the world have striven for greater operating efficiencies and reduced costs, the mining industry has become increasingly sophisticated in its management of OTR tyres. There are hard commercial benefits for mine operators for monitoring tyre pressures. Tyres are a significant cost and small fluctuations in pressure and temperature can have a dramatic effect upon their working life. Benefits include a measurable increase in the useful life of the tyre, increases in the profitability of the mine because of reduced stoppages to shifts due to premature tyre failure and an increased availability of the fleet.

This desire to prolong tyre life has led to the development of UMAN, Bailac’s new tyre management technology. By using internal pressure and temperature sensors, the system prevents tyres from operating outside the ranges of pressure and temperature recommended by the manufacturer, reducing damage to the tyre and maximising its useful life. The continual real-time monitoring of the pressure and temperature of the gas inside the tyre, coupled with alarms situated inside the cab or located remotely, provides warnings when a threshold value is exceeded that could indicate potential damage to the tyre and, consequently, the capacity for continuous operation of the vehicle during the shift in question. The monitoring process is displayed on an easy-to-read display inside the cab of the vehicle. It can also be displayed remotely using a WiFi-enabled PDA mobile device, and on computer screens through Intranet/Internet.

Alberto Bailac, Director of the Chile branch of Bailac San Ltd and the brains behind the UMAN concept, explains: “UMAN was developed to replace the traditional procedure for the control and monitoring of tyres, which is still in use in the vast majority of the mining companies in the world. This technique uses basic tools including manometers, and these give rise to a number of issues. Because it is a manual procedure, it cannot give warnings as soon as a tyre starts to operate in conditions that endanger its structural integrity. Control measurements are carried out daily or every few days, this time frame greatly exceeds the average time for damage to occur, which is around three hours. UMAN has been designed to provide real time monitoring of all tyres on a vehicle, including six-axle vehicles.”

The testament to its efficiency is the number of mining sites that have UMAN installed. In Chile there are nine sites operating UMAN: Compañía Minera Doña Inés de Collahuasi (ANGLO AMERICAN XSTRATA), El Soldado (ANGLO AMERICAN CHILE), Mantoverde (ANGLO AMERICAN CHILE), SQM-Nva. Victoria (SQM), Minera Esperanza (ANTOFAGASTA Minerals), El Teniente (CODELCO – Corporación del Cobre de Chile), Mina Sur (CODELCO), Chuquicamata (CODELCO), Los Colorados ( Pacific Steel Company).

Within these sites, the variety and range of vehicles carrying UMAN is as varied as it is long: 34 Komatsu trucks 930E, two Komatsu loaders W900, two Caterpillar trucks 797B, seven Komatsu trucks 830E, eight Caterpillar trucks 777, nine Caterpillar trucks 785, three Le Torneau loaders L1850, four Caterpillar loaders 994 and five Toro 010 Sanvick Tamrock loaders.

Alberto Bailac continues: “The success of Bailac is down to our customers receiving a service of such a high standard that it enables them to increase their operational safety, prolong the useful life of their tyres and increase the time that their vehicles are available, and this increases the productive capacity of the mining shift in tons per hour. Another element of our value is that our customers can rely on Bailac to identify other tasks that require attention at the mine, which although these may not have a direct relationship with the extraction process, are critical activities that enable it to be carried out more efficiently.”

At the heart of the UMAN system is the tyre pressure monitoring system (TPMS), which can facilitate the early detection of faults. The data provides historical analysis of the collected information (behaviour versus distances and loads, selection of tyres, maintenance schedules), and can be used to manage shift patterns and mine operations.

The UMAN TPMS includes the Tire Monitor System (TMS), which is manufactured by UK company AM Bromley. TMS delivers a solution for monitoring the internal pressure and temperature of a tyre, and Bailac relies on its quality, efficiency and effectiveness for accurate measurement of pressure and temperature in order to provide a competitive solution for the Chilean and international markets. The relationship that has blossomed between Bailac and AM Bromley is based on mutual understanding and the flexibility to react to the ongoing improvement of the product allowing new functions to support the mining customer. For that reason, in 2010, Bailac and AM Bromley signed a marketing agreement where Bailac became the exclusive distributor of its UMAN products at world level.

