The drill and blast method of surface mining just got a whole lot safer thanks to Jevons Robotics and RCT.
The companies joined forces to deliver a safer alternative to carrying out blast quality assurance, loading or stemming, replacing it with a single battery electric machine able to carry out the process on any bench condition including severely contoured or cavity filled ground.
Jevons Robotics can now deliver explosives or stemming via their ARTEV6000 product using an RCT’s remote control set either via Line-of-Sight or Teleremote control.
Implementing this technology has eliminated the need for personnel to conduct quality assurance or load the blast holes manually which removes exposure hours associated with highwalls, cavities and fatigue.
RCT’s Custom Manager David Wright said this project was different to any job done before and therefore our specialised bespoke department given the job.
“It is the first time we have remote controlled this type of vehicle carrying out this job scope,” said Mr Wright.
“We were able to use standard loader code, getting it on the machine and talking to the machine,” he said when asked about the execution of the project.
The job, in its manual state is well-known as being high-risk which also makes the role difficult to not only recruit for but then retain the staff.
“The great thing about the Jevons platform is that it can be used for a variety of applications on a mine site to remove additional hazards and its flexibility Is something that will bring great value to the industry, so we were so pleased to be able to work together on it.”
Jevons Robotics CEO Todd Peate said that when Jevons were looking for a teleop and line-of-sight capability we were immediately drawn to the established competency of RCT and its deep experience in mining.
“We wanted a solution that eased our customers mind on automating this process and we certainly have that with RCT,” said Todd.
Operations are now more efficient and safer for a Western Australia-based Earth Moving team thanks to the deployment of a ControlMaster® remote-controlled technology package to an Amphiroll Mud Scroller.
The mud scroller, used to aerate the caustic mud of the tailings pond to dry it out, was previously a manual operation requiring two machines operating at one time for personnel safety reasons.
The ControlMaster® Line-of-Sight solution has removed the operator from the cabin and allows them to control the machine from up to 200M line of sight. This custom one-off kit was designed, supplied, and installed by both the Perth Customer Service and RCT Custom team, the company’s designated bespoke solutions department.
“This solution removes operators from any potential danger that could arise from them physically being out on a tailings pond and allows them to instead carry out the task from the safety of a light vehicle located nearby,” said RCT’s Account Manager, Phill Dean.
The introduction of this technology has also dramatically changed how the Mud Scroller is transported to various sites.
“Previously amphirolls were twice the size requiring oversize movement permits and weighed about 18 tonnes so moving this piece of machinery required large multi-lift crane operation.” he said.
“Now, the logistics of moving the small unit is easier and only requires a large tile tray and this in itself reduces mobilisation costs substantially.”
As well as deploying the ControlMaster® technology. RCT designed, manufactured, and installed the EarthTrack® custom dashboard.
“This dashboard was designed to display all the integral information in an easy-to-read format. It will let the operator know the pump pressures, engine temps, fuel level and an overall live health report,” he said.
The new and improved mud scroller remote solution was deployed at the beginning of the year in trials and is being used today with great success to value add to their long-term clients.
Global mining supplier Getman enlisted RCT to provide a mobile, Teleremote control solution for an A64HD Water Cannon, bound for its client in Indonesia.
RCT Custom was enlisted for a bespoke solution that would allow the client to control the Water Cannon from a safe distance with all the same functionality as if they were driving it from the cab of the machine. The solution had to be flexible enough to allow the operator to control the machine from various locations on site.
The end-result was the ControlMaster® Portable Teleremote solution, which allows the operator to conveniently set-up operations at a safe distance, where required on site.
“The flexibility this solution provides ensures that the machine can access all areas of the mine site it is needed to carry out the job safely and in a productive manner,” said RCT’s North America’s Regional Manager, Andrew Sells.
RCT Custom designed and manufactured the solution to allow operators to tram the mobile machine and use the Water Cannon boom control via remote control. Operators can see the working area clearly by utilising the cameras on board the machine which relay vision of the machine’s movements to the operator via the Portable Teleremote solution. RCT’s US branch completed the install at Getman’s HQ and our permanent technician based at the end client’s mine will provide ongoing maintenance and support for the solution.
A range of RCT’s solutions from across four of its five sub-brands were used to fit out two Land Cruiser Troop Carriers, transforming them into mobile Automation Centre bound for Metals X’s Nifty Mine site recently.
Retrofitting a troop carrier isn’t a job out of the ordinary for RCT however, this particular request was extensive and made possible through client and RCT Customer Service collaboration.
The retrofit consisted of the installation of RCT’s ControlMaster® Teleremote platform, Muirhead® Engine Protection systems, and AusProTec™ Maxi Vision Camera for reverse vision.
