Tag Archives: Cat

WesTrac building Caterpillar autonomous training facility in Western Australia

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

Caterpillar dealer WesTrac has announced it will build a technology training facility in Collie, Western Australia, focused on providing courses in autonomous operations.

The centre will be the only Caterpillar Autonomous Training Facility in the world apart from Cat’s own testing and training ground in Arizona, USA. The facility will be developed on land owned by Bluewaters Farm Holdings in Collie’s Coolangatta Industrial Estate.

The project is supported by a grant through the Collie Futures Fund, awarded to WesTrac by the State Government’s Department of Jobs, Tourism, Science and Innovation.

The announcement was made at a ground-turning event in Collie attended by Western Australia Premier, Mark McGowan; Minister for Regional Development, Alannah MacTiernan; Collie-Preston MLA, Mick Murray; and WesTrac CEO, Jarvas Croome.

Croome said the investment includes a new fully autonomous Cat 789D off-highway truck, construction of an autonomous operations zone and training room facilities. The construction is scheduled to commence this month at the greenfield site near Collie’s Bluewaters Power Station.

Local contractor Piacentini & Son will carry out the earthworks and installation of key infrastructure, with training scheduled to commence in May.

“The initial focus will be to provide training in fit-out and maintenance requirements for the conversion and operation of existing Caterpillar haulage vehicles,” Croome said.

“Over time, we anticipate expanding the range of courses on offer to ensure the facility caters for the recognised skills of the future that will be in demand as the resource sector evolves.

“It’s an opportunity to position Collie and Western Australia as a world leader in advanced technology and skills development in automation and autonomous operations.”

McGowan said: “People will come from all over the world to utilise this facility – the first of its kind in the southern hemisphere and the second worldwide for Caterpillar.”

While WesTrac had evaluated several potential locations, Collie was the ideal centre for the training facility, according to Croome.

“The town has a long mining history and an experienced workforce with the potential to help run and develop the training facility over time,” he said.

“There’s also a vibrant community and plenty of supporting business infrastructure, plus a unique range of natural attractions and easy access to the wider South West region, which adds appeal for Australian and international training participants.”

Croome said WesTrac and Caterpillar clients across the Asia Pacific region had shown significant interest in having access to such training and strong demand was expected when the facility commenced operations.

Jean Savage to retire from Caterpillar surface mining and tech post

Automation, Mining equipment, Mining people, , ,

Caterpillar has announced that Jean Savage, currently Vice President of the Surface Mining & Technology Division, has elected to retire from the company.

Trinity Industries, a provider of railcar products and services in North America, had earlier announced that Savage, a member of the Board of Directors, would be appointed CEO and President, effective February 17. She is to retire from Cat, effective February 14.

Savage joined Caterpillar in 2002 and held numerous leadership roles in Caterpillar’s Progress Rail division, before being named VP of the Advanced Components and Systems division in 2014. Savage went on to lead the Innovation and Technology division before being named VP of the Surface Mining and Technology division in 2017.

Prior to joining Cat, Savage worked for 14 years at Parker Hannifin, a leader in motion and control technologies and systems, where she held a variety of manufacturing and engineering positions. In addition, Savage served nine years in the Army Reserves as a military intelligence officer.

Denise Johnson, Resource Industries Group President, said: “We thank Jean for her 17 years of service to Caterpillar. Jean has been instrumental in delivering Caterpillar mining products and services that are focused on accelerating customer benefits in safety and productivity. We appreciate all of her contributions and wish her well in her new role at Trinity Industries.”

Cat said a replacement for Savage will be named at a later date.

RCT improves safety at South Africa diamond operation

Automation, Diamond mining, Mining equipment, Mining safety, , , , , ,

RCT says it has installed its ControlMaster® Line-of-Sight solution on equipment at an open-pit diamond mine in South Africa.

In 2019, RCT installed and commissioned the solution on a CAT 994 wheel loader, which has been utilised to clear pit benches of debris falling from the crest of the bench above at the mine, owned by a major mining company, RCT said.

RCT’s locally-based Field Service Technician carried out commissioning works and empowered site equipment operators with the training necessary to efficiently manage the wheel loader, it said.

RCT’s Johannesburg-based Business Development Manager for Africa, Mike Thomas, said: “South Africa’s Department of Mining Regulations prohibited any mining personnel to be in close proximity with the bench’s toe.

“The Line-of-Sight technology meant equipment operators could stand at a safe distance in accordance with regulations and carry out their work as if they were sitting in the machine’s cab.”

