Robots Enhance Digital Mining Safety,

Performance, And Profits

Advances in robotics and automation are changing the way mining operations run in
dramatic and transformative ways. Automation is reducing operating costs and improving
safety. Across all areas of mining operations, from the office to the mine site, robotics are
playing a prominent role and are another example of how using digital technology is driving
innovation in the mining industry.

Robots let mining firms capture more data and reduce downtime. Areas once thought too
dangerous to mine are now opportunities with advanced technology. When robots are
paired with smart products and Big Data analytics, firms gain a better understanding of
processes and faster decision-making.

Competitive landscape
The mining industry faces several major challenges. First, commodity prices have fallen
almost 50% from recent highs. A lack of skilled employees and capital spending have
driven operating costs up. Mining productivity has lagged behind other manufacturing
sectors. By comparison, the automotive industry has realized major gains driven mostly by
the increasing use of automation.

In a 2015 survey of 190 miners by IDC, the top priority was reducing costs. Profit pressures
are driving many of these mining firms to turn to technological solutions. Sixty-nine percent
of mining companies are exploring remote operations and monitoring centers. Twenty-nine
percent are looking at robotics and 27% at drones.
Progressive mining firms today see robotics, smart machines, and automation as the
industry’s future. Firms using them are well-positioned for growth and profits. Smart
machines are often referred to as part of the Internet of Things (IoT). The IoT is products
fitted with sensors, software, and wireless technology that connect with each other.
Together, robotics and the IoT provide formidable tools.

Bonus: Click here to learn more about Digital Transformation in Mining.

Let’s take a closer look at the ways robotics is changing mining.

Material handling
The loading and unloading of material is an area ideal of automation. Robotic systems
remove many of the repetitive and dangerous transportation tasks. Today, automated
trucks are moving rock and ore without drivers. Loaded trucks use GPS technology to leave
the area, dispose of material, and return to the excavation site. Remote monitoring ensures
safety and allows for changes to speed or direction as needed. Installed sensors track tire
performance, maintenance needs, and gas performance. Yet workers still have the ability
to monitor and modify the truck as needed.

Excavation
At one time the “world’s largest robot” was a 3,500-ton, 75-meter automated dragline. In an
open-cut coal mine, the machine can grab 120 tons of rock at once. Precision sensors help
automate certain functions, including the management of its 100-meter boom.

Safety improvements
Advancements in recent years have greatly reduced safety issues in mining. Laser- and
sensor-equipped robotic carts can do underground navigation, mapping, and object
detection. Inertial navigation systems and gyros, along with sensors, help other robots to
offer accurate position estimates. Other robotic detection systems can identify materials
and gases. Not only are these dangerous activities automated, downtime due to shift
changes is reduced.

Automated loading
A growing innovation in mining surrounds changes to excavation and loading. Enhanced
sensor technology and vision systems help excavators know where to dig, unload, and
move. Complex lasers “see” through dust to pinpoint where the excavator digs. While many
of these excavators do not perform as efficiently as humans, it is early in these products’
development lifecycle. Equipment makers are studying human operators’ movements to
create rules about machine movements. Efficiency may be lower, but robotic excavation
reduces injury and downtime. Robots don’t suffer from fatigue or need lunch and rest
breaks.

Operations management
Is there opportunity in using digital technology in mining? A McKinsey & Company
study says yes. McKinsey sees a $270 billion worldwide impact from digital innovation in
mining by 2025. The biggest area of opportunity is in operations management. Robotics
provide for better understanding of resources, material, and equipment flow.
Equipment management
Robotics and sensor technology heighten equipment management by anticipating failures.
Unscheduled breakdowns are reduced and equipment lifespans lengthened. For example,
automated belt scanning tools measure conveyor-belt wear. Operators are alerted of
needed maintenance or repair work well in advance. The costs and downtime of
unexpected repairs drop.

Equipment supply
IoT devices provide rich amounts of data that when analyzed are revelatory. This
information can improve purchasing decisions. Analytics inform decision-making in areas
from product design to assay interpretation.

New markets
Robots can go where workers cannot. Submerged mines, underwater locations, and severe
weather sites are now viable opportunities.

Mining Big Data about mining

Big Data analytics allow for collecting massive amounts of information and speeding up
decisions. One example is assay analysis. Geologists today don’t need to wait weeks or
months for offsite assay results to recommend next steps. Onsite, fact-based decisions are
much easier with Web-based applications. Geologists now rely on robotics to feed
information on field operations, safety, maintenance, and drilling. Data is sent either directly
by the devices themselves or by staff using mobile phones, tablets, or laptops. Monitoring
systems for spatial production decisions are also improved. Integrating data from mine
planning, ventilation, safety, rock engineering, and mineral resources improves forecasting.
Robust software programs can generate nearly instantaneous reports, alerts, and
dashboards. Supervisors have onsite access to the analysis through a Web browser or
app. This data has many uses. Drilling managers save time and can make quicker
decisions on next moves. Office staff can order fuel and supplies and invoice faster.
Accreditation and safety data is immediately accessible.

Conclusion
The potential is significant. Robotics, smart devices, and Big Data are the present and
future of mining. Nimble firms that invest wisely in these technologies are best positioned to
secure new profits, improve safety, and reduce operational costs.

The global Mining and Metals industry is going to come together to talk more about digital
innovation impacting the mining industry July 12-14 at the International SAP Conference for
Mining and Metals in Frankfurt, Germany. Find out more and register. Don’t miss this
opportunity to meet with world leaders and learn how your organization can become a
connected, digital enterprise.