All posts by Paul Moore

Scania at MINExpo – efficiency by thinking big but acting small

Automation, Bulk handling, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Sustainable mining

At this year’s MINExpo in Las Vegas, Scania is demonstrating how its ‘Think big, act small’ approach is supporting mining companies in their quest to become more agile, lean and sustainable. The Swedish-based manufacturer is offering it says not only the most efficient combustion engines in the industry but has also introduced electric and autonomous truck solutions on the market.

Scania says it is renowned for its focus on cost and operational uptime, thinking that stems from how Scania has been run for more than 100 years and translates into payload efficiency in the mining industry. “Our ‘Think big, act small’ approach has really struck a chord with our customers,” says Tobias Ekstedt, Director and Head of Scania Mining. “They understand how well it meets their challenges and how we at Scania, with our payload-efficient, truck-based solutions, are offering a sustainable pathway to the future for them.”

Scania’s stand at the MINExpo fair is dominated by a R 620 10×4 mining truck that is fully equipped with a sensor system for autonomous operation. “It illustrates all the traits that Scania’s mining offer is based on: industry-leading payload efficiency, faster cycle times, low emissions, high safety standards and, at the end of the day, lower cost per transported tonne compared to other alternatives.”

“The global mining industry is in a transformation process right now, just like so many other sectors,” says Ekstedt. “Our solutions regarding autonomy and electrification are on the brink of a breakthrough in agile mining. Until it really takes off we also offer the industry’s most sustainable and efficient solutions: the autonomous truck we have on display at MINExpo is a perfect illustration of our capabilities.”

Scania’s background as a world-leading provider of transport solutions and as part of the TRATON Group is the foundation of its customer-oriented offers. Vast resources make for its strong presence (some 12,000 Scania mining trucks are operational right now) and its importance for the mining industry.

“Being successful in the mining industry takes certain capabilities for suppliers like us,” says Ekstedt. “But rest assured that with our long experience and our willingness to spend on R&D, we are offering exactly what the industry needs. Basics must be in place, and on top of that we are at the forefront by offering sustainability and the very latest technology within autonomy and electrification for increased payload efficiency per head.”

alwaysAI partners with Becker Mining Systems to revolutionise mining with Vision AI

Automation, Communications in mining, Equipment maintenance, IoT, Mine shafts and equipment, Mine surveying, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software

alwaysAI, a developer of Vision AI technology and Becker Mining Systems, a renowned leader in mining solutions and technologies, have announced a strategic partnership. The collaboration “aims to transform the mining industry’s value chain, significantly enhancing productivity, safety, and operational efficiency.”

Together they will develop advanced computer vision (CV) applications that will address challenges such as restricted area monitoring, personal protective equipment (PPE) compliance, equipment utilisation monitoring, and more. By automating critical processes and providing real-time monitoring, the CV applications aim to reduce reliance on manual supervision. This leads to greater efficiency, cost reduction, increased revenue, and valuable data-driven analytics for mines.

Possible use cases include real-time conveyor belt monitoring where users can continuously monitor the health of their conveyor belt in an extended version of Becker Mining Systems’ Belt Rip Detection System (BRS4.0) in order to detect wear, cracks, or other damage at an early stage. Exclusion zones can also be monitored to ensure that no unauthorised personnel enter dangerous areas. Real-time alerts enable proactive intervention and minimise downtime.

It will also allow the tracking of movement of personnel and equipment through the cage/lift system. Unauthorised or inefficient use is flagged to prevent delays and maintain smooth operations of mine processes.

Customers will be able to monitor PPE specifications and track the movements of personnel and vehicles in real time. Thanks to Becker Mining System’ tagging & tracking solution and Proximity Detection System (PDS4.0), the risk of accidents is minimised. Real-time alerts enabled by computer vision allow for quick intervention in the event of violations or dangerous situations.

Mines can also monitor restricted and authorised zones within the mine in conjunction with Becker Mining Systems’ location technology, triggering alerts for unauthorised entry or prolonged activity; and enhance safety protocols by tracking personnel movements in both restricted and routine work areas.

