Case Study: Crushing Services Australia

Cone Crusher System for CSA

Overview

Crushing Services Australia (CSA), a leader in mobile crushing and screening services, needed a smarter way to manage its cone crusher systems—an essential piece of equipment in mining operations for producing refined material. To meet the challenge, Telemation delivered a fully automated control and diagnostic solution built to enhance safety, maximise efficiency, and give operators complete, remote system control.

Cone crushers are particularly vital in intermediate and fine crushing stages following primary crushing. Their hydraulic release capabilities make them uniquely capable of safely ejecting uncrushable material, which helps protect the machinery and reduces downtime.

The Challenge

Operating a cone crusher requires strict attention to system conditions, as improper function sequences or overlooked faults can result in serious equipment damage or operator risk.

CSA sought a solution that would:

  • Prevent misuse through operator error
  • Monitor performance and faults in real time
  • Enhance operator safety
  • Streamline maintenance and fault diagnostics

Our Solution

Telemation engineered a bespoke cone crusher control system that centralises system operation and live diagnostics into one streamlined interface.

CCpilot VA

A rugged HMI offering clear visual access to system status and diagnostics.

VersaTEQ Remote Receiver

Enables wireless machine control with robust reliability in harsh mining environments.

Epec control unit 3724

EPEC 3724 Control Unit

The system’s brain, running advanced automation logic and safety interlocks.

Smart Safety Protocols

To protect operators and equipment, the Cone Crusher System incorporates several layered safety measures:

  • Function Interlocks: Ensures operations only execute under predefined safe conditions.

  • DMG (Dead Man Grip): Prevents accidental or unintended machine activation.

  • Warning Alarms: Provides immediate alerts for system faults and pinpoints affected functions.

  • Shutdown Sequences: Triggers complete safe shutdown during critical system failures.

These features empower operators with confidence and control, while reducing risks and operational delays.

Total System Control & Real-Time Feedback

Positioned as the central command unit of the machine, the Telemation Cone Crusher System offers:

  • Live Monitoring: Constant feedback on critical system metrics

  • Comprehensive Diagnostics: Detects early warning signs before faults escalate

  • Full Operator Control: Streamlined control over all crusher functions, reducing the need for manual intervention

Whether performing day-to-day operations or troubleshooting under pressure, the interface gives mining crews everything they need to work efficiently and safely.

Conclusion

CSA’s upgraded cone crusher systems now deliver improved performance, reduced downtime, and safer day-to-day operation in the demanding mining environment. Telemation’s solution has transformed the crusher from a reactive tool into a proactive and intelligent machine, capable of self-monitoring, safety enforcement, and operator-friendly automation.

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