Vehicle Automation is Key to Building the Smart Mine of the Future

The mining sector is in the midst of a technological revolution with automation and smart technologies witnessing an uptick. While the global mining industry is gradually recovering from a steep downturn, miners around the globe are investing in smart technologies to boost productivity and improve safety. Precarious commodities, lower ore grades, slashing productivity, spiraling operational costs, and a dearth of skilled resource pool have remained longstanding challenges for the mining sector. Automation has the potential to address these challenges; however, higher investment can pose challenges to widespread adoption.

Mining Companies Blaze their Way to Vehicle Automation

Some of the most notable advances in vehicle automation technology for mining sector include LHDs (load haul dumps), trucks, and trains, which use autonomous technology and robotics. Autonomous Solutions, Inc. (ASI) first started working with some of the key manufacturers and mining giants, including Rio Tinto, Barrick, Komatsu, Caterpillar, and others to develop autonomous vehicle technology for mining applications.

Autonomous truck haulage systems and LHDs are ideal for implementation in underground and opencast mines. Similar to a GPS and mapping tools present in autonomous drills and shovels, these vehicles also possess a GPS, perception technology, and on-board intelligence that assist their autonomous operations. These vehicles are fuel-efficient; they can enhance tyre life using a TPMS (tyre pressure monitoring system), minimising the probability of a collision.

Remote-controlled automated train transportation is another pivotal development wherein loading and transportation are controlled remotely. Driverless or unmanned haulers and dozers form another set of advanced technology automated vehicles for mining.

Dominance of Automation: Bright Prospects for Smart Mining

Following automation in mining systems, the industry is currently marching ahead to the fourth generation automation i.e. vehicle automation. Integrated ICT is a critical factor that brings about automation and digitisation in each section of mining in order to gain improved productivity and efficiency at reduced risks. This, eventually results in transformation of conventional mines into smart mines that are highly competitive and profitable.

The global smart mining market is pegged for stellar growth in the near future, reaching the revenues worth US$ 13 Bn by the end of 2020. The revenues from the largest smart mining segment i.e. automated equipment are estimated at US$ 1.5 Bn by 2017, accounting for over 70% market share.

While mining excavators and LHDs continue to lead the segment, the market will see remarkable adoption of robotic trucks in the next few years. Consistent developments mark only the momentous beginning of the smart mining transformation; the industry will however continue to witness many more innovations in the next few decades.

Driverless Trucks, Automated Trains, and Unmanned Lorries: The Mine of the Future

AHS (autonomous haulage systems) were first commercialised for mining by Komatsu ADR, one of the leading manufacturers. These vehicles have a wireless network system, a high precision GPS system, vehicle controllers, and obstacle detectors. Komatsu’s AHS soon gained popularity due to the ability of operating safely throughout a complicated load, haul, and dump cycle. They can easily integrate with other components of an automated mining system. 

To overcome the scarcity of mining staff in 2008, the mining giant - Rio Tinto first invested in a large fleet of automated haul trucks (AHT).

Use of these trucks was previously a commonplace across regions in Western Australia. Komatsu began AHS trials in a partnership with Rio Tinto, hauling millions of tonnes of ores and other material in Pilbara region and Chile. The emergence of AHS technology proved to be a breakthrough for the mining industry, as it opened doors for lucrative possibilities of unmanned mining trucks, in addition to augmenting overall productivity and safety. Komatsu’s robot monster trucks were also recently launched in Las Vegas.

Rio Tinto is the first in the mining industry to own two fully functional mines that operate using entirely autonomous vehicles.

Driverless vehicles operate 24x7x365 and can be supervised from anywhere across the globe. Around 70 driverless trucks operate the two mines in Nammuldi and Yandicoogina, along with the Hope Downs 4 Mine, which work autonomously to transport millions of tonnes of iron ore, and can be supervised by expert resources working miles away from the actual mine locations. The first batch of these vehicles by Rio Tinto was trialled in 2012, across several mines, trains, and ports. These trucks have efficiently travelled over 3 million kilometres till date, independently moving around 25 million tonnes of high-grade iron ore a month.