Rodolfo Zalavari, Project Engineer for Bailac explains: “Delivering reliable data from the tyres is key to the development and marketing of UMAN. When it came to selecting the technology provider, we found that AM Bromley had the sensors and the kit for storing information on pressure and temperature, but would it work in the mines of Chile? After conducting on-site tests, we were able to verify that TMS could be integrated into UMAN, and was able to deliver measurements under diverse environmental and operational conditions, such as operating in extreme temperatures including snow, operating at sea level and at an altitude of 5000 metres, and operating on tyres covered with steel chains. Fortunately, the R&D period was not very long – AM Bromley was the second supplier of TPMS sensors that we tried, and the results speak for themselves.”

Because the Bromley TMS sensor transmitter is mounted on the inner wall of the tyre, one of the main challenges faced was whether Bromley’s TMS receiver inside the driver’s cab would be able to read the RF signals through the steel mesh in the tyres, or through tyres covered in steel chains. However, after exhaustive tests, the results were successful and the system proven to work.

“Following the successful trials and implementation, Bailac developed a new version of UMAN which was launched in October 2010. From that moment the company began an aggressive plan of consolidation and penetration of the Chilean and international markets, with the expectation that during the remainder of 2010 a total of a further 50 vehicles will be fitted with our system. In 2011 we expect to extend across a significant number of mining sites in Chile, and to consolidate international business, with a plan to penetrate mining markets such as those of Australia, South Africa, Peru, Colombia and Bolivia.” added Zalavari.

The mining companies that rely on UMAN have seen positive changes in their operational management. This includes redirecting the work of maintenance staff to tasks of greater overall value and avoiding the risks of accidents when bringing samples to the site, because these are now carried out in an automatic manner by the system. The workers have an awareness at an early stage of the tyre condition that could endanger their integrity, and the companies see an increase in the performance of the tyres of at least 10%.

Alberto Bailac concludes: “Bailac is fortunate to possess a great deal of knowledge about tyres and about their usage in the heavy mining industry. Thanks to the aptitude and flexibility of AM Bromley, we have been able to develop a series of improvements aimed at the automation of current manual operations that will clearly differentiate UMAN from its competitors. Because of this, in October 2010, AM Bromley developed a new generation of sensors that correspond to the first stage of improvements agreed between the engineering departments of both companies. The future of the Tire Monitor System and UMAN, in our opinion, could progress to the point where it acts not only to gather information, but also take corrective action in real time.”

Bailac has developed a substantial footprint in South America and currently has five repair and retreading plants, strategically located over the length of Chile, as well as a plant in Utah, in the USA. These plants are supported by more than 600 specialists working on-site in the mines, and this has enabled the company to service tyres and tyre-related needs of large mining companies across the regions.

Part of Bailac’s marketing strategy is to cover the majority of the Chilean market with its UMAN solution, not only providing the relevant hardware and software, but also supplying information management services for the operational and administrative areas of each mining company. On an international basis, the company is targeting mining operations in the following countries Peru, Colombia, Bolivia and Brazil, Australia, Russia and South Africa.

Singleton Birch took delivery of the large Volvo L350 in February direct from the new Volvo Construction Equipment facility in Immingham. Prior to its delivery to the Melton Ross quarry Earthmover Tyres (Wakefield) Limited, who have been working with Singleton Birch on tyre supply and service for the past 12 years, installed TMS to the loader whilst it was at the Volvo depot.

The Goodyear 875/65 R33 tyres on the wheeled loader were fitted with the small battery powered pressure sensors, the receiver and the operator interface were fitted inside the cab. The system provides the driver with real time information on the status of the pressures in each tyre and an alarm alerts the driver of any issues such as low pressure or high temperature.