He concluded: “Our ControlMaster automation technology integrated seamlessly into the wheel loader’s operating system and carries out the same range of functions as specified by the original equipment manufacturer.”

PYBAR takes Command of Dargues automation with new Cat R1700 LHDs

Automation, IoT, Mine operation news, Mining equipment, Mining services, Precious metals, , , , , , , , , , , , ,

PYBAR has taken a step closer to advanced underground automation at the Dargues gold mine in New South Wales, Australia, with the arrival of a second new Cat® R1700 underground LHD at the Diversified Minerals-owned site.

The new loader visited the PYBAR head office in Orange, en-route to the mine site, where it was met by executives and senior management from PYBAR and WesTrac.

The first of two new R1700s purchased for Dargues from WesTrac was commissioned at the mine during August and the company, in November, announced that the underground loaders were undergoing staged testing that will see them move towards improved automation in early 2020.

Dargues is owned by Diversified Minerals, an associated company of PYBAR Mining Services. The mine is expected to have a 355,000 t/y capacity gold processing facility comprising crushing, milling, flotation and filtration circuits and produce a sulphide concentrate for export. This could see Dargues produce an average of 50,000 oz/y of gold in the first six years of production.

The new machines are equipped with Caterpillar’s next generation Command for underground technology, giving them automation capabilities that will allow them to be driven via tele-remote from the surface from early-2020. This will realise significant productivity, efficiency and safety gains, according to PYBAR.

Command is part of the Cat Minestar™ integrated suite of offerings designed specifically for mining, PYBAR said.

PYBAR Chief Technology Officer, Andrew Rouse, said: “With the second loader now on site we will complete the tele-remoting set up in time for stoping early next year.

“Our intention is to be able to tele-remote from the surface from the outset when both loaders go into full operation. It’s a milestone all three teams (Caterpillar, PYBAR and WesTrac) have been working towards and will deliver.”

The new loaders were purchased after trials at the Vivien gold mine in Western Australia during 2017, PYBAR said. These trials delivered impressive results, including quicker bucket loading, faster cycle times, greater payloads and less fuel burn, according to PYBAR.

PYBAR said: “These benefits were further highlighted when the Cat R1700 was tested against the R1700G at Vivien (owned by Ramelius Resources) in June 2018, prompting PYBAR to place the order for the new loaders.”

Rouse added: “We were extremely impressed with performance of the new loader during testing. With the knowledge gained from the activity at Vivien, we were able to carry out a rigorous analysis around the loader combinations required for the Dargues operation with the R1700 proving to be the most cost effective.”

Since the first new loader has been put into operation, PYBAR has been preparing for advanced automation through the use of the traction control and Autodig features on the new machines, it said. The feedback has been very positive with full buckets consistently being achieved, the company added.

“The Command technology enables remote operation from the surface or underground, providing productivity and efficiency gains, improved safety of personnel, more accurate tunnel navigation, and reduced machine damage,” PYBAR said.

Caterpillar’s Commercial Manager for Underground Technology, Randy Schoepke, said PYBAR has long seen the value of being on the “leading edge of technology” as a contractor and an owner miner.

“The new Cat R1700 loader will be a huge complement to their technology portfolio leveraging the most advanced features in the industry,” he said.

“The R1700 features of traction control, live payload, Autodig, and ride control will not only provide operator comfort and productivity but also be leveraged by Caterpillar’s latest generation of Command for Underground, Caterpillar’s remote and autonomous control system.”

Schoepke concluded: “When there is a requirement to remove the operator from the underground environment, the technology allows safety and utilisation to be taken to the next level. We look forward to our continued work with PYBAR on this project.”

WesTrac General Manager of Mining Sales, Jody Scott, said this development was the culmination of more than two years work with PYBAR to “identify and test the technology that will have the most impact and benefits for them and their clients”.

He added: “Extensive testing has enabled us to fully evaluate the challenges posed by the harsh underground environments in which the machines are required to operate. It has also allowed us to set up the machines to get the most out of their automation and tele-remote capabilities.”

Cat’s 7495, 7495HF shovels receive an AC drive boost

Equipment maintenance, Mining equipment, Mining maintenance, Mining services, , , , , ,

Caterpillar has updated the AC electric drive system for Cat® 7495 and 7495 HF electric rope shovels to, it says, deliver even greater reliability, improved maintenance access, enhanced safety and expanded ability to perform at high altitudes and in extreme temperatures.

