Efficiency and productivity have increased significantly at a Western Australian Gold and Copper mine thanks to the implementation of RCT’s Digital, Autonomous technology across its mobile mining fleet.
The site was no stranger to RCT’s state-of-the-art autonomous solution, having benefitted from our analogue technology for many years before the latest upgrade.
The decision to transform operations was made to future proof themselves with RCT’s latest digital solution.
The project involved transitioning a mixed machine fleet consisting of three existing Sandvik 514 loaders and two 1700 CAT loaders. The technology upgrade utilises RCT’s Connect - the full-scale digital communications solution that is designed to meet the demands of autonomous machines in real-time for both existing and future fleet needs.
“RCT’s innovative technology ensures all remote loaders on site can operate autonomously now and well into the future,” said RCT Account Manager, Scott Phillips.
As well as improved operating efficiencies, the upgrade in technology has enabled operators to remote from the mine’s surface.
While the technology implementation is still relatively new, a spokesperson from the mine said there have been a myriad of benefits so far.
“Managing the fleet from the surface or "hot seating" has boosted production. Capturing the lost time from shift change and continued operations over firing has tangibly improved our remote productivity,” said the mine site’s spokesperson.
“In addition to this, the digital system is proving to be a very reliable and easy to manage solution,” they added.
The changes have been well-received by our operators with improved picture quality following the digital upgrade.
RCT’s digital solution also paves the way for multiple machine control which was also a deciding factor for the upgrade.
“This particular mine site is known for its long production drives so having one operator operate multiple machines simultaneously will allow the operation to dramatically increase productivity – it’s the perfect scenario,” said Mr Phillips.
“This progressive mine site is now set up to introduce RCT’s latest features as they are released,” he added.
Capcoal Mine in Central Queensland is leading the way in safety with the implementation of RCT’s cutting-edge technology.
Located in the Bowen Basin in Central Queensland, it is a combined open pit and underground operation that produces coal.
This industry-leading project has seen the site implement RCT’s Teleremote technology on a Komatsu D475 dozer, allowing operators to relocate from the cab of the machine to the safety of a Remote Operations Centre (ROC) situated nearby.
RCT’s technology was chosen as it is a proven, agnostic solution that will safeguard dozer operators working in hazardous areas.
“Feed valves on stockpiles are a known industry hazard,” said Brisbane’s Project Manager, Jared Collard.
“The edge of the live feed cone of coal stockpiles are known for being unstable environments. Remote operation of dozers removes the coal mine worker from any exposure to this hazard,” he added.
For this project, the standard tele-remote control configuration included a few additional customisations to meet the client’s specific needs.
This included the implementation of geofencing around the dozer’s operating zone, ensuring it remained in the boundaries of the dedicated working area.
Self-cleaning cameras was also an additional upgrade, giving operators improved visualisation on the coal stockpile so the operators could spot any potential hazards from the remote control room.
RCT was asked to provide custom interfaces to the CAS Warning System and Emergency stop button to allow operators to shut down the feeder from the ROC if necessary.
An existing, portable building was repurposed to house the RCT ROC site for sustainability and cost-saving reasons.
System training was provided to the on-site operators and the maintenance team to ensure competency and site self-sufficiency.
Mr Collard said the project was a great example of a mine being proactive with the safety of its operators front of mind.
The technology has been operational on site since January and the feedback so far has been positive with plans to implement the technology on more dozers on other sites in the future, said RCT Account Manager John Capehart.
“The site itself has set themselves their own goals to meet and they are reaching them with operators taking up the technology well.”
“This solution really does eliminate exposure to a well-known hazard that the coal industry has been struggling to find a solution to,” he added.
“It was a major step to eliminate risk."
The commute to work has just got easier for Gold Fields’ Granny Smith operators after securing RCT’s cutting-edge Remote Operations Centre (ROC) to manage some of its mobile equipment fleet from its Perth head office – an astounding 740km away from site.
This major advancement will revolutionise the way they do mining by allowing operators to control or supervise semi-autonomous fleet activities in real-time from the comfort and convenience of a central office location.