“We’re excited to partner with Becker Mining Systems, which will significantly enhance worker safety, reduce mechanical failures, and enhance operations in mines,” said Marty Beard, CEO of alwaysAI. “Our computer vision solutions are designed to provide real-time insights and alerts that reduce risks and improve operational efficiency, especially in high-risk environments like mining.”

“This partnership with alwaysAI allows us to bring powerful computer vision applications to our customers,” said Prof Dr Wolfgang Wegener, Co-Chief Executive Officer of Becker Mining Systems AG. “By integrating this cutting-edge technology into mines, we can help minimise risks and reduce machine downtime while boosting overall performance.”

alwaysAI and Becker Mining Systems will jointly develop and deploy computer vision applications. In addition Becker Mining Systems will oversee the installation of on-site infrastructure, including cameras and edge devices. The applications integrate seamlessly with Becker Mining Systems’ existing infrastructure.

 

 

Caterpillar demonstrates new Cat Automated Energy Transfer Solution

Automation, Bulk handling, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Sustainable mining

Caterpillar Inc has announced a new solution to support battery electric truck charging – the Cat® Automated Energy Transfer System (Cat AETS). The company successfully demonstrated this new technology for customers recently at its Tucson Proving Ground in Green Valley, Arizona.

Cat AETS utilises robotics, robust vision systems and controls to fully automate the connection between a battery electric machine and a two- to six-megawatt stationary charger. The system replaces the manual process of mine site personnel connecting and disconnecting a charger from a battery electric machine.

Cat AETS enhances mine site safety by removing site personnel directly from the machine charging process, facilitating a more fully autonomous site operation. Automating the charging process can also reduce downtime and improve consistency and reliability of the machine charging process.

Caterpillar Senior Vice President Greg Hepler explains: “When it comes to meeting production goals, every second matters on our customers’ mine sites. Through our advancements in mining technology and automation, our repeatable processes enhance machine reliability and ultimately reduce downtime. Caterpillar is proud to offer the solutions that create benefits for the battery electric machine charging process.”

Cat AETS is a complementary offering to the company’s recently announced Cat Dynamic Energy Transfer system (Cat DET).

The development of AETS dates back to 2022, when NZX-listed Scott Technology announced an agreement with Caterpillar to develop an automated connection system to support stationary charging of electrified machines including battery mining trucks. Scott’s expertise in this space derives from its Robofuel product, which successfully automates the traditional diesel refuelling process of mining vehicles. Under the collaboration, Scott has applied this technology to enable solutions in electrified applications.

Hitachi to begin mass production of 120 t class mining excavators in Indonesia

Bulk handling, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services

Hitachi Construction Machinery says it will begin mass production of the 120 t class EX1200 ultra-large hydraulic excavator at its Indonesian production base PT Hitachi Construction Machinery Indonesia in West Java from November 2024 to address the demand for ultra-large hydraulic excavators in the country.

Currently, Hitachi Construction Machinery primarily produces ultra-large hydraulic excavators and rigid dump trucks at the Hitachinaka-Rinko Works in Japan for delivery to customers around the world. In addition to the production of medium hydraulic excavators, Hitachi Construction Machinery Indonesia has also been in charge of producing front structures (booms, arms, and buckets) for ultra-large hydraulic excavators, truck frames, rigid dump truck beds, and other welded structures for mining machinery.

As the largest market for mining machinery in southeast Asia, Indonesia has a comparatively large number of small and medium-sized mines, and it is a region with a high demand for 120 t class hydraulic excavators. In addition, there was a need to strengthen the production capacity of the entire group to rapidly meet the demand for mining products throughout the world including the Americas market where the Hitachi Construction Machinery Group is accelerating its independent expansion.

Against this backdrop, the group decided to extend the Hitachi Construction Machinery Indonesia’s Cibitung 2 Factory and newly establish production facilities and assembly space to produce the EX1200 ultra-large hydraulic excavator. Furthermore, advanced welding technology will be applied in the extended area to expand the production items of welded structures for mining products.

