Automation in the Mining Industry - UBC Engineering ... · A machine to make our ... Caterpillar...
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Transcript of Automation in the Mining Industry - UBC Engineering ... · A machine to make our ... Caterpillar...
Definition: Automation
Discipline to program & manipulate equipmentmanipulate equipment
Instrumentation, sensors, final-control-elements, control systems, network
i ticommunication
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DefinitionRobotsDefinitionRobotsDefinition: Robot
"A reprogrammable, multifunctional manipulator designed toA hi t kmanipulator designed to move material, parts, tools, or specialized
A machine to make our lives easier
devices through various programmed motions for the performance of athe performance of a variety of tasks"
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http:// www.physiologytoday.com
DefinitionIntegrated SystemsDefinitionIntegrated SystemsDefinitionIntegrated SystemsIntegrated Systems
Integrated Systems which emulate and enhance the human ability to:
Perceive Reason Act
… and this includes
PERCEPTIONincludes…
REASONINGincludes…
ACTIONincludes…includes…
Sensor systemsand recognition
includes…
Artificial Intelligence
includes…
Control Systemsthe Human-MachineInterfaces required toand recognition Knowledge Systems Actuators
qoperate these systems
44Dr. Greg Baiden – Mining Conference – Chile 2008
Automatic Operation
Direct Tele-operation H C t ll dAutonomy
Robot InitiativeSafeguarded and
M it d H I iti tiDirect Tele-operationManual Operation
Human ControlledTele-autonomy Robot InitiativeMonitored Tele-operation
Human Initiative
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INCO
Mount Keith Mine
Automation in the Mining Industry
Drilling operations
Driverless haulage trucks
Semi automatic load haul dump truck (LHD) Semi-automatic load haul dump truck (LHD) • onboard video systems front and back
Environmental monitoring systems• Ground water monitoring
W t t fl• Waste water flow• ARD (acid rock drainage)• Temperatures
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• Temperatures• Ventilation
Mining Automation Application
Andina Mine (underground copper mine in Chile)
Tele-robotic LHDs
Improved safety p y
One operator runs multiple vehicles
Operator located outside mine Operator located outside mine
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LHDs example: Caterpillar R2900G Load Haul Dump vehicle.
Autonomous Haulage Trucks
Removal of workers from potential dangersp g Reduction of Green-House Gasses (GHGs) Reduced Maintenance Costs Reduced Maintenance Costs Improved Productivity
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Autonomous Haulage Trucks
2005 – Komatsu: Codelco Komatsu: Rio Tinto
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Autonomous Haulage Trucks
2007 – Caterpillar: BHP-Billiton
Expand the Mt. Keith open pit
Fully-automate the Olympic Dam open-pit
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Mount Keith Mine Olympic Dam
History
2010 – Opportunity of new projects
2009 – Caterpillar: BHP-Billiton
pp y p j Drilling Hauling Hauling Digging
Autonomous-capable Reedrill drill rigs
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Komatsu’s FrontRunner (AHT)
History
First Approach ( Moon-Shot)pp ( )
AutonomyT l Robot InitiativeTele-autonomy Robot Initiative
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History
New approach – Baby Stepspp y p1 – Manual2 – Computer Cruise Control3 – Telerobotic4 – Tele Remote5 Sensors for Safety5 – Sensors for Safety6 – Semi Autonomous7 – Fully Autonomous7 Fully Autonomous
Komatsu Autonomous Haulage Trucks
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Automation Workshop – Chile - 2008CAT’s Integrated Object Detection System
g
Autonomous Haulage System Elements
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Autonomous Truck Sub-systems
Communication Equipment
Breaker Controller
Acceleration Controller
R d S
Vehicle Speed Controller
Radar Sensor
Obstacle DetectorFront Wheel Steering
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Front Wheel SteeringAngle Sensor
Key Performance Indicators (KPIs)
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Key Performance Indicators (KPIs)
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Balanced Scorecard
FINANCIAL CUSTOMER ENVIRONMENT/COMMUNITY
INTERNAL EMPLOYEESATISFACTION
LEARNINGAND GROWTH
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Key Performance Indicators (KPIs)
KPIs give “before” & “after” pictures
KPI’s assist with decision-making
G l i t / it Goals are easier to measure/monitor
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Implementation
Manual Robotic
KPIKPI
(core)
KPI(core)
(core)
?% AHT0 100
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Implementation Challenges
Challenges : Management decisions and strategies Workplace changes
Cultural barriers and union beliefs
Possible Solutions :Possible Solutions :
Long–term vision and commitment
P id t i i t id b t Provide training to avoid sabotage
Regular and consistent communication
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Avoid Labour Replacement as an objective
Ethical Considerations of Automation
If an automated machine kills a person, who is responsible?
The manufacture? CEO? Mine Supervisor?
Ensure legal and insurance systems are engaged in developing laws governing automated machinesautomated machines
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Simulate how variability of driver performance together with driver replacement by sensors and g p y
control affect mine performance
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Simulation of AHT
Deterministic / Probabilistic Simulation
Focus on Production
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Modelling Approach
Shovel/ Manual Truck model Shovel/ Manual Truck model
Shovel/Autonomous Truck model
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Simulation of Manual Trucks
Fuel SystemRoad Condition Tire wear
Control System
Limited to Driver’s Performance
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Simulation of AHT(sub-systems)(sub systems)
L li ti C t li d S t
Telecom Control SystemsSensors
Localization
Navigation
Centralized System
Intervehicle LocationTire WearFuel System
Obstacle Avoidance Human Presence
Design of an
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Driver Performance Driver Performance
Max SpeedMax. SpeedAcceleration/Deceleration
St i d Di tiSteering and Direction
Cycle Time Fuel ConsumptionFuel Consumption
Tire Wear Road Wear
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Manual and AHT Model Output
The model will output Benchmarking KPIs:
Productivity
Safety Safety
Breakdowns
Cycle times
Maintenance and labour costs Komatsu Maintenance and labour costs
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Sub-Questions in the ResearchKey Performance Indicators - Targets
+ 30%AHS AHS AHS AHS AHS
+8%
-10%-7%-12%
ManualManual Manual Manual Manual
Fuel consumption
Truck haulage speeds
Investment cost per truck
MechanicalAvailability
Tire Wear
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Sub-Questions in the ResearchKey Performance Indicators - Targets
AHS
12%
AHS AHS AHS AHS
+ 5%12%
-5%-14%
ManualManual Manual Manual-40%
Increased Truck life
Maintenance costs
Increased Productivity
Labour costs
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Conclusions
AHT improves safety, productivity and maintenanceNew Commitment
AHT cannot be seen as employee replacementThe future of AHT in mining looks bright – implementation should be considered a priority to remain competitive and
Simulation bias must be avoided
Simulation can be used in real time to evaluate changes
ensure a safe and effective operation
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