In addition to RCT’s products, its technicians installed additional features as per requested by the client. This included stand-alone air conditioning, Ice Pak and carrier to support the condenser, a custom bull bar, UHF radios and UHF. The team also removed the front passenger chair and supplied and installed an alloy floor plate to allow the operator easy and safe access in and out of the vehicle.
The rear windows were also removed and sheet metal installed to increase durability and safety of the vehicle. Finally, bulkhead was also installed to significantly increase connection points.
The extensive modifications on the troop carriers were significantly different to any other light vehicle RCT had completed previously.
“It was a custom-driven solution as requested by the client and made possible by RCT’s Customer service team,” said RCT’s Account Manager, Phill Dean.
RCT is proud to announce its latest Custom project which will significantly improve operator safety and increase productivity at an underground mine in South East Asia.
The mine site wanted to further safeguard operators by removing all personnel from the truck loading chute chambers which are exposed to extreme environmental hazards such as wet muck rushes.
RCT Custom designed, manufactured and will soon install a bespoke remote control solution that allows operators to control the chutes, used to load trucks, from a safe location.
Operators will be able to control up to 10 chutes from four operator stations located in a central control room, with plans to expand the operation in the future.
The customised chute control solution works in conjunction with RCT’s ControlMaster® Guidance Automation solution installed on the site’s Caterpillar AD60 underground articulated trucks. Guidance ensures the truck autonomously makes its way to the chute chambers.
The new chute control solution eliminates the need to have operators
in the hazardous area completely and therefore directly meets the client’s needs.
Stay tuned for more on this project….
RCT has helped the world’s largest underground copper mine, El Teniente, successfully and safely mine in mud, in what is believed to be a world-first mining method in these conditions.
This impressive feat was facilitated by the company’s specialised department, RCT Custom. The bespoke team helped deliver a state-of-the-art ControlMaster® Automation solution allowing the copper-rich mud to be accessed with minimum risk.
The Codelco-owned site is prone to mud rush caused by ice melting on the Andes range situated on the surface, a hazard that closed the exploration area for months on end. This combined with the company’s plan to expand operations to the seventh and eighth levels made it crucial to find a solution that would allow them to mine mud ore safely.
Codelco issued RCT with the challenge of retrofitting RCT’s ControlMaster® Teleremote and Guidance Automation systems previously installed on a surface dozer, loader and truck at its Andina mine.
RCT had to upgrade this equipment for fitment onto the site’s Sandvik LH517 loaders operating in the El Teniente underground mine. Operators were relocated to a surface control room connected to the loaders over the mine’s communication network.
“It was quite a challenging engineering project which required the combination of proven RCT solutions with a mine’s network – but RCT thrive in these situations,” said RCT’s Senior BDM. Phil Goode.
“Projects like this are the reason we have our specialised division, RCT Custom.”
While the existing solutions would suit all mine conditions and achieve the outcome desired by the client as is, a factory refurbishment and upgrades were essential to ensure the retrofit went to plan.
“This project highlights just how versatile RCT’s Automation solutions are. It was a significant bespoke engineering project that required the existing solutions to be fully factory tested before being installed at the mine and integrated into El Teniente’s existing network.”
Installation and commissioning were undertaken by RCT with its channel partner, Power Train Technologies (PTT). This required the system to integrate into Codelco’s existing Digital WiFi Network, which required the collaboration between the client’s mining, maintenance, engineering and innovation teams.
“The integration of refurbished equipment, installed on working production loaders into the existing mine network posed unique challenges, all of which were overcome by professional collaboration between, Codelco, RCT, and PTT,” said Mr Goode.
El Teniente’s Chief Automation Mine, Rafael Guzmán, explained that the system utilises the standard wireless network, configured and managed with its own resources, which is used in various systems of underground work.
“The important thing for the site was to have a robust and reliable communications system, which in our case translates into one of the largest networks of this type in mining,” added the Department Corporate of Automation’s Senior Engineer, Norma Vargas.
RCT’s Automation solutions ensure the loader travels along the optimum path and at a speed that will deliver consistent cycle times across all drivers, during every shift. As well as tramming faster, the loader will avoid walls and obstacles significantly reducing machine damage and unplanned downtime.
The operators’ working environment vastly improves, as the operators were removed from the cab of the machine and relocated into an Automation Centre on the surface of the mine.
This customised solution was located in an office on site, complete with amenities. In addition, the Guidance Automation technology removes disparity between drivers and the time it takes to complete the checklist during shift change has also decreased which further increases productivity.
Guidance Automation technology will prevent damage to the loaders while allowing them to be driven in third gear – which results in more buckets each shift.
“Productivity and safety can go hand-in-hand. We have a precious treasure waiting to be extracted from the muddy water, and we are now on the right path thanks to RCT’s Automation,” said El Teniente Mine’s Innovation and Development Project Manager, Pablo Gándara.
