Tag Archives: MineStar Edge

Caterpillar looks to reduce haul road dust with new Cat 777 (05) Water Solutions Truck

Caterpillar has released a new water truck that, it says, provides an integrated solution to help reduce haul road dust by solving overwatering and underwatering issues.

The new Cat® 777 (05) Water Solutions Truck is built on the Cat 777E truck platform, proven at mine, quarry and construction sites globally. An innovative truck that uses less water for controlling haul road dust, the design integrates the truck, tank and water delivery system, connected with technology, the company says. Its Cat Water Delivery System (WDS) combines with Cat MineStar Edge™ connectivity to help operations manage the site more safely and productively with flexible levels of technology to meet site needs.

Boasting a 75,700 litre Cat-branded water tank, the 777 (05) comes complete with spray system, splash guards, fill chute and rock ejectors. It is powered by the 765 kW Cat C32B engine that meets China Nonroad Stage III emission standards, equivalent to US EPA Tier 2.

The new water truck’s exclusive Cat WDS features a self-contained hydraulic system that controls spray patterns independent of engine rpm for consistent watering, Caterpillar says. Variable water flow, based on the truck’s speed, automatically starts and stops when the truck slows or comes to a halt, preventing overwatering and subsequent poor traction at road intersections. The pump features soft start-ups and automatically shuts off when the tank is empty to prevent system damage.

WDS components include a water cannon, oil cooler, variable displacement pump, hydraulic oil tank, electronic control boxes and hydraulic motor/water pump. Covering up to a 24-m-wide road in a single pass, the system sprays at rates reaching 0.8 litres/sq.m at speeds from 4-40 km/h. With its maximum 61 m spray distance, the truck’s water cannon offers a maximum flow rate reaching 4,732 litres/min.

Factory-installed, ergonomic water controls are integrated into the truck’s design for convenient system operation, Caterpillar says. Its automated water delivery feature enables the operator to remain focused on driving and site traffic to enhance safety. Complete with auto shut-off to prevent overfilling, the water tank is filled remotely, allowing the operator to remain inside the cab during the cycle to reduce potential operator slips and falls.

Flexible levels of the cloud-based MineStar Edge technology are integrated with the Cat WDS to collect and communicate machine data, allowing site supervisors to monitor the water truck to know where and when it’s spraying water. Asset management options include productivity, water usage, fuel and water tank levels, when and where to apply water, geofencing, asset location and remote management of water distribution.

Providing tracking capabilities without the need for infrastructure investment, Edge Equipment Tracking delivers basic connectivity without interfering with existing fleet management systems. Equipment Tracking helps to achieve a lower total cost of ownership, providing insights to help mines better manage their assets, the company said. It features service meter readings, fuelling and recording data, location accuracy and replay, time utilisation tracking with downtime and operator tracking, automatic stoppage measurement and health event recording.

Paired with Equipment Tracking, MineStar Edge Production Recording delivers premium connectivity with an accurate and automated near-real-time measurement solution that reports on every aspect of the watering cycle without requiring operator input. Giving visibility to the entire operation, it helps to discover opportunities for improving productivity. This premium package also includes water usage by truck/fill station, volume and rate of water put down over time and area covered, water delivery system setting by location, truck, and conditions, activity breakdown with time and distance – watering, not watering, stopped, etc.

This integrated system with Cat-branded tank options is fully supported by the Cat dealer and parts network. Covered by the Caterpillar factory standard warranty, the water truck, including tank and components, is eligible for Cat equipment protection plans and customer value agreements. Cat dealer installation of the integrated system is available, and retrofit kits for existing Cat 777E truck platforms in the field have planned availability in the future.

Caterpillar, Barloworld, AMS and Sandfire collaborate at Motheo in Botswana

When Sandfire Resources produces the first ore from its new Motheo copper mine in Botswana, southern Africa, later this year, the company will officially be on its way to developing a long-life copper production hub in the central portion of the Kalahari Copper Belt of Botswana and Namibia.

That first ore from Motheo is just the beginning of the company’s long-term growth plans in the region. Before the development of the mine was even completed, Sandfire had already announced plans to enlarge the operation by exploiting an additional deposit and building an expanded processing plant to handle production.

Recognizing the potential of the Kalahari Copper Belt, Sandfire and its chosen operations partner for Motheo — Perenti Group’s African Mining Services (AMS) — made a commitment to the highest standards of productivity, safety, responsibility and sustainability.

