Department of Employment, Economic Development and Innovation
Tilman Rasche BE MSc
Senior Inspector of Mines, DEEDI
A Regulator’s View of Automation, Proximity Detection and Collision
Avoidance Systems
2© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Link between Proximity Detection and Automation
Triumph of partial and full automation will depend on the success of proximity detection and collision avoidance technologies and approaches.
Therefore ….
We can learn from our current experience (successes and mistakes)
3© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Assumptions…..
Two blondes living in Brisbane were sitting on a parkbench talking........ and one blonde says to the other, "Which do you think is further away..........Melbourne or the moon?"
The other blonde turns and says "Helloooooooooo, can you see Melbourne ...?????"
4© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Dictionary
Assumptions are beliefs or ideas that we hold to be true — often with little or no evidence required.
We make assumptions every day of our lives…
…. blondes have more fun….
…. the earth is flat…..
…. as a driver on the highway, I assume that other drivers will obey traffic signals, so that when I go through an intersection with a green light, I assume that the cross traffic will stop at its red light.
5© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Stats from the US - perspective
http://lifesavers.ky.gov/lifesavers_2006/session17-allred.ppt#671,2,Red Light Running
11%
4.5 in 1000, 1 in 222
6© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Assumptions ‘solve’ a lot of problems we would otherwise have to investigate and answer for
7© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
~ 3 out of 4 = ~ 75% - vehicle related
Scientific investigation into large scale accidents has allowed us to
come a long way
8© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Why do we see what we see…
Increasing dependence on mine vehicles – OC & UG
More & more vehicles, increase in size & speed– Visibility and space around machine – Operator & worker behaviour– Recurring accidents– Same picture worldwide
Key mining hazard but there are solutions
– Need to clarify assumptions……
Its up to all of us to solve the problem….
9© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Source : DEEDI - Serious accidents and high potential incidents Mining and Quarrying Compilation of reports for March 2011
HPIs as of March 2011
10© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
23232121181814141010MinorMinor
(eg first aid)(eg first aid)
25252424222219191515InsignificantInsignificant
(eg(eg no injury)no injury)
2020171713139966ModerateModerate
(eg medical / (eg medical /
hospital treat)hospital treat)
16161212885533MajorMajor
(eg permanent (eg permanent
disability)disability)
111177442211Catastrophic Catastrophic
(eg fatality)(eg fatality)
RareRare
(almost (almost
impossible)impossible)
Unlikely Unlikely
(not likely to (not likely to
happen)happen)
Possible Possible
(heard of it (heard of it
happening)happening)
Likely Likely
(has (has
happened)happened)
Almost Almost
certaincertain
(common / (common /
repeating)repeating)
Likelihood
Consequence
Assumptions??
Maximum reasonable consequence?
Most likely consequence?
Likelihood?
‘Pegging’ the Risk - Rank
11© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Hazards• Moving equipment (‘tons’ of kinetic energy - CAT 797F, payload 360 ton GVM
623 tons, 3,800 HP, top speed 67 km/h, 14.8m long, ~10m wide) Boeing 747-400 178 tons 3.5*
• LTA visibility• LTA hazard awareness
12© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
CAS
NOW
Automation
13© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Basic design assumptions
What is the basis for ….
• Road widths - 3.5 rule• Separation distances – vehicles in motion require ??? m to stop• Maximum allowable speeds to allow safe braking• Queuing and parkup distances• Detection envelopes for proximity detection technology – cloverleaf-
shape???
• Where is the empirical data to substantiate the above???
• Braking distances• Operator reaction times• How will people react?
We too often assume we know what the problem is
14© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Q: What is the minimum length of runway for the safe landing of a Boeing 747?
A: Google
http://www.boeing.com/commercial/airports/acaps/747_4.pdf
Engineering Assumptions
Q: What is the braking distance of xyz haultruck? (50 km/h,
level ground, dry road, loaded)
15© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
16© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
What is the problem?
V2V V2P slow speed e.g. Parkup areas
V2V collision or reversing over dump
V2V – overtaking collision V2V – high speed rear end collision
V2V - rear end collision
V2V V2P V2I reversing collisions
V2I or V2P forward collision
V2V collision - intersection V2V collision – mining face V2V collision – fast –slow moving vehicles
V2V – head on collisionV2V – slow speed rear end collision
17© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Typical Underground Scenarios, there are many more…..
Shuttle Car Continuous Miner
No Go-Zones !
18© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Example – design decision partially responsible for mining deaths MSHA - UG Fatalities - Continuous Miner
29 fatalities or 72% of victims were operating the remote at the time of the accident.
Most/all could be avoided if Proximity Systems had been available and installed
Not operating the remote
Maintenance activity
Victim locationX
Operating the remote
Legend
A moving RCCM collided withanother at an intersection,causing the stationary RCCM
to pivot and crush the other Op
19© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Stopping distance
Acknowledged braking capability
Behavioural expectation
20© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
‘There are only so many ways to kill people, and we know them all’
21© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Visibility = Opportunity to identify a hazard & react in time
??
22© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Shuttlecar or Truck Miner
23© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Person vs. Machine 1
Human Reliability - People are inherently unreliable
Mental processing time• Sensory – perception/recognition• Interpretation – what does this mean – friend or foe? (Car stopped in the
middle of the road)
• Response Selection – what happens next?