“Our goal was to use technology to reach this somewhat hazardous reserve, which has a potential of about 2 million tons, with purity of 0.9 that is very important,” said El Teniente Mine’s Innovation Project Manager, Nicolás Montecino.
As well as delivering the technology, operators underwent RCT product training on the new solution to ensure they got the most out of the technology.
“It was great to have spent time with the El Teniente mine operators to deliver hands-on training and guidance to help them take ownership of the new technology,” said Mr Goode.
El Teniente’s Innovation Engineer, Nicolás Montecino, said he was not only amazed with the system but he was impressed with RCT Custom’s level of professionalism.
“The mine will be able to recover reserves that were once abandoned after being deemed too dangerous to access by our operators who would be exposed to mud water pumping through the area,” said Head of Diablo Regimiento, Leonardo Barría.
There is a goal of producing 600 tons per day in a six-month period with plans to implement another loader with RCT’s Guidance Automation to reach 2,500 tons per day.
El Teniente said it will look at replicating this technology to other areas of the mine prone to mud and humidity if the technology performs well.
“This was a significant, innovative engineering project for RCT, and we are proud to have been part of it,” said Mr Goode.
Roy Hill’s multi-billion-dollar iron ore project is now home to the first dynamic multiple Geofence package to have been successfully interfaced to fixed and mobile asset elements within the boundaries of the Coarse Ore Stockpile (COS), and RCT is proud to have played a big part in this momentous achievement.
The Geofence technology was successfully and safely interfaced with two D11T CAT dozers and the radial stacker infrastructure, including the boom which can be maneuvered in multiple directions.
Both dozers were equipped with RCT’s ControlMaster® Teleremote solutions which removed the operator from the machine and relocated them to an operator station, equipped with vision package from the area; allowing them to control all machine functions from an ergonomic, safe environment.
In addition to the five cameras on the dozers, six PTZ cameras were installed at the site on the COS stacker, tertiary crusher infrastructure, and two mobile communications trailers to give operators greater spatial awareness during operation.
The decision to install a virtual perimeter around the dozers stockpile area was to safeguard operators and to ensure the machines can operate in the same area seamlessly without any risk of collision with the fixed stacker infrastructure or the dozers falling into vaults or driving off the stockpile boundary.
The interfacing of all the dynamic elements on the one site was achieved in partnership with SITECH’s Collision Detection technology – Trimble GNSS and RCT Custom – a team dedicated to creating and delivering adaptable, bespoke integrated solutions from the company’s existing technology.
There were a large number of factors that had to be taken into consideration for the Geofence to work effectively.
Multiple workshops and risk assessments were carried out, both independently and most importantly collaboratively to define the Geofence boundaries or virtual perimeters within each element. This included the two dozers, the movement of the stacker boom and the five vaults. The boundaries were also designed to be configurable with the correct level of authorisation in the system, allowing flexibility for the operators.
The SiTrack software was designed to provide the Geofence boundaries, monitor all interactions and provide alerts within the boundaries allowing the RCT system’s semi-autonomous control over the two dozers. This was achieved by using High Precision (HP) GNSS equipment to measure and detect the proximity of the moving assets in the potentially hazardous stockpile to an absolute accuracy of around the +/-25mm range. While the software utilises the accuracies of these solutions, it had to be teamed with a bespoke software solution to provide the operator with the ability to control the dozers, semi-autonomously operating with RCT’s ControlMaster® Teleremote system in order to avoid the possibility of collision between the two dozers and other dynamic elements.
RCT Custom worked with SITECH and Roy Hill to develop and deploy the dynamic Geofence system to interface with the ControlMaster® Teleremote solutions to ensure machine functionality is inhibited by the ControlMaster® system at different levels of detection on the SiTRACK system.
The integration resulted in the creation of a variety of configurable Geofence boundaries within the site to prevent fixed assets and the dozers. Each boundary has different zones to alert the operators of potential danger (green, blue, orange and red).
RCT Custom’s Project Manager David Wright described the project as both challenging and rewarding.
“A number of factors had to be considered throughout the duration of the project. This included integrating Roy Hill’s technical architecture and communications system and designing and creating a number of engineering solutions to meet the requirements,” he said.
The installation, implementation, commissioning and acceptance of the project all involved RCT liaising with numerous departments at Roy Hill including, engineering, operations, mining, maintenance and IT communications teams.
“The process was made easier thanks to everyone’s willingness to work together in a collaborative manner,” said Mr Wright.
With vision being fed from numerous PTZ and dozer cameras, the dozer pitch/roll machine dashboard information and the Trimble tablet display, Roy Hill decided bigger screens were required to cater to the extensive vision available to operators.