The digital ROC’s deployment represents the next major development in Gold Field’s autonomous mining operations and enables their personnel to work effectively from a major city which makes the job more accessible to a wide range of workers and reduces the company’s carbon footprint.
The project is made possible by RCT’s ControlMaster® digital automation solution which is already utilised by Gold Fields to manage its underground loader fleet from the mine’s surface.
However, the digital ROC technology means Gold Fields can offer significantly more flexible working arrangements and accommodate work/life balance requirements among their workforce.
Initial testing proved the ROC can instantaneously manage multiple underground loaders at one time operating in different locations within the underground mining complex.
The digital ROC technology means Gold Fields’ operators will be able to access ControlMaster®’s latest features as they are released which will help enhance semi-autonomous fleet operations onsite.
RCT and Gold Fields’ engineers worked together to implement the ROC and link it with the mine site through Gold Fields’ secure, dedicated network.
“The Perth Remote Operations Centre (ROC) started as a proof-of-concept trial following the digital upgrades project in December 2021. The ROC was aimed at showcasing Gold Fields Australia’s network capability and RCT’s digital operating technology but has now opened the doors to exploring future avenues in how we work at our underground operations,” said Granny Smith’s Mine Manager Michael Place.
RCT Account Manager Scott Phillips said the ControlMaster® ROC incorporates RCT’s latest digital technology which will fully empower Gold Fields to fulfil its mining fleet needs going forward.
“We are pleased to help Gold Fields take this next major step in their autonomous mining journey and implement technology that brings about major operational efficiencies,” said Mr Phillips.
“This project is only the beginning, and we look forward to working closely with Gold Fields to advance their mining operations in the future,” said Mr Phillips.
RCT’s latest partnership with Gold Fields in Australia has seen the transformation of its Granny Smith mine and machine fleet into a state-of-the-art, digitally connected powerhouse, in a project which embodies the mining company’s key value of innovation, designed to increase productivity.
Gold Fields’ Granny Smith mine is no stranger to RCT, having been one of their technology partners for more than 20 years.
This latest project has seen the Eastern Goldfields underground gold mine become one of the most innovative, digitally connected mines in the world. The project saw RCT’s Kalgoorlie-based team of innovative technicians upgrade the site’s six existing Cat loaders from analogue to digital. This required the Kalgoorlie branch team to design and build specialised mounts and overhaul the site’s existing cabins. In addition, a total of 11 Area Access Controls (AAC) were also converted from analogue to digital to facilitate the upgrade.
“We recognise that they made a significant investment into the original technology, and we wanted to find the most cost-effective and sustainable solution available,” said RCT’s Kalgoorlie Branch Manager, Rick Radcliffe.
The team converted three of the site’s existing analogue TeleCabins and transformed them into digital ControlMaster® Automation Centres for underground use and two surface Automation Centres to digital, bringing them into the future.
The site chose to use RCT’s own full-scale digital communications solution – RCT Connect to meet the demands of autonomous machines across the mine site. The technology will cater to Granny Smith’s current and future machines.
The Kalgoorlie branch finished the upgrades in December last year, and although the technology has only been in place for a few months, the site has experienced amazing results from day one.
“The ability for the operators to mine from the surface with a pristine picture/video thanks to the digital network, has meant they have been able to increase the number of buckets per shift, while adding to the comfort of the operators,” said Granny Smith Mine Manager Michael Place.
“Implementing the new digital infrastructure RCT Connect has significantly improved both the availability and reliability of Granny Smith’s semi-autonomous remote production loaders and stoping fronts to date,” said Mr Place.
The upgrade saw the popular analogue technology that utilises the Yagi antenna replaced with RCT Connect.
“While the Yagi’s have been a tried and tested technology for many years, our digital RCT Connect Access Points has taken the Control Master underground communications system to another level. The system is now more reliable and provides a clearer picture and improved operator visibility,” Mr Radcliffe said.
“The feedback we have received from site is that the operators love the new technology and they wished they implemented it ages ago,” he said.
