Rick Longstaff of Vista Training, a training solutions provider, says simulators are intended to provide convincing examples of many commonly encountered equipment operating situations. Even affordable PC-based simulators are very sophisticated. Technology advances allow simulators to be programmed to respond to a variety of human actions and reactions to ordinary and unexpected situations. For example, simulators used to train operators of off-highway heavy haul trucks, excavators or wheel loaders used in surface mines can familiarise new operators with all truck controls and operating techniques. The same simulator may visually create situations requiring emergency response action in a wide variety of situations. It may also be programmed to show the actual site where the equipment will be used to help orient new operators. And these techniques are accomplished in a totally safe environment and may be repeated until safe, efficient and cost-conscious operating practices become instinctive and automatic. Simulators can also be very effective in spotting operating errors and keeping records for follow-up corrective action. Doing the same thing in an actual piece of equipment may prove prohibitively expensive and generally involves potentially dangerous activities.
Longstaff cautions that no one can possibly program into a simulator every single scenario that may occur in the real world. “Mines still need to have in place a comprehensive training curriculum, which may include traditional classroom and hands-on training or multimedia, computer-based training with integrated record keeping. “No simulator can prepare operators for every possible contingency. Ever changing work sites create new hazards as they develop. Increased site traffic and additions of new, less experienced operators offer un-programmable simulation situations. Unpredictable mechanical failures provide a host of unknowns when trying to prepare operator responses. Climatic changes often affect operating conditions in very unpredictable ways that technology may not be able to simulate. “Smart simulation development takes recognised hazards into consideration and programs the simulator to elicit correct hazard response. Simulation programming techniques also train equipment operators to get the most out of the machine without abusing it. Those two things alone can pay handsome dividends to equipment owners. Proper training that avoids a single accident with a multi-million dollar haul truck or mine excavator can pay for a room full of simulators. Teaching proper operating techniques to extend tyre and overall equipment life will dramatically decrease operating costs. These benefits alone help ensure continued employment by keeping the operation profitable and competitive. And if that’s not enough, well trained operators save lives.”
Putting Longstaff’s ideas into practice, VISTA Training and Simlog, a pioneer and leader in the development of PC-based personal simulators for cost-effective heavy mining equipment operator training, recently announced the availability of SimLogic course manager software developed by VISTA Training exclusively for Simlog’s Mining Truck Personal Simulator. The development involved close collaboration between the two companies, SimLogic course manager software leverages the unique instructional design of Simlog’s Mining Truck Personal Simulator to serve as a computer-based training ‘front end’ to the hands-on training provided by the simulation software. This Simlog unit features a built-in instructional design for haul truck operator training that enables trainees to develop essential core skills by working through a series of simulation modules at their own pace, and without the need for instructor supervision. Each simulation module builds upon the skills learned in the previous one to emphasise best practices for both new and veteran operators alike. Another key feature of the simulation software’s instructional design is automatic measurement of key performance indicators pertaining to the productivity and quality of the trainee’s simulator-based work. This data can be used to assess the rate of skills development before trainees move on to train at the controls of real mining trucks. SimLogic course manager software provides a seamless front-end for this truck simulator that explains to trainees what they are about to experience in the simulator. It also interprets the performance data produced by the simulation software to help trainees to understand how to improve their performance. These reports can also be used by trainers to provide in-the-field coaching. SimLogic displays a list of available simulator sessions, descriptions of each session and the trainee’s status in the session, all in a convenient, easy-to-understand tabular view. When the trainee clicks on a lesson, SimLogic launches a set of computer-based training screens that introduce the lesson, and explain the task the trainee is about to perform in the simulator. SimLogic then launches a set of three simulator trials for each lesson. SimLogic also captures the performance data from the Mining Truck Personal Simulator, and interprets the trainee’s simulation results to determine a score based on pre-established target values. A report is generated that includes the trainee’s score along with specific suggestions for improving performance in the form of helpful hints. This report also includes a set of notes that field trainers can use as coaching tools to help correct weak areas of the trainee’s performance.