Hexagon unveils newest Collision Avoidance System adding 4D radar enhancements

Automation, Equipment maintenance, IoT, Mining equipment, Mining safety, Mining services, Mining software

Hexagon has announced the newest generation of its advanced Hexagon Collision Avoidance System (CAS), now supporting 4D radar technology, enhanced insights, and interoperability with the Hexagon Personal Alert tagging system. The significant upgrade it says positions Hexagon CAS as the most advanced collision prevention system on the market.

The upgraded CAS has already been installed in 15,000 vehicles around the globe. “Its standout feature is inclusion of advanced 4D radar technology, which enables vehicle-to-object detection and vehicle-to-vehicle alarming in GNSS-denied areas. GNSS (Global Navigation Satellite System) depends on the use of satellites, and there are areas of mining operations where satellite reception is inaccessible or unreliable. The 4D radar enablement in Hexagon CAS means the select customers who have installed the updated system as part of its initial release now have the capability to help prevent collisions in these challenging areas.”

At the same time, Hexagon is introducing CAS Insights – a robust insights platform available for use with CAS, which offers customisable, filterable reports that pinpoint the unique collision-risk issues faced at the customer’s site. CAS Insights provides timely information about device health and identifies high-risk event areas, enabling operations to make targeted interventions for refining their processes and infrastructure to avoid vehicle collisions.

Lastly, the upgraded Hexagon CAS now includes interoperability with the Hexagon Personal Alert system. Personal Alert uses ultra-wideband technology for vehicle-to-person protection. Together with CAS and the award-winning Hexagon Operator Alertness System (OAS), it provides a critical additional layer of safety.

The advanced Hexagon CAS system, already recognised for its simple installation and accurate alarming, retains its EMESRT Level 7 and 8 compliant vehicle-to-vehicle alarms while offering a scalable pathway for safety upgrades to Level 9 protection.

“Our commitment to creating a zero-harm mining environment is at the heart of everything we do, because the most important thing to come out of any mine is the miner,” says James Dampney, Vice President Resource Optimisation and Material Movement at Hexagon. “The enhanced CAS system and its interoperability with other Hexagon safety solutions will provide our customers with the monitoring, interventions and actionable intelligence they need to ensure not only the protection of people working on their sites but also the efficiency and sustainability of their operations. It represents another significant stride towards safer, smarter mining.”

Christian Schorr, Hexagon Senior Product Manager, and Chithra Rathinavelu, Hexagon Product Manager, Fleet Analytics, will be conducting tech talks on Hexagon CAS and Insights at the Hexagon Booth in the West Hall of the Las Vegas Convention Center at MINExpo 2024 next week.

Caterpillar outlines Cat Precision Mining advanced mining vision

Automation, Bulk handling, Equipment maintenance, Explosives and blasting, IoT, Mining consumables, Mining equipment, Mining maintenance, Mining services, Mining software, Sustainable mining

Caterpillar’s advanced mining vision, Cat Precision Mining, is designed to improve and streamline every step of the mining process, from extraction to processing, bringing mine-to-mill theory into reality, the company says. The initiative will bring everything together as a fully integrated, end-to-end solution that is customised to the mining operation’s specific requirements and unique orebody characteristics.

Cat Precision Mining will feature a suite of Cat and third-party technologies, including sensors installed across the site’s mobile equipment, processing plant, and other fixed assets, all integrated into the Cat MineStar ecosystem. Leveraging data from Caterpillar, Caterpillar company Peck Tech Consulting Ltd, and collaborating partner technologies from Orica Digital Solutions, IMA Engineering, Stream Systems, Skycatch, Inc., and Information Alignment PTY LTD, the advanced mining solution will help operations more rapidly and precisely adjust their planning activities based on measured orebody variations that are present.

Providing the tools customers need to make quick and accurate decisions, Cat Precision Mining “will enable blast plans designed in 3D, while collecting rock property data to help optimise blast designs that accommodate for natural ore-body variations.”

The intelligent mining solution will gather data related to blast fragmentation, muckpile uniformity, payload, and ore material properties for efficient material handling and assists with making sure the right material gets to the right place, reliably and predictably. Advanced ore sensing and sorting help to ensure consistent and repeatable feedstock is delivered to the mill to offer higher recovery rates, reduced energy costs and less waste.