Mark Sacker, Quarry Manager at Singleton Birch is focused on increasing productivity and reducing costs, running the new Volvo machines complete with the tyre pressure monitoring system will help ensure that the tyre pressures are kept at optimal levels.

Mark says: “There have always been issues with tyres on 4 wheel loaders, they are extremely hard working and it is critical to run them at the correct pressure to maximise tyre performance. In fact, we run the tyres at slighter higher pressure than normal, something we have found to be advantageous. The service we have received from Earthmover Tyres (Wakefield) over the years has been very good and now, with the addition of TMS, we have the complete tyre management programme.”

Singleton Birch produces high calcium lime and the only natural hydraulic lime in Britain at their Melton Ross Quarries in North Lincolnshire. They have been quarrying Lincolnshire Chalk for nearly 200 years, producing up to 400,000 tonnes of lime and over one million tonnes of chalk annually, the products are supplied to many industries such as steel, building, chemical and environmental.

“We are delighted that the kit is continuing to help Singleton Birch to optimise the performance of the tyres and the loader.” reported Darran Stone of Earthmover Tyres (Wakefield). “We have been the UK distributor of the TMS since May 2009 and, following the success of the Hillhead show last month, the UK is recognising the benefits of the system and we are installing an increasing number of kits. It is not just information for the drivers but also the logged data held in the system that can be used to identify any potential issues such as a machine with periods of operation with low pressure which can lead to early failure of the tyre. TMS can assist in preventative management which, in turn, can save tens of thousands of pounds.”

Tire Monitor System, a OTR TPMS system developed by A M Bromley Limited, is being integrated into a data collection system for mine haul trucks in Chile and Latin America. Bailac, the Chilean giant that specialises in rendering complete OTR tire maintenance, control, repair and retread services, launched UMAN (Unidad de Monitoreo Activo de Neumáticos) which is the Active Tire Monitoring Unit in July 2009. UMAN can be communicated with via WiFi, Ethernet or RS232, enabling it to be implemented in several applications above and below ground, UMAN can also be integrated with other industrial solutions relating to the management of OTR vehicles.A M Bromley Limited export Tire Monitor System sensors and receivers to Bailac in Chile, the specialist vehicle telemetry and integration is managed by Bailac to produce the complete UMAN solution, configured using a single TMS sensor per tyre, and a standard TMS receiver with two antennas. Type of vehicles that have been equipped so far, include CAT 777, CAT 785, CAT 797, Komatsu W900, CAT 994 and Letorneau L1850 with tyre sizes up to 63 inch! Bailac attach the pressure sensors inside the tyre using patch repair techniques.

Increasing the availability of mine haul trucks and the rising cost and supply of OTR tyres is being tackled in Latin America by insuring that the tyre pressures are maintained and that early warning detection is given if values go outside the thresholds that are permitted and recommended. Ensuring the correct tyre pressure has many benefits which are well known in the OTR tyre industry such as improving fuel efficiency and reducing vehicle downtime.

Tire Monitor System (TMS) is a direct tyre pressure monitoring system designed specifically for large off road applications such as mining and construction, earthmoving, and container and cargo handling, as well as tire testing and research. It includes a tire-mounted battery-powered pressure and temperature sensor and wireless transmitter.

A M Bromley will supply sensors, transmitters and receivers to Chilean company Bailac (www.bailac.cl), to incorporate into its UMAN tire maintenance system, which currently interfaces with the ‘Dispatch’ (soon to also interface with ‘Jigsaw’) mining systems and provides WiFi and Internet access to tire monitoring and performance data. UMAN is used by Bailac to provide support services to the mining industry, as part of its full on-site tire maintenance and control service for the mining industry in Chile and other South American countries.