A critical contributor to meeting that commitment will be the use of mining technology. And key partners in that effort will be Caterpillar and Cat® dealer Barloworld Equipment, who are working with Perenti/AMS to provide a suite of technology solutions that will deliver innovation to the mining operation.

Crew with mining truck

“We know that Sandfire Resources, our customer Perenti, and the entire team at Motheo is committed to using technology to build the safest, most productive operation possible,” Nathan Wescombe, a Senior Account Manager at Caterpillar, said. “We’re proud that Perenti has chosen Cat technologies to help them become the operator of choice within the region and deliver innovation to their mining practices.”

To ensure the successful deployment of technology in an area of the world where mining technology is not the norm, Caterpillar conducted a three-day information-gathering and change management workshop to consult with key stakeholders to help ensure they are technology-ready.

“Change management is a key to the implementation of technology in any operation,” Leslie Fengu, a Senior Regional representative for Caterpillar’s Mining Technology Solutions division, said. “And it’s even more critical in an area where it’s being introduced for the first time. Fortunately, Caterpillar has a team that has plenty of experience in helping our customers manage this change – understanding the challenges, developing possible solutions to address them, and providing ongoing support through implementation and beyond.”

Held in August 2022, the workshop was very well attended, met with positive feedback, provided critical knowledge of the operation, and identified opportunities moving forward to ensure success for all stakeholders, according to Caterpillar.

Greg Lawson, a General Manager at Perenti/AMS, said: “Incorporating technology into our operations is an important piece of our global strategy. Having the support of Caterpillar and Barloworld as we implement these solutions in a new region is proving to be instrumental in helping us realise our goals. We appreciate the value of their expertise not only in the technology itself but also in addressing the significant change management that goes along with its implementation.”

The Motheo copper mine

Motheo Copper Mine is located in the Kalahari Copper Belt, a major zone of strata-bound copper-silver deposits extending for 1,000 km along the northern margin of the Kalahari Craton in Namibia and Botswana.

The greenfield project is being developed by owner Sandfire Resources, an Australia-based mining and exploration company with a global presence. Open-pit mining services are provided by contractor AMS, the Africa-based surface mining arm of Perenti Group, a global mining services company also based in Australia.

Motheo represents the foundation for Sandfire’s long-term growth plans in Botswana and is expected to generate approximately 1,000 jobs during construction and 600 full-time jobs when fully operational.

After a positive feasibility study in December 2020, Sandfire’s board approved the development of Motheo. The feasibility study identified a robust initial 12.5-year operation with annual production of high-quality copper concentrate estimated at 3.2 Mt. Site construction commenced in 2021, with first production scheduled for mid-2023.

The Motheo Copper Mine will be based on an open-pit operation for the original deposit, identified as T3. The drill-and-blast operation will focus on 10-m benches, using suitable blasting methods to minimise dilution. Trucks will be loaded by 250-t excavators. Direct run-of-mine ore will be delivered directly to the crusher or placed on stockpiles for future rehandling.

AMS selected a fleet of Cat trucks to handle hauling duties, supported by a variety of other Cat machines. Barloworld recently delivered 20 139 t Cat 785 trucks, four D10T dozers, two 777 water trucks and two 18 motor graders to the mine.

Beyond the quality expected from the Cat machines, a major factor in the equipment purchase was related to the Cat MineStar™ technology products that accompany them. AMS, Caterpillar says, selected three separate but integrated solutions that will impact the efficiency and production of the operation, the uptime of machines and the safety of its people:

  • MineStar Edge™, a cloud-based equipment management and production recording platform that provides access to highly accurate production data and gives visibility to the entire mining operation;
  • Health – Equipment insights, a user-friendly data visualisation and reporting tool that allows sites to easily access, view and analyse machine health information and gain insights to help reduce unplanned downtime and prevent failures; and
  • Cat Driver Safety System, an in-cab detection technology that can help sites identify operator fatigue and distraction and address it in real time.

Introducing technology in Botswana

Sandfire and Perenti are no strangers to mining technology. Sandfire’s DeGrussa copper-gold mine in Australia was an early adopter of autonomous mining, using Cat MineStar Command for underground to automate a fleet of underground loaders. The Perenti Group, too, recognises the value of technology in mining, and has added a dedicated services and products business to its portfolio to provide technology and consulting services to the mining industry.

But bringing a technology mindset to this region is not business as usual. For Caterpillar, this is just the third such implementation in southern Africa and the first in Botswana. Cross-departmental interconnectedness is paramount for Perenti and AMS to realise its return on investment as the Motheo team strives to deliver on business demands, Fengu, whose knowledge of the region and its history are extremely valuable to technology implementation in Botswana, said.