Key to the Cat Precision Mining initiative, Caterpillar is developing its Intelligent Decision Support System which will leverage the capabilities of Cat MineStar to consolidate Cat and third-party technology and sensor data, allowing miners to make data-driven decisions and continually refine processes. The solution will aggregate, analyse and report data from across the drilling, blasting, loading and hauling, and processing operations.

MineStar Material Management and Reporting will provide ore tracking from mining exploration and extraction processes right through to the finished product and can be utilised for evaluation and future prediction. When layered with Cat Command for hauling, the solution will provide even more consistent and efficient operations and lower operational costs.

“The broad portfolio Caterpillar offers in drills, loading tools, trucks, dozers, graders and support equipment, along with the integrated suite of MineStar technologies, make us uniquely qualified to efficiently advance the mine-to-mill theory into reality,” commented Marc Cameron, Senior Vice President Resource Industries Sales, Services and Technology. “We already have most of the pieces to the puzzle in place and are adding technology collaborators to enhance and bring this initiative all together.”

 

SafeAI partners with RTI to set a new standard in autonomous solutions

Automation, Bulk handling, Communications in mining, Mining equipment, Mining services, Mining software

SafeAI, the global player in autonomous solutions for heavy equipment, has announced a new partnership with Real-Time Innovations (RTI), the infrastructure software company for smart-world systems. This collaboration aims to integrate RTI’s connectivity framework into SafeAI’s autonomous systems, further advancing the capabilities and reliability of autonomous operations in the heavy equipment industry and beyond.

RTI Connext®, based on the Data Distribution Standard (DDS™), is a robust software framework that facilitates real-time, distributed applications. Utilising a publish-subscribe model, Connext minimises unpredictability and ensures seamless communication between embedded and enterprise devices or nodes. This integration elevates SafeAI’s autonomous technology by providing a reliable, high-performance connectivity layer for real-time data exchange and system operation.

SafeAI will integrate Connext with its autonomous technology as part of this partnership. It will leverage RTI’s powerful admin console to monitor and manage real-time data, including the position and orientation of autonomous guided vehicles (AGVs) in dynamic environments. DDS effectively manages data readers and writers, providing comprehensive visibility into system performance and enhancing operational reliability.

In addition to the Connext integration, SafeAI is using Applied Intuition’s simulation tools to complement and accelerate the development process. Their simulation technology is instrumental in validating fleet automation, streamlining map integration, and generating critical training data for machine learning models. SafeAI states: “By simulating and refining motion planning and controls in virtual environments, SafeAI can rapidly iterate on autonomous scenarios, reduce the need for costly physical tests, and explore complex edge cases that are challenging to replicate in real-world settings. This simulation integration with Connext and SafeAI’s autonomous solutions significantly enhances our ability to deliver faster, more reliable, cost-effective autonomous systems.”

Bibhrajit Halder, Founder and CEO of SafeAI: “Our collaboration with RTI represents a significant step forward in optimising the performance and reliability of autonomous systems. By integrating RTI’s industry-leading connectivity solutions, we enhance operational efficiency and safety and reinforce our commitment to providing robust, scalable, autonomous solutions for the industry.”

The integration of Connext will also underscore SafeAI’s capabilities as a certifiable Safety Element out of Context (SEooC). This certification is pivotal for companies developing safety cases, as it ensures an end-to-end chain of safety assurance. SafeAI says the successful integration with RTI’s trusted framework highlights its ability to seamlessly connect with third-party libraries and maintain high safety and performance standards.

“Autonomous vehicles powered by AI and vehicle telematics are moving the mining industry into the future. RTI Connext brings continuous, highly reliable data connectivity to remote, challenging terrains. We’re pleased to partner with SafeAI to enable autonomous functionality that brings unparalleled safety, efficiency, and scalability to next-generation mining vehicles,” said David Barnett, VP of Products & Markets for RTI.

The statement concludes that the strategic collaboration “builds on SafeAI’s commitment to advancing autonomous solutions through cutting-edge technology and industry partnerships. By combining SafeAI’s expertise in autonomous systems with RTI’s superior connectivity framework, the two companies are poised to set new standards for reliability and performance in the heavy equipment industry.”

