Changing the Way We Look at Conventional Mining

Author: Ryan W Siggelkow

Special Projects Manager



Introduction:
Mines today use various methods of mining to extract ore. Because of the dangerous nature of many of
these processes, remotely controlled LHD machines are being used to extract the ore from the draw point.
The remote control system, although being made safer all the time, has remained virtually unchanged for
many years. The basic functionality is an operator switching the machine to remote control, getting out of
the cab, walking up a stand, operating remotely, returning to the cab, switching to manual, driving
manually, switching to remote, and switching to manual. It seems repetitive, and time consuming, does it
not?
Networking, convergence, video, voice, and data infrastructures, and other technologies are growing by
leaps and bounds in virtually every industry and region, except for mining. From the comfort of the living
room couch, a Canadian can play hockey online with full voice conversations over the Internet with
someone in Russia in real time. Yet, a mine superintendent must jump through hoops to have a private
conversation with the front line supervisor underground. "Is Joe around anywhere?" If Joe hears the
message, he will respond. If not, who knows? Maybe he's hurt. Maybe he's not. Where is Joe? Nobody
really knows, and that is scary. Today, surface knows that the workers disappeared into the cage at 7:00
a.m. They also know that the workers will probably and hopefully return at 3:00 p.m. Is there not a better
way to handle this?
With such a complex industry, it seems as if, for the most part, the introduction of new technology into
mining has either been overlooked or has been met with some resistance. It is time to step back, look at
the process, and see how it can be improved. Key areas of focus will be safety, productivity,
dependability, and cost-effectiveness.

The MUCKMASTER Radio Remote Control System:
In 1997, the MUCKMASTER system was born, being designed from the ground up to be used on
underground mobile equipment. See Figure 1. It was not adapted from cranes, or locomotives, or ship
yards. It is designed and built to withstand the harsh environment of underground mines. HLS
revolutionized the remote control industry with that release by providing a turn-key package that included
valves, hoses, electronics, software, installation, and after-sales service. The traditional interface box,
with relays, timers, and terminal blocks, was rendered obsolete as all logic and safety systems were now
controlled directly from the Master Unit. Most of the available systems today are yet to catch up. The
very first MUCKMASTER system released included full CANBUS functionality, which only recently is
being used on some newer machines. The simplicity of the system is one of the reasons that there is so
little downtime on the equipment. Fewer parts and connections equal much less chance of failure and
lower cost of ownership. That is a motto that has
proven itself time and again in every aspect of life.
Troubleshooting is also very simple because there are
so few parts involved.
Because HLS is the manufacturer, the same robust
system that was designed for load-haul-dump
machines has now been used on excavators,
locomotives, mobile and stationary rock breakers,
block hole drills, ITH drills, Simba drills, jumbo
drills, as well as many other types of machinery. The
ability to modify programming, output scaling, as well
as the strong maintainable background of the
equipment has led to a world trusted remote control
system.
Users of the MUCKMASTER Control System will
testify that the MUCKMASTER Remote Control System provides very low total cost of ownership and
very high availability of equipment. So much so, that many customers around the world are willing to
waive a preferred brand of machine, if the manufacturer refuses to provide the machine with the
MUCKMASTER system. A remotely controlled machine is not worth the steel it is made from if it is not
available to move material. For those who are not currently using the MUCKMASTER, here is an
invitation to put it to the test.