“Disruptive technologies, such as those chosen by AMS, require a site-wide approach to achieve successful implementation and sustainable operations,” he said. “Supervisors and their teams are required to effectively manage the implementation and functional changes that will be required with technology, adapting staffed conventional mining techniques to get the most value out of the new mining system.”

To ensure the success of these systems in a country where they have not operated previously, Caterpillar identified an opportunity to leverage the knowledge and capability of its Cat Solutions & Services team, as well as other Cat and Barloworld technology experts. The initiative was led by Caterpillar Technology Change Enablement Manager, Brett Haskins, working with Joel Patterson and Jenny Krasny as key consultants.

“We organised a workshop to develop a deeper understanding of how we could assist in this change, walk through opportunities to help them become more comfortable with the technology and better appreciate how it can help support their roles in the operation,” Wescombe said.

Understanding the site and its culture

This workshop included site observations, interviews, education and facilitated discussions designed to understand the current culture – with a lens toward building operational readiness to capitalise upon the benefits that MineStar Solutions can provide.

The visit occurred over three days with a high level of engagement from every area and level of the deployment. The visit was designed to maximise exposure to the day-to-day goings-on in the operation. Pit operations, departmental interactions and daily activities were observed to determine site mining practices, with a view to assess site readiness to apply MineStar and take advantage of the offerings.

“Understanding the history of change in all organisations was an important part of the workshop and visit,” Wescombe said. “We wanted to learn about change that had been managed well and identify areas for improvement. We did that by asking a lot of questions of people from every aspect of the operation. We engaged the site at all levels – from equipment operators to a representative from Perenti’s office in Perth, Australia.”

The discussions invited participants to share concerns or perceived challenges surrounding daily operations. They were encouraged to contribute ideas around how the daily operation and a change to the site’s mining system can be effectively managed from their perspective.

Workplace culture was also explored, gaining insight into how the site is managed and identifying areas of success and opportunities for improvement. Fengu said: “The goal of this effort was to help reduce incidents and unintended operational consequences, and to provide guidance to remedy any shortcomings through application of the technology.”

In addition, the workshop was designed to strengthen the collaborative relationship between the site, corporate office, Barloworld and Caterpillar. Caterpillar says it and its dealer are essential stakeholders who are pivotal to the successful deployment of MineStar Solutions.

“In a nutshell, our goal was to best understand how we could support AMS through the process of change management,” Patterson, Caterpillar Operational Readiness Consultant, said. “We started by encouraging all participants to leave preconceived ideas at the door on the way in to the workshop and asking everyone to be open-minded to change.”

Developing a path forward

All stakeholders agree that the workshop is just the beginning of ongoing engagement into getting the maximum value from technology at Motheo.

“The workshop helped us start the process,” Sam Farhand, Group Asset Manager for Perenti, said. “We learned a lot about the site and about each other. But now the hard work begins – addressing those challenges we’ve identified and ensuring that we never stop paying attention to how the technology is being used and continuing to find new ways to reap the benefits it delivers.”

An important outcome of the workshop is a 30-plus-page report that identifies the areas impacting successful implementation of MineStar technologies at Motheo and provides recommendations and possible solutions that will help address them.

The report is designed to:

  • Ensure understanding of the “why” for change management, and the benefits of using the Caterpillar team for this initiative;
  • Summarise the vision for the deployment as voiced by Perenti and AMS employees;
  • Articulate the landscape in which the project is taking place;
  • Highlight activities on which to partner or reinforce;
  • Present identified opportunities to adapt, build and embed new processes;
  • Identify the unique needs of the people who will be impacted;
  • Outline a change management plan to support the deployment; and
  • Share immediate action items to facilitate a successful deployment.

Sharing positive feedback

When asked about the success of the workshop, all stakeholders had positive things to say.

“The on-site engagement and participation in the workshop were outstanding,” Pierre Hill, Country Manager for Barloworld Botswana, said. “Attendance was terrific. It was a fantastic example of collaboration and teamwork.”

Wescombe agreed: “We were very pleased with the willingness of the key stakeholders to break traditional silos, open up lines of communication and actively engage in rich discussions between corporate, dealer, OEM, maintenance, planning and operations.”

But the most important feedback comes from Perenti. “We thought the workshop was very beneficial,” Farhand said. “It has helped us build a strong foundation on which to base our focus on innovation and technology.”

As the Caterpillar Manager for Perenti, Wescombe is quick to point out the teamwork and collaboration necessary for the success of the workshop – and the future of the technology in the years ahead.