As well as experiencing the significant benefits of digital technology today, Granny Smith is futureproofing themselves, allowing them to make small, incremental changes as and when they are ready.
RCT Connect is a plug and play system, making it easy to install and maintain. The technology has produced a remarkably clearer picture which has greatly assisted Granny Smith personnel to continue operating their machines safely, in high-risk locations.
“Another added benefit to moving to digital is that RCT can now remotely support our clients to a higher level and are able to monitor and complete repairs in a short timeframe, as it eliminates the need for a technician to travel to site to troubleshoot in many cases,” Mr Radcliffe said.
Thanks to the deployment of RCT's market-leading digital automation technology, a prominent gold mine in Victoria has been able to achieve major productivity improvements on site.
This transformation has resulted in an upgrade to the site’s mobile equipment fleet capabilities, enabling fully autonomous production loader cycles as well as providing a pathway for future operational improvements.
RCT’s latest ControlMaster® technology empowers site personnel to control the entire fleet from Automation Centres located on the mine’s surface and allows for rapid cross-shift changes.
With RCT’s digital automation offer, machine operators can supervise seven Cat R2900 underground production loaders from the surface, which significantly improves operations.
The ControlMaster® Multiple Machine Control (MMC) feature means an operator can switch between production loaders during auto tramming and supervise specific elements in the load-haul-dump cycle.
RCT Account Manager Wayne Carrington said the team is pleased with the outcomes of this significant package of work on site.
“The project represents the next chapter in a longstanding relationship between the companies with the gold mine having used ControlMaster® across fleet operations for many years now,” he said.
“Our new digital offer will set the site on a pathway to advancing their entire operations and realising strong and consistent productivity gains over the life of the mine.”
“With operators now relocated to the mine’s surface, the technology is demonstrating a new standard of safety for mining personnel.”
“Our technical team have supported the site throughout this transition and we will be here to support site personnel with any future needs as well.”
In what is believed to be a word-first, RCT together with equipment manufacturer Rham Equipment has deployed the first fully autonomous battery-electric Rham loader into the African mining sector.
This impressive technological feat saw RCT work with Rham to specifically engineer the automated loader to effortlessly work in height-restricted drives in a South African platinum mining operation.
RCT’s market-leading ControlMaster® automation technology was seamlessly integrated with the Rham ultra-low profile (ULP) 25HD battery-electric loader with the package installed at Rham’s factory, prior to the loader’s deployment to the site.
This project perfectly showcases ControlMaster® as a proven interoperable automation platform that can be integrated across any mobile equipment make, type or model.
With the technology established onsite, the loader operators are able to manage Load Haul Dump (LHD) operations from the safety of a ControlMaster® Automation Centre on the mine’s surface.
In addition to this RCT interfaced with the Rham dash display and replicated it on the Automation Centre, to provide the operator with important machine health information.
The project also includes the implementation of RCT Connect, a specialised underground communications network designed to enhance autonomous fleet operations.
Rham Managing Director Kevin Reynders commented: “This joint venture project has run effortlessly creating safer machines for our miners.”
“Rham Equipment, a Level 3 B-BBEE South African, (Pty) Limited Company, has been producing specialised mining equipment since 1980. The company has been providing the South African mining industry with quality products and top-of-the-range services for the past four decades.”
“The product range includes underground transporters, excavators, load haul dumpers, dump trucks, roof bolters and conveyor drives, to name but a few. To date, Rham Equipment has supplied over 2000 units to some of the most prominent South African platinum, gold- and coal mines who we count amongst our customer portfolios,” Mr Reynders said.
“The South African mining industry is well developed and prides itself on its technological development, productivity, and safety, and in line with this philosophy the company has built an enviable reputation as the supplier of choice, producing products that are durable, safe and cost-effective.
By keeping all our manufacturing in-house allows RHAM to control the quality of all our workmanship giving customers that all important peace of mind.”
“Now in its fourth decade of operation, the company continues to develop new products to best suit the needs of our customers.”
RCT Business Development Manager for Africa Mike Thomas said the project represented an important milestone on many fronts.