Northern Lights College in Tumbler Ridge, British Columbia, Canada uses the combination of this Simlog Personal Simulator and VISTA Training’s SimLogic course manager to enhance the practical training component of its haul truck training program. “Simlog’s simulators are the system of choice in our region for mine training because it is an affordable option that allows students to learn important operator skills in a safe environment, and eliminates risks to physical safety and equipment damage,” explains Donna Merry, Workforce Training and Continuing Education Coordinator at Northern Lights College. Northern Lights College trains mining truck operators for several mines in the region. The combination of computer-based training and simulator-based training has allowed the college to prepare students for roles as haul truck operators using learning activities the students enjoy, that directly support their understanding on the job, and that reduce the costs of training to the college’s clients. This approach uses less manpower, less fuel and tyre wear, and less risk to personnel and equipment. “Now, when a student takes the driver’s seat in a real mining truck with the trainer alongside, the trainer can focus on higher level skills development because the fundamentals have been covered in our simulator lab. Training at the mine can be based on areas showing need of improvement according to the student’s simulation results as measured by our Mining Truck Personal Simulator and reported by SimLogic,” adds Merry.
Immersive forges on
Immersive Technologies says it is the “mining industry’s leading training simulator provider.” It is certainly continuing to record great success and earlier this year achieved another significant milestone with the successful certification of its 700th participant in its unique simulator program ‘TrainerAdvantage’. TrainerAdvantage was launched by Immersive Technologies in March 2006 to support the growing demand for its Advanced Equipment (AE) Simulator. The three-level certification program includes comprehensive classroom and hands-on sessions working with the AE Simulator under the instruction of an Immersive Technologies’ certified instructor. Each level is designed to progressively increase the training personnel’s knowledge from basic operation of the simulator to advanced training administration operation. Peter Templeton, Global Customer Service Manager for Immersive Technologies and coordinator of the TrainerAdvantage program, has to date deployed the course in 29 countries around the world. He said, “In the last four years since the course’s commencement, we have witnessed the mines that have completed the course, significantly increase their level of simulator utilisation, understanding and sophistication resulting in improved training programs that are producing safer and more profitable operators.” Immersive says its “TrainerAdvantage program is recognised as the global certification standard for simulator – trained personnel in the mining and earthmoving industry and provides mines with a means to identify qualified staff when recruiting.
AE Simulators are considered vital to many of the world’s leading mining companies such as BHP Billiton, VALE and Rio Tinto. From the Congo to northern Canada, mines are increasing safety and reducing their cost per tonne by using Immersive Technologies’ simulators daily to train and test their operators. The company has exclusive licensing and technical information alliances with the leading Original Equipment Manufacturers (OEM), including: Caterpillar, Hitachi, Komatsu, Liebherr and P&H MinePro. Immersive has just released its next generation AE Simulators – the PRO3 for surface mining and the UG360 for underground mining. Incorporating a series of new technologies to increase training effectiveness, they significantly raise the standard for mining equipment training simulators. Designed to simulate surface mining equipment, and available in transportable and classroom versions, the PRO3 builds on the huge success of its predecessor the AES Series 2B which, Immersive says, “has become the global standard in mining over the past 10 years with many hundreds of units now located across 29 countries. The new UG360 has been designed for the specific needs of the underground mining industry. It is the first of its kind to deliver the level of realism accuracy required for training.”
