Mining Automation: Sensing Technologies Jonathon Ralston CSIRO Exploration & Mining 2008 Narrow Vein Mining Conference
PRESENTATION OVERVIEW Why Mining Automation? Smart Sensors for Automation Case Study: Longwall Automation Success New Sensing Developments Summary
WHY MINING AUTOMATION? What is the industry asking for? Mine in ways that reduce the need for people and dramatically improve safety and health How can we maximise asset utilisation? We want to access ore that we presently can t
GOALS OF MINING AUTOMATION Mining Automation seeks to provide new options through: Supporting Sustainability Knowledge retainment Scope to modify personnel roles Improving Productivity Consistently dig-to-plan Optimal resource utilisation Increasing Safety For both personnel and the environment [less waste]
MINING AUTOMATION TECHNOLOGIES Core Technologies Sensing Processing Control Communications Visualisation Automation requires these tasks to be accomplished in-situ and in real-time
SMART SENSORS FOR AUTOMATION Sensing 101 Question: Why do we use sensors? Answer: To measure something! The key is to identify the parameter of interest and then choose the right type of sensor for the application Typical Examples: Distance, direction, location, volume, temperature, material thickness, etc
SENSING FOR MINING AUTOMATION The Utility of Sensors To make measurements that a human simply cannot make: Electromagnetic: Thermal infrared, radar, nuclear, Pressure, force, To constantly see things when the operator is not looking High accuracy measurements High speed acquisition Generate new information about the process for monitoring, control, and automation
SENSING: SOME QUESTIONS Scientific Can the sensor actually measure what we are after? (e.g., radar for range) Can it actually function in the intended environment? (e.g., video cameras in poorly lit surroundings) Technical Can a robust system be developed to sense and survive? (e.g., laser scanners in flameproof boxes) Can it provide useful data for real-time control? (e.g., output rate, processing requirements) Productivity & Safety Is it economically feasible? What is the cost vs benefit? (e.g., inertial navigation technology) Does it contribute towards improved safety, and are there risks? (e.g., roadway structural monitoring)
SMART SENSORS FOR AUTOMATION What Makes a Sensor Smart? Operational Context Remote, hazardous, extreme environmental variations, operating restrictions Output requirement Reliable, physically robust, self-managing
Degree of Difficulty SMART SENSORS FOR AUTOMATION The Lab Mars Sensor Operational Environment
SMART SENSORS FOR AUTOMATION Sensing is more than just the sensor! Integrating the sensor into the process Understanding the impact of introducing the sensor Providing the necessary supporting infrastructure Success requires a holistic (system-level) approach to sensor integration vendors, OEMs, minesite, developers
LONGWALL AUTOMATION
CASE STUDY: SENSING FOR LONGWALL MINING AUTOMATION
LONGWALL MINING AUTOMATION Automation motivated by productivity and safety
LONGWALL COAL MINING PROCESS
SMART SENSOR EXAMPLE: REAL-TIME POSITION AND ORIENTATION SENSING Operational Context Underground, limited access, explosive atmosphere, fluctuating power supply, communications interruptions Output requirement High accuracy, continuous unsupervised operation, physically robust, self-managing
SENSOR OUTPUT: MACHINE PATH Inertial navigation sensor Accurately measures the 3D position of the mining equipment
SENSOR DEVELOPMENT Emerging Sensor Systems for Automation 1. Tracking and Navigation (thermal infrared) 2. Material discrimination (radar) 3. Volumetric assessment (laser)
AUTOMATED HORIZON SENSING: THERMAL INFRARED TRACKING Horizon Control Sensor Coal-band features invisible to the operator can be detected using a shearer-mounted infrared camera Direction of camera view
SENSOR DEVELOPMENT Resource Horizon Sensing Cross-face panoramic reconstruction (thermal infrared)
SENSOR DEVELOPMENT Positioning for Navigation System reliability enhancement through radar-based sensing Sensing for joint creep/retreat measurement system
SENSOR DEVELOPMENT Roadway Structural Monitoring Radar to look for subsurface cracking and delamination Developing subsurface radar (GPR) for non-invasive survey Applying radar technology for resource discrimination
SENSOR DEVELOPMENT Void detection and monitoring on a longwall face
SENSOR DEVELOPMENT Real-time Volume Measurement Haul Trucks scan whilst moving Combine with weight to get material density
SENSOR DEVELOPMENT Real-time volume sensing Load distribution and characterisation Automated anomaly detection 3D information for easier operator analysis
SUMMARY Automation provides new options to improve mining CSIRO to continues develop intelligent real-time sensing systems Major automation successes come at the system level These technologies are now being adapted for underground non-entry metalliferous mining
THANK YOU FOR YOUR ATTENTION Any Questions?