BME releases InnovexT 300D emulsion to tackle dynamic water in surface mining

Environmental, Explosives and blasting, Mining consumables, Mining safety, Mining services, Sustainable mining

In line with its continuous innovation of blasting solutions, BME has developed Innovex™ 300D – a high-strength bulk emulsion explosive for challenging surface mining conditions including dynamic water. According to Dr Rakhi Pathak, BME’s Global Manager – Strategic Partnerships, dynamic water is a common issue for surface mines, and leads to various operational and environmental challenges.

“When there is excessive water flow in and around blast holes, emulsion ‘run-off’ often occurs due to cracks or fissures in fractured geology,” Dr Pathak explained. “This is particularly problematic in conditions such as damaged ground, fractured or weathered rocks, sensitive geology and acidic mine conditions.”

She noted that these conditions exacerbate operational difficulties and environmental hazards. They can lead to misfires and incomplete detonation, for instance, as well as the possible leaching of nitrates into the environment.

“Dynamic water can also lead to higher levels of nitrous oxide (NOx) fumes being generated,” she said. “This results from the dampening of explosives – which can cause incomplete detonation – as well as from the oxygen balance and chemical reaction being affected by the presence of water.”

To counter these challenges, BME’s Innovex™ 300D offers enhanced resistance to dynamic water, reducing the likelihood of misfires. The product features an adjustable rheology, making it suitable for highly friable and fractured geological conditions.

“Our solution allows the viscosity and flow behaviour of the emulsion to be adjusted to meet any blasting requirements,” she said. “This ability to adjust the rheology makes a valuable contribution to optimising the material performance – improving handling, ensuring safety and achieving the desired blasting outcome.”

BME’s blasting system includes a mobile manufacturing unit equipped with an in-line monitoring device for real-time viscosity adjustments and monitoring. Innovex™ 300D is also highly resistant to free ammonia, which is commonly found in mine water and tailing dams; it also resists acidic sulphate soil conditions, such as rocks containing pyrite that can produce sulphuric acid.

Nishen Hariparsad, BME’s General Manager Technology and Marketing, highlighted that Innovex™ 300D supports the company’s commitment to the environment, and enhances the sustainability efforts of BME customers.

“Preventing environmental contamination is non-negotiable among responsible mining companies, and our solutions support the industry’s ongoing progress in this regard,” said Hariparsad. “Minimising nitrate leaching is an important aspect of this imperative.”

He noted that BME is well known as an innovator in emulsion explosives, and invests heavily in ongoing research and development (R&D). The company has developed considerable in-house expertise and capability to conduct the various stages of R&D to commercialise its advanced technologies.

“We have built a strong technical foundation from which to optimise our formulations, including the necessary testing, regulatory compliance, customer feedback and new application requirements. We respond to market needs and trends by developing continuous improvements – as we enhance the performance, safety and efficiency of our emulsions and other solutions.”

Dr Pathak concluded Innovex™ 300D has been formulated with an advanced emulsion matrix, delivering superior strength to ensure optimal blast outcomes.

“The system comprises a high-strength bulk emulsion matrix specifically formulated with rheology modifiers, surface-active agents, and a unique blend of diluent oils and emulsifiers. This formulation is the basis for us to provide customers with an adjustable and instantaneous bulk emulsion rheology suited for their toughest blasting conditions.”

Caterpillar introduces powertrain flexibility into large mining truck strategy

Bulk handling, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Sustainable mining

In an update on its large mining truck strategy ahead of MINExpo 2024, Caterpillar Inc says it is reinforcing its commitment to deliver product design choices in alignment with customers’ operational, sustainability and productivity goals that increase the value of a machine throughout its lifetime. These designs align with Caterpillar’s strategy to deliver integrated site solutions to support customers today and through the energy transition.

As the industry looks to the future, Caterpillar is “purposefully” designing a modular Cat® 793 large mining truck platform with powertrain flexibility. This platform will include diesel mechanical, diesel electric and battery electric options.