Today, driverless vehicles rule the mines in Nammuldi and Yandicoogina

Following the success of automated trucks, Rio Tinto has already embarked into a trial for robot drill mining. Unmanned trains are being trialled under the company’s ‘Mine of the Future’ programme (2008). Automated lorries (similar to cars being researched at Tesla and Google) however seem to be a lengthy achievement for the company, following the fact that driverless trucks still need remote manual supervision.

Nevertheless, Rio Tinto expects a fully operating, autonomous railway line

BHP Billiton ADR has recently accomplished trials of fully automated, driverless lorries at a Mexican coal mine in collaboration with Caterpillar Inc. - the world’s topmost heavy equipment manufacturer. Moreover, the company has plans to expand its existing fleet of driverless trucks, and is currently testing unmanned lorries for underground tunnels.

A few new Caterpillar driverless trucks are currently under the trial at BHP’s Jimblebar mine.

Fortescue Metals Group introduced automated robo trucks at the Western Australia-based Soloman Hub mines, in collaboration with Caterpillar Inc. The company has reached dramatically increased productivity levels post-implementation of these autonomous haulage systems. Moreover, the Queensland mining industry awaits a fleet of driverless trucks, especially for underground mining.

Volvo takes a leap in underground mining with robot mining trucks.

Recently, Volvo announced its ambitious plan of a flagship automation project that would probably represent the highest possible level of mining vehicle automation - robot mining trucks or driverless trucks designed for operating in underground mines. Partnered with Boliden (a Swedish mining group), the company is currently testing driverless trucks in Sweden’s Kristineberg mine.

Workforce Safety: A Strong Factor to Adopt Vehicle Automation in Mining

Even before productivity, the most important reason that strongly prompts at the need for vehicle automation in mining, is safety. The infamous accident in Chile (Copiapo – 2010) had trapped a large number of miners for around 70 days; the rescue operation by other mine workers was constantly in process. Getting trapped inside the mines as well as rescuing those who are trapped, both are equally dangerous and cumbersome.

The popular Bingham Canyon Mine faced a massive landslide that left behind a substantial hazard to mines and miners. Eventually, it also created a vast, highly dangerous, unstable terrain to work on. To add to these notable incidences, a recent survey indicates that the U.S. and China have seen numerous coal mine deaths within the past decade – fatalities in the U.S. was over 300, whereas those in China were nearly 45,000. Post-incidence cleaning includes heaps of manual labour as well.

The immediate and right information signalled at the very moment a mine collapses, plays a critically important role. It accelerates search and rescue efforts of the rescue crews, which otherwise may take lengthy time due to the accumulation of explosive gases and poisonous vapours, and flooded tunnels, weakened shafts, and so on.

Using automated vehicle technology can certainly omit the mine disaster threats, curbing such incidences and saving thousands of lives. Robotic components of fully automated mining vehicles automatically handle all the functions, from ignition, acceleration, braking, and transmission, to accurate navigation. Today, obstacle detection and avoidance is considered to be one of the most novel features. The eventual output is a significantly higher productivity, coupled with the optimum safety.

A Move Away from Manual Jobs: Potential Impact on Mine Employees

Improved productivity, enhanced operational efficiency, minimised infrastructure and reduced downtime, safer and more sustainable mining conditions, and decreased need for skilled staff, are some of the many advantages that mining businesses are seeking through vehicle automation technology.

Although innovations are rapidly transforming the industry for betterment; it has been facing bad press from certain parts of the world. The mines in future will have a higher percentage of automation in vehicles, which may partially or entirely replace the workforce in the mining industry. This has been creating a fear of being unemployed or obsolete among mine workers.

However, some of the leading mining companies have already indicated to create new, upgraded job profiles rather than eliminating existing workers. Retraining and communication programmes will redefine mining for most of the labours. Whereas, specialised mine workers are likely to be in demand post-implementation of automated and semi-automated vehicles.

Out of near 50,000 haul trucks operating in mines across the globe today, not even 1.0% are autonomous. However, mining industry certainly seeks a commendable future with rapid-paced penetration of autonomous vehicles.