The Process of Remote Controlled Mining:
Mines are pushing the limits of conventional remote control systems today. Before, it was not customary
to work too far out of view of the machine. Today, however, some stopes are so long or large that there is
no visual contact with the machine. Because of this, many customers are comfortable with using video
cameras on the machine and working over a monitor. Some would say that the video gives a better
perception because it is mounted on the machine and the operator usually cannot see over the machine
from his vantage point without video assistance.
HLS has developed, with some assistance from
customers, custom video systems including in-
cab video, pan/tilt/zoom capabilities, (See
Figure 2) a combination of hard-wired or
wireless video, as well as many combinations of
the above mentioned systems. This has enabled
users of the MUCKMASTER system to push
the limits of conventional mining. Operators are
becoming very productive working with
machines over video.
Figure 1
Figure 2
What is really wrong with how remote controlled mining is being carried out today? Operators are getting
very efficient. The MUCKMASTER has been making the process much less complex and easier to
troubleshoot. The technology has become an integral part of the mining process being used widely all
over the world. But, there are downsides. The operator still must get on and off the machine multiple
times every shift. Each time, there is a risk of injury to the operator from slipping or falling. While the
machine is operating in remote, there is always a risk of a brake failure, operator error, or many other
factors that may cause serious injury or death to the operator. This is because there isnt usually much
room for error in remote controlled mining. Some mines have remote stands for the operators, while
many, many more do not. Many times, the drift is only slightly larger than the machine, not allowing
room for stands or other infrastructure. During the remote to manual change, and vice-versa, there is time
involved. The operator has to ensure everything is safely put in its place and properly put away. This time
adds up as operators will make this change many, many times in a single shift. Very often, the joystick
units, or transmitters, are left out somewhere improper, and accidentally driven over, which is at great
cost to the mining company. The time involved to work in a remote controlled area is usually very great
because material is moved from the draw point and hauled by the LHD to an area that is far away. Every
minute that the draw point is open adds risk of rock bursts and machine burial.
Question: Would an operator accomplish more in a day if he never moved from a single location. What if
he wasnt required to jump on and off a machine several times every shift, and instead, could simply
move to his work area, sit down, and move material all day. Imagine, for a moment, that the remote
mining process literally had no intended downtime. There would be a stope to draw from and a designated
ore pass, or remuck to move the material to. A manned machine would then take that material and load it
into a truck or move it further, if required. The countless hours of operators getting in and out of machines
today are completely wasted. No material is moving and no productivity is being made.
Another Question: What is the likelihood that an operator would be injured if he was not near the
machine? Today, there is much discussion about warning when the machine is within a certain proximity
to the operator. This would prevent the system from accidentally driving too close, or even, on top of the
operator. But, what happens when the braking system fails? What happens when the proximity system
fails? It seems as if this approach is not a final solution to the dangerous nature of remote controlled
machine operation. Instead, it would seem to give a false sense of security, which amounts to nothing
more than hoping that nothing goes wrong, rather than a proper solution to a problem.
In safety discussions, if a hazard is identified, it is discussed by the management, safety representatives,
and workers. The first discussion is, "Can the hazard be removed?" Sometimes, however, the hazard can
not be removed as it is an integral part of the process. The next discussion would be; "How can we guard
this hazard?" If guarding would prove to be very difficult, the final discussion is; "How can we protect the
worker?" This is normally accomplished through masks, gloves, or other personal protective equipment.
Thinking about remotely-operated machinery, "Can the
hazard be removed?" The answer is yes. The hazard can be
removed by simply moving the operator further from the
machine and keeping him out of the dangerous area. See
Figure 3. Why would safety discussions jump over the first
step into guarding or protecting when the option is available
to remove? By making a system to automatically stop the
machine if it is within proximity of an operator, the hazard is
simply being guarded, but as was already discussed, the
available guards today are not without hazards themselves.
In a factory, when a remotely controlled machine, or
automatically controlled machine is operating, it is usually
contained in a cage that is completely enclosed and cannot
be entered without powering the machine down. In this way,
there is no hazard to the workers and the machine is free to
produce all day.
What about productivity? If the operator could simply be pulling the material from the open stope and
moving it to a close area, where it is handled further; could productivity be improved? The dollars and
cents of the operation are in taking the material from the blast and moving it out so the area can be
backfilled and a new area can be started. If remote machines could do the job of remote machines only
and manual machines deal with the material in a safe area, the savings would be astronomical. Today, the
machines tram the material down the drift to another area. During this time, productivity at the draw point
is wasted and the machines are being beaten up, performing a job that they are not really meant for.
Trucks and locomotives are better suited for haulage. Why is the movement of material being done with
LHDs?