Immersive Technologies funded a significant investment in research and development over a three-year period resulting in the PRO3 and UG360 simulators setting new standards for the industry. Designed from the ground up, the key objectives for the PRO3 and UG360 were to maximise training effectiveness, simplify usability and extend reliability. Inspiration was drawn from many sources, including Immersive’s many years of experience with its large, global, customer base, feedback from its OEM exclusive alliance partners, staff feedback and ideas from other industries. Major technological advancements for the PRO3 surface mining simulator include a seamless 180° visual display system, together with a unique feature that dynamically adjusts the perspective of the operator, providing a true real-world view outside of the cabin whilst simultaneously increasing the operator’s level of depth perception. The UG360 simulator includes a new 360° visual system designed specifically for the unique needs of underground mining. Both simulators are installed with new, highly responsive motion platforms that accurately simulate the movement of mining equipment. The level of simulation realism delivered by the PRO3 and UG360 has not previously been experienced by the mining industry. Also added are a series of advancements for transportation, increased ambient temperature operating range, occupant comfort and simplified usability and serviceability. “Our next generation simulators are a quantum leap forward for our customers and for the mining industry. I am pleased to say that the Immersive team has excelled itself by delivering two exceptional training simulators. Immersive is focused squarely on increasing the operator safety and the profitability of our mining customers. The PRO3 and UG360 together with our integration and support services provide mines with unparalleled solutions that are capable of delivering outstanding results.” said Peter Salfinger, CEO, Immersive Technologies. Displayed for the first time at the AusIMM 7th Large Open Pit Mining Conference in Perth Western Australia, the PRO3 received substantial interest from new and existing Immersive Technologies’ customers. During this prestigious event, Paul Davis, Executive Global Business Development Manager for Immersive Technologies, presented delegates with a paper on Linking Operator Competency with Performance. This presentation highlighted the success in business improvement generated to date by the PRO3’s predecessor the AES 2B. “We are excited by the release of these remarkable new simulators and look forward to them achieving even greater success for our customers as they take their place in mines around the world. We encourage our customers to experience both new simulators first hand.” said Davis. An important benefit of the PRO3 is its compatibility with 500+ existing Immersive Conversion Kits (interchangeable machine controls), custom lessons, scenarios and custom mine sites previously developed. This allows AES 2 and AES Series 2B customers to move up to a new PRO3 simulator and not have to replace their existing Conversion Kits and supporting systems.
Early this year Exxaro’s Grootegeluk coal mine in Limpopo, South Africa, which operates the world’s largest coal beneficiation complex, again selected ThoroughTec Simulation as its simulator systems provider of choice after an exhaustive open tender supplier evaluation process. ThoroughTec offers the range of Cybermine simulators. In keeping with Exxaro’s commitment to operational excellence and high safety standards, the Cybermine simulator will be an integral component of training procedures at the mine. In addition to the Cybermine simulator (fitted with a six degree-of-freedom motion platform), Exxaro has purchased ‘plug-andplay’ interchangeable cabs to simulate both the Komatsu 730E haul truck and P&H 2300 electric shovel. Grootegeluk also opted to purchase the development of an ‘own-mineworld’ which will accurately replicate the topography and operating conditions of the open pit to provide trainee truck and shovel operators with the highest possible realism during training. The simulated cab is the heart of ThoroughTec’s simulators – a realistic replica of the actual equipment, with fully functional simulated instruments and controls mounted on a high-end motion platform providing accurate motion perception cues. The cab is surrounded by a wide angle, high- resolution projection display system coupled with surround sound audio. Control of all training aspects is exercised in real time from a feature rich instructor station. The entire system is housed in a well-appointed, self-contained ISO container, which also facilitates ease of transport.
Training in the Yukon
Canada’s Yukon Mine Training Association (YMTA) has introduced two new ThoroughTec simulators from for its training programs. It has taken their training initiative to the next level with the introduction of two new Cybermine surface and underground simulator systems. YMTA is a partnership between the Yukon’s mining- and resource-related industries and the First Nations. Its aim is to maximise employment opportunities emerging from the growth of the mining and related resource sectors in the North for First Nations and other Yukoners. The YMTA ensures that safety training is developed and delivered, meeting industry standards. It chose four ‘plug-and-play’ interchangeable simulator cabs to cover four critical processes of drilling, digging, loading and hauling using four cabs to provide a complete training solution: Komatsu PC1250 excavator, Caterpillar 773F truck, Sandvik DD420 drill jumbo, Sandvik EJC115LP LHD. The two surface simulator cabs will operate on a six degree-of-freedom motion platform whilst the two underground simulator cabs operate on a three degree-of-freedom motion platform. Both are based on latest generation electric actuators which impart accurate self motion perception cues such as acceleration, braking and suspension effects. ThoroughTec says Cybermine simulators offer a feature rich instructor station giving the instructor the ability to set up and modify a set of standard exercises, inject faults randomly or on command, view historical and real-time graphs of subsystem states, view the students’ operating violations as they occur and then replay exercises for after-action review and student debriefing. The instructor station is situated next to the simulated cab for one-on-one student/instructor interaction. The jumbo simulator for instance, in training mode shows the students the correct drill placement position and drilling path. The student is then scored and assessed according to correct operational procedures. Historical reports can then be compared to assess a student’s progression. The YMTA has big plans for simulators according to Tracy Thomas, Executive Director. “The simulators are going to be integrated into other programs, such as the Heavy Equipment Operator training program, in order to facilitate complete learning for the students. Students will be able to graduate with classroom, simulator and then hands on training, which will increase their employability to the Yukon industry.”