“Without Greg Lawson and Sam Farhand from Perenti, this event would not have happened,” he said. “They helped us gain the traction we needed from internal stakeholders to get this off the ground. Plus, Sam and the on-site AMS Motheo team were instrumental in coordinating and supporting the workshop to ensure its success.”

“Our Caterpillar and dealer teams also deserve recognition. Leslie Fengu and Joel Patterson were key contributors to this effort, along with Pierre Hill and J.P. Briggs from our Cat dealer Barloworld. These folks worked closely with the Perenti team to build a preliminary understanding of the site challenges in order to optimise discussions during the site visit.”

The collaboration was a great example of the “three-legged stool” Caterpillar talks about when dealing with its customers in partnership with dealers. “When all three entities are working toward the same goal, we’re going to be so much more successful than when we go it alone,” Wescombe said. “We’re looking forward to a lot more opportunities to work together with Perenti/AMS and Barloworld in the years ahead.”

This is an edited version of a blog that first appeared here.

Cat to bolster MineStar Edge platform with Guide and Surface Management additions

Caterpillar has added two new capabilities to its cloud-based MineStar™ Edge platform – MineStar Guide and Surface Management.

Accessed alongside Equipment Tracking and Production Recording data from the same office computer or tablet in the field, the additions further augment the Cat® MineStar Solutions suite of technologies.

Edge, Cat says, features the latest technology advancements to measure, manage and optimise mining operations. Using data fusion, machine learning and artificial intelligence, it continues to grow as it collects data, identifies patterns and learns to make decisions.

Guide, available in early 2022, serves as a new platform for high-precision on-board, while Surface Management is an enhanced office platform for Guide, which is currently in development.

Using the advanced capabilities of the Edge platform and the most advanced GNSS technology, MineStar Guide provides the next generation high-precision system for grading and loading operations, according to Cat. Real-time feedback improves operator efficiency and increases machine production.

Featuring a new user interface inside the machine’s cab, Guide offers intuitive operation, which makes it easier to train new operators. Its on-board, dual-receiver system offers improved machine heading and data to increase grading and loading efficiency.

Working through enhanced 3D grade control and design visualisation, Guide provides high-precision block and material identification that is automatically provided to the operator and operations. Grade, block and material designs are also automatically sent to the machine, based on location, to ensure compliance to plan, increase productivity and reduced rework.

Guide offers “stakeless” ore control and regular elevation updates, reducing the need for surveyors in the field to improve safety, Cat says, with the company claiming the enhanced level of automatic blade control provided by Guide will help reduce operator fatigue when grading to design.

Operator and production key performance indicators are sent to the machine through MineStar Edge, empowering operators to stay on schedule.

Guide demonstration units were installed on the Cat 992 wheel loader, Cat 6060 hydraulic mining shovel cab and Cat 24 motor grader displays, as well as inside the technology area, at the recent MINExpo 2021 event in Las Vegas.

3D planning with MineStar Surface Management

Accessed through the integrated MineStar Edge platform, new MineStar Surface Management delivers to the field planning and material information created in the office, Cat says. The next-generation grading and loading platform leverages data provided by Guide-equipped machines for precise execution of planned versus actual production.

With the new Edge platform, Surface Management allows reports to be viewed on office computers or in the field on laptops and mobile devices. Its 3D visualisation of virtual and augmented reality substantially improves project progress viewing, Cat says. The mobile platform gives users the ability to zoom and rotate on particular areas of the site for a more detailed view.

“A powerful material management tool, Surface Management automatically generates fused digital modelling from multiple data sources for improved accuracy,” the company said. “It tracks haul roads, dumps, loading areas and other truck destinations.”

Users can review designs, blocks in progress and as-built areas. Reporting capabilities include timeline advance and comparison with swipe to previous or future and volume calculation. Increasing program flexibility, Surface Management gives customers the freedom to choose the reporting method, according to Cat.

Cat says dozens of mine sites rely on Edge’s Equipment Tracking and Production Recording capabilities with fleet installations ranging from fewer than five to more than 80 machines.

Caterpillar and the next generation of productive hauling

Caterpillar says it is leading the way in the next generation of productive hauling through game-changing efficiency advancements with the Next Generation of Cat® Mining Trucks.

The 785 large mining truck was Caterpillar’s first entry into the mining industry more than three decades ago and, the company says, has been a top performer on sites around the world ever since. It is fitting, therefore, that it is the first of a new generation.

Designed by operators, for operators

“Where does the next generation of productive haulage begin? It all starts with operators, who work in an environment designed for them by other operators,” Cat says.