As a result, the operator station went from having two, 24-inch screens and a 17-inch Trimble tablet to, two 40-inch curve screens, with a 32-inch display for the Trimble screen. A Trimble tablet was also relocated to the side of the operator chair.
“The bigger screens provide the operators with a better resolution of what they are seeing; giving the dozer operators a more advanced level of information to assist in daily operations,” said Mr Wright.
Carrying out dozer functions via Teleremote control from the operating stations eliminates the risks operators are exposed to at the coarse ore stockpile and processing plant, reduces operator fatigue and as a result increases productivity. In addition, the Teleremote solution allows for multiple views from the dozer, which in turn allows them to be more efficient throughout the duration of their shift as well as minimising machine damage and overall general wear and tear. The downtime associated with shift changes decreases which further aids productivity as there is more time spent in the “driver’s seat.”
In addition to the deployment of the solution, RCT delivered training to ensure the operators maximise the solution’s potential and appropriate site personnel are familiar with how it works. Operators are now trained in Line-of-Sight (which was deployed at the beginning of the project), Teleremote and the Geofence solutions.
A Roy Hill spokesperson said that Teleremote dozers using the Geofence collision avoidance system exemplified what can be achieved through collaboration.
“The Teleremote project had several challenges to be overcome. In particular, the vision package had to be installed within the planned process plant shut intervals – every little step was critical to be rigorously planned for,” the spokesperson said.
“The Geofence system has been customised to suit our requirements at Roy Hill. We established the dynamic boundaries for dozers, fixed stacker boom, cone of throw and COS through several risk assessments with key stakeholder’s engagement, and RCT was very collaborative throughout this process.
“We engaged dozer operators and trainers throughout the development process. Their feedback has been a key to Teleremote dozer’s success.”
“We’ve had very positive feedback from Roy Hill and I’m very proud of what our team was able to achieve,” said Mr Wright.
RCT will continue to work with Roy Hill to further develop and upgrade technology for years to come.
Western Contracting Project Overview (1:42min)
RCT has successfully delivered a custom Teleremote project to the civil contracting sector in the US.
The milestone RCT Custom project was for Western Contracting Corporation’s work at Fort Wingate Depot Activity – a former army munitions facility near Gallup, New Mexico. The project required the excavation and off-site disposal of buried unexploded ordnance.
The Iowa-based construction firm subcontracted with AECOM Technical Services for its multi-year contract with the Army Corps of Engineers. Western Contracting provided the project with remote controlled equipment to mitigate the unacceptable risk of operator injury or death by an unintended explosion during excavation activities. Four Caterpillar machines – two 9630 track loaders and two 336E track excavators – were procured for Teleremote operation.
RCT’s USA Service Manager Thomas Laverty carried out the Teleremote installation, said the project was unique for a few reasons.
“Not only was it RCT’s first project in the civil contracting sector in the US; it was also the first time we have installed the ControlMaster® Teleremote solutions on these particular model machines,” said Mr Laverty.
“As a result, RCT’s specialised Custom department’s unique capabilities were required to design and manufacture bespoke kits to suit the machines.”
“While the hardware and componentry were a fairly standard off-the-shelf-product, the Custom team had to adapt the equipment utilising specially made brackets, wiring harnesses and software.”
As a result, the operators are now able to control the machines from the comfort of a specially built concrete and steel Automation Centre, equipped with three Teleremote stations. Each station consists of an operator chair, a joystick and two large monitors that provide vision from five strategically placed cameras on the each machine; giving operators an extensive view of the working area.
In addition to the standard Teleremote, RCT’s solution included the Multi Machine function – Select. This feature allows each chair to remotely control any of the four machines at any given time, with a simple push of a button.
“The Select technology increases flexibility and productivity on site,” Mr Laverty added.
As well as significantly improving safety, the Teleremote solution has also improved the operators overall working environment.
“The operator is no longer exposed to the elements such as vibration, noise and heat to significantly reduce fatigue and helps to increase productivity,” said Mr Laverty.
Western Contracting’s Superintendent, Tim Goslin said the Teleremote technology has been well received by his operators and is clearly the right solution for the project.
“With no prior remote control experience, my operators embraced the opportunity; quickly adapting to the new technology and the transition to remote control was surprisingly quicker than anticipated. This technology allows us to operate safely in a controlled environment outside of harm’s way,” said Mr Goslin.
“Also, the Select feature has proven to be invaluable. During operations, our production is not sacrificed if a machine needs to go offline because we have a standby machine available at the push of a button.”
The hardware and componentry for this project were all designed and manufactured in Perth, Australia before being dispatched to RCT’s Salt Lake City office, where RCT technicians installed the solutions on new machines at Ziegler Caterpillar in Sioux City, Iowa.