Presimulation
All the suppliers offer innovations and one from Fifth Dimension Technologies, known as 5DT, is the time-saving “slide-in, slide-out” technique to swop consoles in minutes. “Our simulators are connected with a single umbilical cord” says Martin Schehle, 5DT’s Mining Division Manager. “for instance: you uncouple the cord on a dozer sim, slide the console out, slide a dragline console in, and you are ready to train again in under three minutes”. 5DT also developed multi-screen technology, allowing an additional screen behind a dozer operator so that he can view the ripping process, or providing classroom view screens so that other trainees can participate in the simulator training session.
Another innovation claimed by 5DT is threelevel training, a concept which was pioneered in military training and simulation. The first is computer based training or CBT, coupled to an advanced learning management system (LMS). The CBT builds up a student’s knowledge. The second level is a pre-simulator. This is a scaleddown simulator which uses the same equipment console as the full simulator. It familiarises a student with the equipment controls. The final stage is the full simulator, where the finer points of safety, productivity, maintenance and emergency response can be worked on. This sequential training means that a large number of students can participate in CBT and pre-simulator training at the same time and greatly reduces the amount of time students need on the full simulator. This dramatically reduces the training cost per student. PT Freeport Indonesia (PTFI) and PT Kuala Pelabuhan Indonesia (KPI) recently purchased four new Doron simulators. These simulators will function as training tools in order to improve the competency levels of heavy equipment drivers throughout the complex. “There are 350 additional drivers being recruited to support levee expansion and increase of our transport fleet. We purchased these four Doron units in an effort to improve the competency of our current drivers and train new drivers, with the aim of safe operation and reducing accidents while at work, as well as to ensure that drivers meet PTFI Licensing and Certification Standards,” explained PTFI Vice President – Central Shop and Transportation Steve Drake. The simulators are located at the Nemangkawi Mining Institute Training Facility. “Doron simulators, which are replicas of the cabin of a truck, are equipped with state-of-the-art technology that simulate topographical and climate conditions found on our roads here. Depending on the training module, drivers may be subjected to various simulated environments, such as rain or fog, even how to manoeuvre on hills and dealing with traffic at intersections. The training modules help our drivers become more familiar with different field conditions and train them to handle these situations while out in the field. As the training program progresses, we are able to create additional modules to enhance the training,” said KPI Superintendent – Training and Development Henky Risamasu. “New drivers will be required to log 100 hours of simulator time prior to 250 hours practical field training using the actual equipment. The Doron simulators will also be used as part of the annual refresher program for our heavy equipment drivers, all in an effort to improve safety at work and support production achievement.”
Simulated spraying
In cooperation with the Technical University (TU) of Dresden, Putzmeister has developed a simulation system based on open-source software to help operators be efficient when spraying underground support materials. Visitors to the Putzmeister stand at this year´s Bauma had the opportunity to try the simulation of the Sika-PM 500 concrete spraying system on a large-format screen. This Putzmeister in-house development is based on TU Dresden’s software framework SARTURIS. The modular software framework was specially developed to simulate the crosslinked subsystems of mobile working machines and vehicles in virtual surroundings. According to TU Dresden, the software provides improved methods for the development of more efficient, robust and flexible software systems for machine- and vehicle simulation. The use of the simulation system during the development of the Sika-PM 500 allowed Putzmeister to take customer requirements into account and test them in early development stages. The system can easily be reconfigured to be used as a training simulator and will now be used in this way. It works through converting the signals of the original control unit of the Sika-PM 500 into CAN-bus signals, which are interpretable by the simulation software. The user controls the simulation model of the machine as well as the sprayed concrete. The results of the simulation are dynamically transmitted to the visualisation model, consisting of tunnel, Sika-PM 500 and sprayed concrete. In this way, an interactive simulation is created. According to Timo Penndorf, Putzmeister specialist for computation and simulation, who was involved in the development of the software, the distinctive feature of the simulation models is the fact that they consist of systems of differential equations which are calculated in real time. Penndorf points out that this improves the “degree of realness” considerably, for example as far as the afterbounce of the spraying arm is concerned. IM