Additionally, Caterpillar is leveraging the knowledge and validation acquired through its Early Learner battery electric large mining truck program to drive common platform benefits for its ultra class trucks, including diesel electric and battery electric offerings for the Cat 794, 796 and 798 models.

Caterpillar says it has a legacy of designing products with customers’ current and future needs in mind. “For decades, Caterpillar and the Cat dealer network have provided flexible solutions to extend the life of mining trucks, including retrofit kits, update and upgrade programs and full machine rebuilds. These options can extend a customer’s equipment to align with current products and technologies while reducing total cost of ownership.”

Caterpillar Group President Denise Johnson says: “No matter the powertrain you desire, we will have a solution. Designing and supporting machine platforms that drive commonality, modularity and a seamless experience across our product lines is not new to us. Our large mining trucks are engineered to integrate with the technologies of today and of the future.”

All current diesel electric and battery electric large mining truck platforms are also compatible with the recently announced Cat Dynamic Energy Transfer system, providing immediate benefit to mine sites that want to lower their operating costs and greenhouse gas emissions while providing flexibility for the future.

Caterpillar Senior Vice President Greg Hepler said: “Caterpillar recognises every mine site requires a unique plan to meet their sustainability objectives, which is why we are delivering a suite of integrated energy transition solutions, including machines with powertrain flexibility, energy transfer systems, energy storage and management capabilities, autonomy and fleet management systems. Together with our Cat dealers, we are committed to supporting customers through every step of their energy transition journeys.”

ABB launches new service offerings to boost productivity for the mining industry

Automation, Bulk handling, Equipment maintenance, Mine shafts and equipment, Mining maintenance

ABB has launched a new suite of service offerings designed to simplify maintenance and improve the operational health of crucial mining assets. This extends ABB’s comprehensive ABB Care program to Mining Automation and Hoisting, unifying the organisation’s mining and technology expertise to help customers continuously evolve their approach to maintenance.

Today, the mining industry is under immense pressure to meet production demands while navigating a complex landscape of rising costs, talent shortages and the urgency to meet sustainability commitments. With productivity as one of the top priorities on every major mining organisation’s agenda, minimising downtime is crucial. Traditional approaches to maintenance often rely on reacting to issues after they occur, whereas shifting to a proactive approach not only prevents availability loss but also enhances the overall efficiency and longevity of systems.

This was recently reinforced by the findings from ABB’s World Class Maintenance Standard for mine hoists study. Customers with proactive maintenance strategies had, on average, 15% higher availability of their hoists than those primarily using reactive maintenance.

ABB’s Care framework offers proactive and preventive services that ensure operations run smoothly and efficiently. It is a robust standardised service framework built around ABB’s advanced services and digital technologies. Users will benefit from optimised performance, maximised availability, reduced unplanned maintenance and downtime, improved safety and overall savings on maintenance costs.

With ABB Care for Mining Automation, customers will have access to a customisable set of services to select the components that best fit their needs. These services cover everything from alarm management and cybersecurity to lifecycle management and loop performance.

“We know that every mine is different and that’s why we’ve created ABB Care for Mining Automation, so that our customers can choose the right service solutions for them,” said Max Luedtke, Global Business Line Manager for Mining, ABB Process Industries. “ABB delivered its first automation system for a mine in 1975. With over 1,200 control systems delivered today, shaped by partnerships with some of the world’s largest mining organisations, we use the best of automation technology and our industry expertise to bring performance enhancing service solutions to our customers.”

ABB Care for Hoisting offers tiered service plans, designed to address challenges across every element of the hoist system from the powertrain to the brake systems. As standard, every plan includes remote support, guaranteed response times, annual inspections and a maintenance time bank.

“Mine hoist systems are at the very of heart of many mining operations around the world,” said Björn Jonsson, Global Business Line Manager for Hoisting, ABB Process Industries. “They offer the most efficient way to transport heavy loads of ore from the depths, and must therefore operate at the highest possible levels of reliability and productivity. ABB Care for hoisting provides customers with a solution to swiftly adopt a predictive maintenance approach, enabling them to reach to world class maintenance standard established by ABB, and keep these crucial components operating with minimal availability loss.”