A New Method of Extracting Material:
HLS HARD-LINE Solutions Inc. has developed a tele-operation system that allows an operator to operate
a machine from a portable remote cabin. This cabin would be completely portable and the required
network is very simple to install and disassemble as required. When remote control is required, the remote
station is set up in a safe area that is close to the working area. This cabin includes a remote control chair
for the machine control, two LCD televisions to view the machines forward or reverse cameras or any
other cameras set up. For instance, a camera could be set up on the overcut, looking down on the working
area. From the chair, Pan/Tilt/Zoom controls are integrated into the joysticks so the operator can use this
camera to look around the stope and find loose or large pieces of material that are about to fall. This can
greatly reduce the risk of burying a machine, or even worse, losing a heading with millions of dollars of
material just sitting there.
A typical system would include a small cabin that would be set up on the overcut or another area that is
close to the work area. This cabin would be completely self contained. From the cabin, a network would
be installed from the cabin to the work area to provide a wireless connection to the machine. The network
is very simple with connectors on all parts. Everything would be preconfigured for that machine. The
Figure 3
machine would already be equipped with HLS's MUCKMASTER Remote Interface Package as well as
video cameras and wireless access to the network. Access to the work area is guarded with barriers that
automatically shut the system down if any machine or person enters the area that is being operated tele-
remotely.
In this method of mining and moving material, the difference is that the machine would simply move the
material from the draw point to a remuck or to a designated dump site. When the draw point is completely
mucked out, the area can be backfilled and the remote machine can move to the next area that requires the
process. If the material is to be loaded into a truck or ore pass further down the drift, a manually operated
machine would be used for moving the material to the next process. Imagine; machines can be used for
the process that they were designed for. With proper mine design around this new concept, productivity
will be improved.
The obvious advantages are numerous. Time is saved because the operator is not climbing on and off the
machine multiple times every shift. Sound and vibration, which are unpleasant and hazards to hearing and
the body, are eliminated. The dangers involved with being within close proximity to a remote machine are
eliminated. The operation of these machines can now be accomplished by a greater percentage of the
workforce. The comfort for the operators is improved, being in an ergonomic chair in an air conditioned
room.

Making Giant Leaps:
The obvious question arises: Why not move the operator immediately to surface? Why not make the
machines run themselves and jump over everything today? Obviously, there are advantages to taking the
operator out of underground and moving him to surface to operate the machine from there. There are even
greater advantages to making the machines operate automatically. However, the paradigm shift from
operating a machine with conventional remote operation to moving directly to surface poses many issues.
The leap is too great to take in one giant stride. There have been very few, if any, real success stories
where mining companies have taken the leap to surface to operate mobile machinery. To clarify the point,
HLS defines success as being cost-effective enough to be widely deployed and dependable enough to be
trusted to make production targets. If a mine cannot trust a remotely operated machine; why use it at all?
Companies must be completely confident in a technology for the concept to succeed. Without this
confidence, the project, and ultimately the entire concept will be a dismal failure.
Food for thought: Would it not make sense to walk successfully before running? The old adage has
proven to be true and has withstood the test of time. A proposed trial would be to start with operating the
machine remotely from a close location. Once trust is built up in the system by the operators and the mine
personnel make a simple switch to surface. By approaching the complex overall picture in baby steps,
operations and maintenance can more easily understand and adapt to the different situations that will arise
in tele-operated machine control. It will allow operators to get accustomed to operating the machine from
a distance while still having the feeling of being near the machine in case of breakdown or other
situations. The normal routine of approaching the work area remains the same with the regular circle
checks and daily maintenance, greasing, and fuelling. Training and safety considerations would be
handled in this project.
After adapting to these changes, make the jump to surface. The machine interface is the same in both
scenarios. The operators hardware is the same in both scenarios, and the network is the same in both
scenarios. The only difference would be to unplug the network from the portable cabin and plug it into a
fibre pair going to surface. Literally, it is that simple. This step will overcome maintenance difference and
pre-shift circle checks.
HLSs biggest strength is taking complex projects and turning them into widely available off-the-shelf
products. Because of this approach, spare parts, troubleshooting, and repairs are made to be routine
instead of confusing. This approach has also allowed complex, and previously extremely expensive
systems to be installed at an extremely reasonable price, which will be billed and payable only upon
successful completion of each stage.
Once the operators are confident in surface control and all of the maintenance, training, and safety steps
are out of the way, take the step over to automated haulage.