Expectation• Expected to brake – 0.7 secs = 0.5 secs perception 0.2 secs
movement• Unexpected – 1.25 secs = 1.05 secs perception 0.2 secs movement• Surprise – 1.5 secs =1.2 secs perception 0.3 secs movement
Movement time• Brake engagement time – foot movement, on pedal, depress,
mechanical delays
24© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Person vs. Machine 2
Other factors• Urgency – time to collision• Cognitive load – ‘non driving’ matters – music, mobile
phone, autopilot• Age ~ lower levels of fitness ~ lower response capability• Gender• Nature of signal – can it be seen? Is it distinct? Is the
vehicle in front accelerating/decelerating? Aspect – frontal/from side
• Visibility vs recognition• Reaction time at night – visual contrast (amber/yellow brown
shooting glasses)
• People will make mistakes (wrong decisions)
25© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Distance travelled (m) vs time (secs)
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
1 2 3 4 5 6Time secs
Dis
tan
ce t
ravell
ed
m
5 km/hr
10 km/hr
20 km/hr
30 km/hr
40 km/hr
50 km/hr
26© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
RA Tools
Human behaviour
Engineering Control
Administrative Control - Procedure
PPE
Elimination
Substitution
Rel
ianc
e on
Peo
ple
to c
ontr
ol r
isk
Risk
Risk
1. Major HazardBaseline RA
2. Project/ChangeIssue RA eg. Coll.
Awareness
4. Individual ‘continuous’
Face RA
3. Routine & Non Routine Task
Planning RA
HR
Control OptionsPeople to administer risk
Req’d HR Resources
Risk & Issue
RA Tools
‘Sp
ecialists’‘G
eneralists’
Mine workers
1. High Level QRA, Engineering type
analysis, FTA, BTA,
FMEA, HAZOP WRAC
2. FTA, BTA, FMEA, HAZOP, WRAC
3. WRAC
4. JSA Deg
ree
of D
iffic
ulty
Tilmans ‘Meaning of Life’ Ver.1.0
27© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Some CAS Technologies
• RFID – tags and readers• Radar• ‘Magnetic bubble’• Laser scanning• GPS – surface only• Cameras• Combination of the above
• Opencut and Underground metalliferous - available now• Underground Coal – requires IS certification – mid 2011• Cost from $5k per vehicle
28© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Fit for purpose equipment - Selection of the equipment
• Sites to review all risk assessments based on local and published collision scenarios
• Change management – change of system functions • Verify that selected proximity detection system is in fact able to
mitigate the collision scenarios• Need explicit underlying assumptions (speed, distance etc.) • Polar diagrams’ showing the actual detection envelope of their
systems, not assumed envelopes - ‘clover leaf’ vs actual pattern. • Clarify CAS - ‘collision awareness/avoidance system’ • Physics - mine sites must understand what the chosen system can
and cannot do - Manufacturers to declare the capabilities of their systems.
29© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Fit for purpose equipment - Selection of the equipment
• Manufacturers to declare if their systems are ‘collision awareness’ or ‘avoidance systems’, and provide sound, logical and unambiguous evidence for their judgement.
• Sites to check inference with other radio frequencies • Hardware – veiling (reflection), clarity of display etc.• Placement of screens/ alarming units – should be in field
of vision
30© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Fit for purpose equipment - Selection of the equipment
• Combination of screens and method of alarming – intuitive exception based alarming based on criticality?
• Mine sites to review the systems ability - future proofing
• Review breaking distances for all vehicles for the range of operating speeds and conditions - verify that current site vehicle separation distances are sufficient
31© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
• Review ‘Operations rules’ i.e. if systems deemed safety critical, then operational procedures must ensure consistency of approach.
• Site champions - effective acceptance and utilisation of proximity detection systems – link between site – operations and maintenance and the proximity detection manufacturer.
• Dedicated maintenance personnel to ensure a successful commissioning and implementation of the system.– Who is going to maintain proximity detection and
automation systems – specialised skill• Proximity detection issues - simulator training• Maintainability – easy and safe access to all external
hardware must be achieved.
Competent People
32© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
• Sites to review and update relevant site procedures incl. prestart checks to ensure proximity detection systems and their importance as a safety control is assured and recognised.
• Proximity detection system requirements for contractor vehicles operating at different sites. Commonality of approach and rule-set.
• Design and roll out a comprehensive training program that outlines how to use the system effectively. Incorporate a section that explains what the system can do and what it cannot do.
• ‘Nuisance’ alarms or conditions may be in fact real alarms due to the systems design and capabilities (physics)
Safe Work Practises
33© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Controlled Working Environment
• Proximity detection equipment must not be considered as the primary solution to mitigate collision risks.
• Must also consider their pit design & layout – intersection, haulroad, dump designs, road separation human behaviours etc.
• Inherently safer operating environment
34© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Market Place
• Collaboration - several prox detection OEMs integrating their systems into ‘one’
• Combined systems better than sum of all• Some machinery OEMs allowing prox system to
manage their machine – eg. braking
• GPS ( high speed) plus radar (slow speed) – opencut
• ‘Magnetic bubble’ plus … - underground • Ability to create non-detection envelopes on the
equipment
35© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
In Summary
• ‘What is the problem, then look for solutions’ - effectiveness• (V2V, V2P V2I) Accidents are preventable• Free lessons from proximity detection systems implementation towards
automation
• Proximity detection systems are not the complete answer but are an essential part of the solution
• Must also look at human factors – human ‘unreliability’• Proximity Detection Technology is available or rapidly becoming
available• Need a side by side integrated combination of approaches• Must be embraced – life saving technology• Key to making automation a safe reality
36© The State of Queensland, Department of Employment, Economic Development and Innovation, 2010
Every miner home safe and Every miner home safe and healthy every dayhealthy every day
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