Rise of the machines

Zach Savit reveals how small-scale autonomous robotic systems fill operational and safety gaps in mining operations following primary fleet automation.

As the adoption of automated mining haul trucks and drills continues across the industry, operations that incorporated autonomy earlier are now finding gaps. Not gaps within the capabilities of this technology; but instead how autonomy interacts with broader operational requirements. In most cases, additional questions raised by autonomous haulage and drilling solutions precipitate the identification of these gaps.

Although the safety benefits of autonomous operations generally drive implementation, unanswered compliance questions about autonomous vehicles persist. How does a duty shift change with continuous operation? When are inspections required if no operator shift change occurs?

While operators work to answer these and establish best practices for emerging technologies, a more pressing question emerges: “what comes next?”

Mines aiming to increase their autonomy, reduce labour costs and increase productivity will seek to take the next steps in automation. This pursuit inherently leads continuous improvement teams in one of two directions: filling enablement gaps or automating the next group of equipment.

FILLING ENABLEMENT GAPS

Each of the new, large-scale automation efforts in mining require nonautomated activities for effective operations. Fuel, lubrication, drilling bits, steel and water all need to be provided for autonomous solutions in haulage and drilling operations. Without these consumables, drilling operations would cease. A clear path to enhancing the efficiency of these operations is automating the delivery and replenishment of these consumables.

Fortunately, forward-thinking companies are developing robotic systems to address these gaps. Consider robotic refuelling solutions such as RAPID, Stratom’s autonomous refuelling, recharging and liquid transfer system. Originally developed to refuel military helicopters and autonomous convoys, the novel system has been adapted for the mining industry to accommodate fuelling autonomous haul trucks.

Robotic refuelling technology relies on visual or lidar scans for localisation, a robotic arm and connection to existing fuelling infrastructure. In addition to providing consumables for autonomous vehicles, this technology can also reduce human exposure to slip, trip and fall hazards in challenging climates.

For autonomous drills, the issue is more complicated. Although autonomous delivery of consumables is feasible – even in rugged mining environments – loading and unloading present additional hurdles. Robotic arms will be the key to solving this challenge, but the technology still requires adaptation and real-world testing.

Looking ahead, autonomous inspections will facilitate greater operational freedom for autonomous equipment. Only maintenance needs (preventative or reactive) will limit a vehicle’s utilisation and availability in the future.

AUTOMATING THE NEXT GROUP

Autonomous vehicles made the first inroads into mining before the turn of the last century. Although many of the world’s largest operations are pushing the envelope with autonomy, adoption rates vary. Autonomous fleet purchases are driven primarily by Australia, with Canada in a distant second. These purchases are increasing in size and frequency and almost exclusively focus on the primary fleet – large haul trucks, LHDs and large drill rigs.

The logical next step is automating smaller ancillary vehicles and their work — the secondary fleet. This secondary fleet is critical to the operation of the mine and currently requires significant labour.

The delay in automating these ancillary vehicles is due to the specificity and technical nature of their tasks. The primary fleets’ tasks are sometimes less technical than those of the secondary fleet and are an easier target for automation. This next stage often requires new, more complex autonomous behaviours, sensing techniques as well as different integration into fleet management systems (FMS) than haulage and drilling.

Developing these repeatable yet valuable autonomous behaviours is challenging but possible. It will, however, require serious cooperation between mining operators and technology firms that understand the specific requirements of mining environments and can deliver robust solutions capable of thriving in those conditions.

DRIVING THE PROCESS FORWARD

Identifying these gaps only becomes possible after initial autonomy deployment. Although critical to the long-term success of any technologically adept operation, these are secondary concerns for operations just now embracing autonomy.

Mines that have successfully implemented large-scale autonomy will be well positioned to adopt secondary fleet or enablement automations. Once the operation is ready, the process for implementing these smaller-scale autonomy and robotic solutions is similar to the previous iteration. Consequently, operators will likely approach these new technologies with less fear and hesitancy and more wisdom. A greater understanding of the workplace culture and integration methods will facilitate a quicker path to achieving value from these technologies.

These examples represent just some of the gaps identified after automating large-scale, primary fleets. As an industry, we should explore all possibilities to achieve the safest, most efficient production possible. Addressing operational and safety gaps with autonomous robotic systems empowers the mining industry to continue evolving and enhancing mine productivity and worker safety.

Zach Savit is with Stratom.