Truck operators provided input, worked alongside Cat’s large mining truck design team and shared feedback to help create a state-of-the-art environment on board the 785 designed for efficiency and ergonomics, and equipped with features that increase comfort, automate functions and boost confidence, from the smallest operator to largest operator around the globe, the company said.

The next generation operator experience is safer, more consistent, more predictable and more intuitive, shortening the learning curve and boosting productivity of less experienced operators, according to the company.

The new speed coaching feature gives operators real-time feedback on how to operate the truck to maximise its productivity, Cat told IM. In field trials, the new AutoHoist controls, meanwhile, have shown reductions of up to 12 seconds in the dumping cycle. “This feature can also reduce fuel burn during this portion of the haul cycle,” the company said.

Features such as Hill Start Assist, Anti Roll Back, Enhanced Traction Control, Dynamic Stability Control, Anti-lock Brake System, Machine Speed Limiting and Cruise Control improve machine responsiveness and controllability, while improving cycle times and reducing operator fatigue, the company added.

Serviceability and reliability

In addition to enhancing the operator experience and efficiency, the next generation truck platform delivers significant improvements in serviceability and reliability, according to Cat.

“We’ve worked to reduce key contributors to downtime with features like the new modular HVAC (heating, ventilation and air condition) system, which improves reliability and consolidates components so the entire system can be removed and replaced quickly,” Cat said.

Field studies have shown this modular element alone can improve physical availability by up to 0.5%.

New “Remote Flash” and Remote Troubleshooting capabilities reduce downtime and maximise machine availability, according to Cat, providing the ability to troubleshoot the machine remotely or update the software of an electronic control module on an engine or machine through cellular service.

“A manager in the back office can securely push machine software updates over the air to the truck,” Cat explained. “This feature reduces machine downtime and technician time, allows updates to be performed when most convenient, and keeps the machine up to date with the most recent software.”

Connectivity and technology integration

Mine sites have access to real-time information and analytics that improve their total cost of ownership, the company claims, with these next gen pre-production machines “quantifying the full value of new features” at multiple customer sites right now ahead of the start of manufacturing in the March quarter of 2021, Cat says.

Cat says it will be easier to integrate Caterpillar and certain third-party current and future technology solutions on the next generation platform, with offerings such as Cat MineStar™ – which includes fully autonomous haulage with Command – able to deliver a step change in productivity, efficiency and safety.

This integration can provide valuable data and analytics to enable near real-time decision making, maintenance troubleshooting, and the ability to predict and proactively prevent failures, according to the company.

Included on the truck is an improved payload monitoring system that comes with more accurate measurements, improved monitoring and an improved interface, according to Cat.

“Information is more accurate and the system provides access to more data,” the company said of this system. “The new system also provides accurate dipper counts, reduces false loading triggers and overload detection, while carryback calculations are more accurate.”

The system also provides detailed haul cycle segmentation and remote access through telematics, Cat added.

The backbone of advanced connectivity on the Next Gen truck platform is the ability to communicate through dual mode cellular 4G/LTE and Satellite, or local Wi-Fi networks – “whatever benefits the mine plan”, Cat says.

“Next generation connectivity delivers faster data transfers, better access to data, consistent and reliable data communication, more insightful and actionable data, improved data analytics and new diagnostic capabilities,” the company explained.

“The NextGen telematics systems can collect and transmit information securely into locally-hosted or cloud-hosted applications, such as Cat MineStar Fleet, MineStar Edge, and Health Equipment Insights. These applications boost productivity and improve maintenance and machine life.”

Built on a solid foundation

With nominal rated payload of 138 t or higher with optional larger tyres, the 785 has delivered lowest cost per tonne in a wide range of mining applications ranging from flat hauls to deep pits, and solid roadways to challenging underfoot conditions, the company said.

Its 3512E engine offers selectable power options so miners can either match the speed of their current fleet or speed up their cycle times, according to the company. The optional Tier 4 engine has shown a reduction in fuel usage by as much as 9%, while advanced electronic transmission controls deliver faster cycle times, faster acceleration, less spillage and reduced haul road maintenance, on top of improved engine and powertrain life. Longer-life components, extended service intervals and easier maintenance contribute to higher mechanical availability.

“The individual features, components, software and systems that make up the Next Generation 785 have one very important thing in common: they are all manufactured by Caterpillar and supported by the Cat dealer network.

“This integration ensures that the entire truck, from tyres to transmissions, engines to electronics, can be fully optimised to deliver the lowest cost per tonne in any manned or autonomous site applications in the world.”