ORBCOMM > Case Studies > Terex Materials Processing: Pioneering Telematics in Crushing and Screening Machines

Terex Materials Processing: Pioneering Telematics in Crushing and Screening Machines

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 Terex Materials Processing: Pioneering Telematics in Crushing and Screening Machines - IoT ONE Case Study
Technology Category
  • Functional Applications - Computerized Maintenance Management Systems (CMMS)
  • Networks & Connectivity - Cellular
Applicable Industries
  • Equipment & Machinery
  • Mining
Applicable Functions
  • Maintenance
  • Product Research & Development
Use Cases
  • Driver Performance Monitoring
  • Usage-Based Insurance
Services
  • Hardware Design & Engineering Services
  • System Integration
The Challenge
Terex Corporation, a global manufacturer of lifting and material processing products, identified a unique opportunity to differentiate their product and enhance customer experience by integrating telematics technology into their crushing and screening equipment. These machines, which are highly specialized and valued in the hundreds of thousands of dollars, operate in harsh and often remote environments. The setup and tuning requirements for these machines vary from site to site, as no two ores or rocks are identical. Failure to properly tune these machines can result in the final processed material not meeting the desired specification. The cost, complexity, and remote nature of crushing and screening operations made a compelling case for the introduction of telematics. Terex aimed to provide the market with innovative features and add more value to their product.
The Customer

Terex Corporation

About The Customer
Terex Corporation is a global manufacturer of lifting and material processing products and services. They deliver lifecycle solutions that maximize customer return on investment. Major Terex brands include Terex, Genie, Powerscreen, and Demag. Terex solutions serve a broad range of industries, including construction, infrastructure, manufacturing, shipping, transportation, refining, energy, utilities, quarrying, and mining. Terex offers financial products and services to assist in the acquisition of Terex equipment through Terex Financial Services. Powerscreen and Terex Finlay, brands of the Terex Corporation, are world leaders in the design, production, and supply of mobile, heavy-duty crushing and screening equipment for use in mining, quarrying, construction, demolition, and recycling.
The Solution
Terex partnered with ORBCOMM, a global leader in IoT solutions, for an intensive 18-month project to develop a customized end-to-end telematics solution. The solution included a cloud platform for data analytics and reporting, robust tracking and monitoring hardware, and 24/7 global connectivity over cellular and satellite networks. Users now have instant access to comprehensive global data on equipment location, start and stop times, fuel consumption, tonnages, cone settings, wear rates, operating hours, maintenance, service status, and more. The system generates pre-set alarms, alerts, and error messages, enabling prompt response to production and machine issues. Users are also notified automatically when their machines are operated outside of set hours and location. Since the initial deployment, ORBCOMM has added highly specialized features, such as sensors that measure wear and tear on critical parts and accurately predict when they are due for replacement.
Operational Impact
  • The integration of telematics technology into Terex's crushing and screening machines has resulted in numerous operational benefits. More effective maintenance and servicing are among the key benefits of remote real-time monitoring. Knowing the actual running hours enables OEM, distributors, and customers to predict precisely when a machine needs to be serviced. Remote sensor-based monitoring can prevent premature equipment expiry, ensure machines are producing at full performance, and protect residual value. Monitoring wear rates also allows dealers and users to anticipate replacement parts and ensure they are available as soon as needed. The system provides statistics and analytics to inform management decisions, generating insights to drive cost savings and optimize fleet planning based on idle versus working time. Terex also anticipates real benefits from better insights into the real-world performance and operation of its machines, using operating and diagnostics data to inform design and manufacturing improvements.
Quantitative Benefit
  • Since starting rollout in 2015, Terex has added telematics capability to over 650 crushers in the existing global fleet
  • Terex is currently activating some 35-45 new units per month
  • Terex now offers telematics on all new machines

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