“We chose AM Bromley’s Tire Monitor System as part of our UMAN system because it’s easy to fit and works reliably and consistently even in the most demanding situations,” said Alberto Bailac, General Manager at Bailac. “It is also very flexible and convenient, as the Tire Monitor System can transmit information to handheld units as the vehicles drive by, they don’t even need to be pulled off their work routines to access the data.”

“We already have 60% of the mine tire service & maintenance market in Chile, and we are growing in Brazil. TMS as part of the UMAN system will help us to get into Peru and other South American mining markets, as well as markets in North America and South Africa” said Alberto Bailac.

“We went to Chile to see the system in action, and received 100% positive feedback on its performance. Even in the Atacama Desert, which is the driest on earth, the system performed perfectly. Under intense heat like this, tire pressure is especially important to performance and longevity,” said Mandy Bromley, Director, A M Bromley.

Monitoring the pressure of the tires in the huge earthmoving machines used in mining and quarrying is vital to the performance and safety of the tires, which are worth upwards of USD10,000 and can have a life of between two weeks to two years. A M Bromley’s Tire Management System (http://www.tiremonitorsystem.com/) can help improve fuel efficiency, reduce wear and predict imminent problems, allowing companies to schedule tire maintenance, losing access to a machine because of unplanned maintenance caused by an unexpected problem with a tire can significantly affect a company’s productivity.

Photo from left to right: Rodolfo Zalavari (Bailac), Sergio Valencia (Bailac), Mandy Bromley (Tire Monitor System) looking at the TMS tire data on the UMAN Mobile handheld unit at Manto Verde copper mine in Chile (owned by Anglo American Chile)

Following the success of TMS in preventing the expensive downtime of one of the scrapers through an overheating bearing, which was detected by the system as an increase in temperature and pressure in the tyre, the power station operators have ordered systems to be fitted to the latest batch of tyres.

“These tyres are sourced from the US and are quite hard to find, it seemed a sensible option to fit the TMS when we fit the tyres to the scrapers. This installation will mean that all of the power station’s scrapers can be monitored using TMS.” explained Darran Stone of Earthmover Tyres.

The system has been well received throughout South America and has been proven in the most extreme conditions in the mines of the Atacama Desert. Monitoring the pressure and temperatures of the tires in the huge earthmoving machines is vital to the performance and safety of the tyres. TMS can help improve fuel efficiency, reduce wear and predict imminent problems, allowing companies to schedule tire maintenance – losing access to a machine because of unplanned maintenance caused by an unexpected problem with a tire can significantly affect a company’s productivity.

In the UK it has proven its worth by preventing a bearing failure in an Terex TS40 Motor Scraper. Fitted as part of a tyre management programme the alarm built into the TMS in the driver’s cab sounded and the tyre pressure and temperature data downloaded from the TMS unit showed that the air temperature in the tyre was reaching the predetermined threshold and triggering the alarm. All known sources of the problem were checked but unable to identify any defect with the tyre or the system the vehicle was returned to service. The tyre monitoring system triggered the alarm once more and finally a faulty wheel bearing was identified as the cause of the tyre heating, transferring heat to the hub/rim and then causing the air temperature inside the tyre to heat up and trigger the tyre monitoring system alarm. The repair was able to be scheduled and downtime minimised.

Earthmover Tyres is a tyre maintenance and fitting company dedicated to the OTR earthmover market and who have found fitting TMS sensors both easy and quick when undertaken as part of a tyre replacement program. TMS is designed and manufactured by AM Bromley of Buxton, Derbyshire and is specifically designed for use in OTR tyres. The TMS system sends information wirelessly from a sensor inside each tyre to a receiver mounted in the vehicle. The receiver is connected to an operator interface in the cab of the vehicle to display real time information to the driver. The operator interface can also be connected to a laptop for historical data viewing and alarm configuration via TMS Manager, a PC application.

Technical advisers from A M Bromley will be on hand on stand R5 at the Registration Pavillion at Hillhead to discuss all aspects of the system.