The updated system also is designed to easily integrate with advanced technologies.

“Caterpillar and our predecessor in shovel design and manufacturing, Bucyrus, have supplied more than 300 AC electric rope shovels,” said Dale Blyth, Product Manager, Electric Rope Shovels. “The most recent advances in AC drives are integrated in this update and demonstrate how we apply our experience to help customers lower cost per tonne and bolster safety.”

Updates include a liquid-cooled motion regulator cabinet for more efficient dissipation of heat generated by electrical components.

The company said: “The new system enables shovels to operate at temperatures of -40 degrees C/F to +50 degrees C (122 degrees F) and altitudes of 5,250 m (17,220 ft) without derating.

“The reliable system also eliminates airborne contaminants in the cabinet and lengthens service intervals – for reduced costs and greater uptime. Additionally, a new, faster propel transferswitch cuts lag time by 75% for improved productivity.” 

New technologies enable consolidating two cabinets in the machinery house to create space for easier maintenance access, while the updated maintenance station is designed for integration of current and future technology solutions, including Cat MineStar™.

The drive system design uses common motors in multiple applications, according to Cat. “That means fewer parts to stock, improved parts availability and simplified maintenance.” 

The new motors also have higher power densities, smaller frame sizes and optimised footprint, which aids access, it added.

The Cat rope shovel electric drive system still features elements such as fuseless insulated-gate bipolar transistor modules. And, the on-board maintenance station continues to aid technicians in identifying faults and resolving issues.

The new electric drive system will be on all new production 7495 and 7495 HF shovels beginning in late 2020.

The system is not intended for retrofit, though some elements, such as the fast propel transfer switch, are available as upgrades to machines already in service, according to Cat.

PYBAR to trial autonomous loading at Dargues underground gold mine

Automation, Base metals, Mine operation news, Mine surveying, Mining equipment, Mining services, Precious metals, , , , , , , , , , , ,

PYBAR Mining Services says it is applying new technology to several automation projects it is currently working on, including Diversified Minerals’ Dargues underground gold asset and the Heron Resources-owned Woodlawn zinc-copper operation, both of which are in New South Wales, Australia.

Chief Technology Officer, Andrew Rouse, says the company’s approach has always been to get the basics right using traditional means and then adding technology to enhance its capabilities. “This guiding principle is being applied to several current automation projects,” he said.

New Cat R1700 underground loaders being deployed at the Dargues gold mine are undergoing staged testing that will result in them moving towards improved automation in early 2020, according to PYBAR.

Dargues is owned by Diversified Minerals, an associated company of PYBAR Mining Services. The mine is expected to have a 355,000 t/y capacity gold processing facility comprising crushing, milling, flotation and filtration circuits and produce a sulphide concentrate for export. Dargues is expected to produce an average of 50,000 oz/y of gold in the first six years of production.

Testing of the LHDs has featured the use of Cat’s next generation MXZ technology, which includes traction control and Autodig, where the machine digs the load instead of the operator, PYBAR said. “Both technologies have made an impact with full buckets consistently being achieved,” the company added.

The next step in the process will involve setting up tele-remote operation from the surface in time for stoping in early 2020, according to the contractor.

PYBAR was part of the team at Ramelius Resources’ Vivien gold mine in Western Australia where the first global underground trial of the Cat R1700 loader took place in October 2017. This followed a global launch of the machine at MINExpo 2016.

Another project has seen PYBAR collaborate with Emesent to test automated drones at the Dargues and Woodlawn operations.

LiDAR and SLAM (Simultaneous Localisation and Mapping) technology is used to track the drones underground and keep them away from obstacles, according to PYBAR, with the trials having delivered some favourable outcomes; among them the swift processing of information gathered by the drones.

“The technology has great potential and PYBAR is investigating how best it can be applied to our business,” it said.

Cat DTH hammers and bits up the ante in blasthole drilling

Equipment maintenance, Explosives and blasting, Mining consumables, , , , , ,

Caterpillar has introduced its first Cat® down-the-hole (DTH) hammer and bits for blasthole drilling as it looks to speed up penetration rates and reduce drilling costs in difficult conditions.

The new Cat DTH Hammer is 152 mm (6 in) in diameter and is the first to be introduced in the new DTH line. Its valved design provides reliable operation, low air consumption, easier maintenance and cost effective rebuild, according to the company. The piston design, meanwhile, delivers long life and efficient energy transfer.