The Ideal Partner:
More often than not, companies piece together PLCs, parts from hydraulic suppliers, computers, third-
party software, proprietary networks and whatever else is needed to stitch together the final project like a
quilt where many different swatches are stitched together. What if the entire quilt was almost done, but
one fabric was discontinued? Another fabric could be used, but it wouldnt be uniform anymore. All of
the pieces could be replaced, but it would prove to be a lot of work. The point is that PLCs and many
other parts are made obsolete by the manufacturer very often. In the middle of the project, everything
looks good until an add-on is required or until a change of direction is required by the customer. If the
PLC is not available, they may need upgrading. Or, even worse, they may all need to be replaced because
of protocol changes. The instrumentation department now requires training and different spare parts
again.
HLS has full control of software, board level design, and system components. Many times, parts have
become obsolete that are core to the MUCKMASTER system. HLS takes this opportunity to design a new
component, while always providing a backwards compatible new component. The new parts always work
with the old parts. Never will a customer be left without a direction to advance or grow the system.
Another downfall of piecing parts together is that everything becomes an unknown. Components react
differently with other components and this could prove to be very unsafe, or even life-threatening. Data
sheets are misleading and sometimes incorrect. Trusted components and overall knowledge of the
complete package will lead to a safer, and ultimately, more cost-effective system.
If a major automotive manufacturer (ABC Co. for the example) started to supply cars with tires, stereos,
speakers, etc... that are now being designed and manufactured by ABC Co., how confident would a
prospective buyer be, knowing that ABC is not experienced in tires, stereos, etc... The idea is absurd
because ABC will always trust the world leaders in these components. Would a steel supplier be the ideal
choice for tires? Would the mailman be the number one choice for diagnosing problems with the human
body? What about highly complex and highly critical machine tele-operated control systems? The brand
that is trusted worldwide and has a tremendous track record of reliability and dependability should be the
obvious choice for a partner in complex control systems.
The MUCKMASTER Control System, Video Systems, and Tele-Operated Control Systems are being
used in countries on every continent and are trusted by hundreds of users.

The Enabling Infrastructure:
The introduction mentioned on a network infrastructure and the lack of communications available today.
It is important to touch briefly on this aspect because, just as the human body relies so heavily on a strong
backbone, any new projects coming in the near future will rely on a dependable infrastructure, or
backbone. The small, contained, simple network that is installed to control machines over can also be
used for mine-wide video, voice, and data. See Figure 4. Because it is based on the Ethernet and Wi-Fi
standards, wireless VOIP telephones, network video, machine and personnel tracking, ventilation control,
ore and waste pass levels, oxygen and CO levels, heading status, as well as many other applications can
be easily implemented. With the vast amount of Wi-Fi compatible parts and sensors that are now
becoming widely available, the imagination is the only limiting factor to the growth of this technology.
This infrastructure, if installed mine-wide can facilitate the control of every piece of machinery from
surface, and eventually automation. Again, this idea is long ahead of the times. However, many
companies today are still relying on, and even investing in old technology for communications for new
mines. New applications will not work over old
technology. Computers cannot communicate
across tin cans, regardless of the condition of
the string. Without implementing technological
change underground as it is being done at a
corporate level, there is no hope for new
technology to make it into the industry. It is
time to start taking steps to implement a new
network underground. HLS has, over the years,
developed the Mine Area Net digital
communications solution, which is the
backbone of tele-operation. This system can be
installed in small pieces for proof of concept so
that the benefits can be quantified to spend
capital.

The Horizon:
Typically, the industry has been very anti-change on many fronts. It has happened too often, that between
the company and the supplier, plans are made to climb an entire tower, without focusing on the first step.
On the horizon, networking will become slightly easier to implement underground as the maintenance and
operations become more familiar with the technology. This can be easily accomplished by installing a
Figure 4
network in key areas and working towards implementing new technologies into new projects that are
coming online. Machine control over infrastructure will be taken in baby steps until everyone is familiar
and confident that the technology is cost effective and feasible. Once the confidence level is raised by
maintenance, operations, and corporate in this technology, it will become the new standard of remotely
controlled mining.