Fatigue and distraction can be a deadly combination when operating large equipment, such as a 240-t haul truck. Freeport-McMoRan began to explore how it could apply technology – specifically a fatigue monitoring system in mine haul trucks – to eliminate the risk and improve the safety of operating these large machines. Called the Driver State System, or DSS, the Australian-made system by Seeing Machines uses cutting edge, eye-tracking technology to detect operator drowsiness and distraction the instant they occur. It is designed to increase driver awareness and reduce fatigue-related incidents.
“Managing fatigue and distraction while operating a haul truck for 12 hours can be a challenge for even our most veteran drivers. Our operators must consider a variety of factors during their shift, including environmental, mechanical and human error,” said John Caylor, Vice President of Occupational Safety and Health, told the National Mining Association (NMA). “Employee safety is our top priority – DSS provides an early warning system and is another tool that we can use to keep drivers safe behind the wheel.”
DSS uses a fully automatic, console-mounted camera to essentially “see” or track the driver’s face and measure the amount of eyelid closure and orientation of the driver’s head. Eyelid closure is processed to determine the level of driver fatigue. By tracking head movement, DSS is able to detect driver distraction. In the event of fatigue, in-cab audio and seat vibration alarms sound immediately to alert the driver, and site dispatchers are notified in real-time.
Freeport-McMoRan first piloted the system in 2010 in ten haul trucks at its Safford mine in Arizona. Since its successful testing in Safford, the system has been implemented and is fully operational at most company mines throughout the world, with the remaining planning for system implementation.
In 2012, Freeport-McMoRan received the Mine Safety Technology Innovations award by the US National Institute on Occupation Safety and Health (NIOSH) for its adoption of DSS. The award was presented at the 2012 MINExpo and recognised the company for extraordinary efforts to apply technology in ways that improve mine worker safety.
“The data indicates that serious accidents have been prevented with the awareness the system has given our haul truck drivers,” said Red Conger, president of Freeport-McMoRan Americas. “As we continue to refine the adoption of the system to the mining environment, we are confident it will save lives.”
Freeport-McMoRan and Seeing Machines are working together to evaluate DSS performance in the mining environment, with Freeport-McMoRan providing critical feedback that helps Seeing Machines further develop the technology to increase safety, efficiency and durability. The partnership has resulted in improved versions of DSS that can withstand the abuse of mining conditions and consider its complexities, such as temperature, vibration, continuous power and interruptions.
In August, Seeing Machines and Toll Mining Services reached an impressive milestone, installing the 100th DSS system into the Toll fleet. The system was first trialled in Toll’s fleet at the Anglo-American German Creek coal operation near Emerald, central Queensland in July 2011. Recognition of fatigue as a major concern in the mining environment and the DSS proven ability to reduce the number of fatigue and distraction events by 70%, quickly saw Toll Mining Services, part of Toll Group, roll out the system to other fleets operating across Australia. These included the BHP Cannington zinc and lead mine near Cloncurry, northern Queensland and at the BC Iron iron ore mine in Nullagine, in the Pilbara in Western Australia. DSS was later rolled out to a further five mine sites across Central Queensland.
Driving safety and fatigue management are an important area of focus under Toll’s “Think safe. Act safe. Be safe.” safety strategy. The DSS capability to provide real time alerts and transmit the data remotely via the 3G telephone network supports Tolls global safety strategy and the units are now installed in Toll’s long haul Dangerous Goods vehicles. These vehicles are carrying loads as diverse as bulk fuel and crude oil in WA, NT and SA, dangerous chemicals in WA and NSW and explosives all over Australia for the Australian Defence Force.
The DSS system is now installed in 100 vehicles from a range of manufacturers including Mack, Kenworth, Western Star, Scania, Powertrans and Freightliner. These vehicles are based out of 13 depots and mine sites Australia wide. DSS is protecting the drivers, their precious cargo and other road users on the country’s long open roads ensuring that everyone has the right to go home safely.