The new hammer is rated to run with compressed air systems driving working pressures up to 34.5 bar (500 psi). Cat explained: “This additional back-head pressure, when combined with corresponding airflow demanded, generates more blows-per-minute to generate faster penetration rates in the hardest of materials.”

Caterpillar also is introducing bits for DTH drilling. Several different configurations of 171 mm (6.75 in) bits are now available in both standard and heavy-duty versions to allow matching the bit to the rock characteristics and job requirements. The bit selections include a variety of carbide shapes (spherical, ballistic) and face shapes (concave, flat, convex).

“Cat Bits are optimised for high wear resistance and improved rock chipping,” the company says. “The aggressive, long-lasting cutting structure in conjunction with the efficient Cat DTH Hammer delivers a superior rate of penetration.”

Caterpillar’s advanced materials and heat treatment technology used in the DTH products yield longer life and result in lower overall drilling costs in demanding conditions, it says. In head-to-head tests conducted in iron ore and quarry applications, Cat says its hammers and bits demonstrated significantly lower total cost of drilling.

Cat to showcase latest longwall offering at Katowice fair

Automation, Coal technology, Communications in mining, Equipment maintenance, Mining events, Mining safety, Mining services, , , ,

Caterpillar says it will present a number of new longwall mining products and solutions at the International Trade Fair for Mining, Power Generation and Metallurgy, on September 10-13, in Katowice, Poland.

Together with the regional Cat® dealer, Bergerat Monnoyeur, Caterpillar will showcase its latest technologies at its booth.

The Caterpillar exhibit will feature digital presentations of new longwall machines, technologies and services—all designed to make longwall mining safer, more efficient and more productive, it said. A highlight will be the virtual reality experience, which enables customers to experience newly developed virtual reality service tools for Cat longwall systems.

Similar technology is used for the new Cat Virtual Reality Training & Simulation system. “Real-time and realistic interactive 3D visualisations of real operations with Cat Virtual Reality Services offer opportunities to help trainees and operators understand the complex mechanics and operations ofa complete longwall system, where so many pieces of equipment are interrelated,” Cat said.

Digital presentations will also demonstrate Cat shearer automation—using technology for face alignment, horizon control and extraction control. Also, the latest version of Cat longwall machine monitoring, Cat MineStar™ Health for Longwall, will be shown. “Health for Longwall is a cost-effective and user-friendly data visualisation and reporting tool. It empowers managers to efficiently view, manage and use machine data to make informed maintenance decisions that will help maximise the availability of longwall equipment,” the company said.

Caterpillar designs and manufactures complete longwall systems customized to optimise performance in specific applications. The Katowice exhibit presentations will feature new longwall components, such as the Cat EL1000 Shearer, designed for low- to mid-seam heights. This latest addition to the successful range of Cat shearers covers seam heights from 1.6-3.2.6 m (63-126 in).

The recently introduced Cat PF HD Line Pan for armoured face conveyors is especially designed for heavy-duty longwall applications with demanding conditions, Cat said. “The new pan is the most robust and reliable Cat line pan, lasting up to two times the life of corresponding PF5 and PF6 pans.”

The exhibit will also preview the Cat HTD4100 High Torque Drive System for longwall armoured face conveyors. “The drive enables a higher level of automation for enhanced speed and torque control and real-time monitoring, and its modular design simplifies installation and maintenance. The converter-controlled torque motor offers fast response and precise control to reduce conveyor chain wear and failures.”

Caterpillar will also preview its next generation roof support control, PMC-R 2.0, which is the successor to the Cat PMC-R control unit. “The new roof support control unit is designed to meet the automation needs of modern, high-performance longwall operations. Advanced microcontroller technology with increased computing power and enhanced communication capabilities offers improved functionality to control roof supports in a self-advancing longwall system. The new controller also features enhanced serviceability.”

The company continued: “Caterpillar and Cat dealers have created a one-of-a-kind, on-site support network for delivering expert service, integrated solutions, after-sales support, fast and efficient parts fulfilment, world-class remanufacturing services and more. Services now include Caterpillar Accredited Rebuilds (CAR) for longwall roof supports. The CAR program offers a like-new roof support with a new machine warranty and a new serial number, all at a fraction of the cost of a comparable new roof support.”

At Katowice Mining Fair, Caterpillar and Cat dealers will also show their commitment to work alongside customers to improve performance across the operation, leveraging every longwall system component, tool and technology to help improve safety, efficiency and productivity, the company said. 

National Group buys semi-autonomous dozer contractor specialist Wolff Group

Automation, Equipment maintenance, Mining equipment, Mining mergers and acquisitions, Mining services, , , , , , , , ,

National Group says it recently acquired Wolff Group, bolting on a range of automated and innovative solutions such as large scale satellite bulk dozer push and semi-autonomous blast hole drilling to its existing range of mining services.

Wolff, the first company in Australia to use Command for dozing, a Cat® Minestar™ offering, also provides contract mining services, excavator pre-strip fleets, civil earthworks, site clearing and rehabilitation works, according to National Group.

The National Group, meanwhile, comprises companies from the mining, resource, logistics and personnel supply industries that, through its National Heavy Haulage and International Global Logistics subsidiaries, regularly delivers mining equipment nationally and internationally.

National Group Managing Director, Mark Ackroyd, sees the acquisition providing niche business opportunities.

“Adding Wolff to the National Group will allow us to deliver additional services in autonomous operations, so it was a logical choice for us,” he said.

“Terry (Wolff, Managing Director of Wolff Group) and his team at Wolff have a very similar organisational culture to ours and that was one of the most important things we spoke about during our discussions. The other was their work in autonomous operations and the focus towards the future of mining.

“We want to provide our customers with the best there is and staying on the cutting-edge of technology goes a long way in allowing us to do that.”

As part of the acquisition, National Group and Wolff have agreed to adopt a “business as usual” approach to ensure minimal to no effect on the current Wolff workforce and customer base, National Group said.

Terry Wolff, who will stay actively involved in the business, said: “National Group met all of our foundations and culturally aligned with the way we already do business here at Wolff, so that made this decision a lot easier for us. We couldn’t think of a better company to pass on the baton to.

“National Group values our people, autonomous expertise and our ability to operate in the segments where we have a depth of knowledge and experience.”

Wolff is well-known in the industry for its focus on innovation and technology and already has an established partnership with Caterpillar and Hastings Deering to implement and optimise semi-autonomous tractor system technology in a world’s-first application into a mining production environment, National Group said.

Ackroyd concluded: “Here at the National Group, we are excited for the future and look forward to further extending the range of automated features for our expansive fleet of dozers and drills.”

RCT and GBF reflect on decade-long automation partnership

Automation, Communications in mining, Equipment maintenance, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software, , , , , , , , ,

RCT and underground mining specialist, GBF, have marked 10 years of working together to implement autonomous technology into underground mining operations.

Since 2009, when GBF & RCT conducted underground trials of the ControlMaster® Guidance Automation system at Gold Fields Caves Rock mining operations, RCT has delivered 19 autonomous systems including Sandvik LH203s, CAT 2900Gs, R1700s, R1700Gs and R1300Gs at multiple GBF-run mine sites throughout Western Australia’s Goldfields, according to RCT.

The work collectively amounts to roughly 15,000 hours of machines operating on Guidance Automation within GBF-run operations.

“ControlMaster Guidance Automation has seen numerous software iterations over its product life starting with dynamic operator engagement, surface control to independent autonomous tramming and, more recently, multi machine control via RCT’s latest automation offering,” RCT said.

GBF Maintenance Superintendent Alan Moyle, who played a key role in the initial trials and has seen the Guidance Automation system evolve over the last 10 years, said RCT’s technology has significantly improved safe machine operations by removing personnel from the mine face as well as better operator fatigue control.

“Greater control features have reduced the amount of machine damage due to operator errors with consistent machine cycles enabling us to improve productivity and it provides us data when tendering for new contracts,” he said

“RCT have also provided multiple opportunities for GBF apprentices to gain experience with their latest modern technology which they have subsequently applied to their work.”

RCT Product Manager Automation & Control, Brendon Cullen, said GBF’s early adoption of RCT’s technology meant its operations have benefitted consistently as the product has evolved.

“GBF has been influential in driving features and improvements to the system over time and develop new features such as G-Dash which empower operator’s decision making by presenting a dashboard of the machinery in relation to its surrounding in real time,” he said

“GBF’s operators have also consistently provided feedback over time, resulting in improvements such as faster tramming times, better cornering speeds, more efficient braking and the evolution of the fully automated tramming cycle.

“As the mines are becoming deeper the drive to operate the machinery from the surface is becoming a key requirement to maximise production times. RCT continues to work in partnership with GBF to allow them to reach their goals as cost efficiently as possible using the technology available onsite at the time.”