“We are very pleased to work with Rham Equipment to deliver this project and we regard them as a highly competent and organised OEM with a skilled workforce who can deliver high-quality technology.”
“ControlMaster® has an extensive history integrating with diesel powered equipment, but this project proves that the technology can interface seamlessly with battery-electric mobile machines,” he said.
“Battery-electric equipment fleets can significantly reduce a mining operation’s carbon footprint while eliminating the costs associated with diesel consumption, so we expect to see a greater uptake of the technology around the world."
“The technology will relocate the machine operators to a safe working area on the mine’s surface while enabling optimised autonomous machine operations.”
“A cornerstone of ControlMaster® is its ability to integrate with any machine and this project proves that our technology can interface with Rham’s loader, which is an entirely new machine for us.”
RCT’s technical team will empower mine site personnel with comprehensive training and technical support to operate and maintain the equipment going forward.
The project demonstrates RCT’s automation technology can successfully integrate with battery-electric mining equipment and is an important step toward delivering an autonomous, carbon-friendly mining fleet of the future.
RCT was selected as the preferred automation partner by Kalgoorlie-based company Westauz Mining.
Westauz Mining is an underground mining specialist that will equip two of its Komatsu WX07 loaders, with RCT’s world-leading Digital Automation solution.
These loaders will be deployed at the Norseman Project, a gold mine site located in the Goldfields – Esperance region of Western Australia.
RCT is thrilled to collaborate with Westauz Mining to maximise remote production with the deployment RCT’s latest innovative digital technology. Machine installations are currently in progress, and it won’t be long until they are operating on site.
Watch this space for updates on the project!
RCT’s leading Fleet Management system, SmarTrack® Global has transformed operations at JDK Management’s storage facilities in Victoria.
JDK Management is one of the largest storage warehouses in Shepparton, with more than 35,000 pallet spaces of storage in varying temperatures from -18c to +8c. The company prides itself on providing the best facilities and the most accurate and efficient customer service.
Therefore, their decision through their materials handling partner, L&P Mackin forklifts to install SmarTrack® Global at the facility was an easy one. In this instance, the system was combined with RCT’s two-camera DVR recorder to further safeguard operations.
JDK Management’s General Manager, Paul Kalafatis, said the combination of the solutions has been very successful in enabling them to identify the causes for incidents relating to their material handling equipment.
“As a result, management has been able to identify environmental risks, initiate additional training, and generally heighten safety awareness within the organisation,” he said.
SmarTrack® Global helps to optimise materials handling operations and increase bottom-line profits. The fleet management system delivers relevant, customised information in real-time to employees, provides pre and post-start checklists, event reporting, access control and monitors the weight and speed of industrial equipment.
JDK Management noted the compliance aspects of SmarTrack® Global including the checklist reporting and access control, were big factors in its decision to purchase the solution.
The ability to understand when and what weight their forklifts were carrying was also of significant interest from a safety and utilisation perspective.
RCT’s high level of support was also another factor for JDK Management in implementing the system. The high level of support RCT provides to all its clients across its extensive solution range was also a stand-out.
“It is reassuring to know that this product is locally supported through L & P Mackin,” said.
Due to its willingness to adopt new technology over the years, to ensure a safer and more effective workplace, JDK Management has maintained its forefront of the industry for the last 25+ years. Its adoption of SmarTrack® is a great example of this.
RCT’s latest automation technology has been successfully deployed at the Sunrise Dam Gold Mine in Western Australia. Sunrise Dam is wholly owned by AngloGold Ashanti Australia Ltd, with underground mining operations contracted to Barminco.
Barminco’s Sandvik and CAT loader fleets, which were already operating with ControlMaster® Guidance Automation, were fitted with enhancements including Multiple Machine Selection (MMS) and Multiple Machine Control (MMC). This cutting-edge technology gives an operator control of numerous mobile machines from the one station. This project was a first for all parties involved who collaborated to achieve successful delivery.
“For example, this allows one operator to tram one machine, while digging with another to make the process more efficient,” said RCT’s Automation and Control Product Manager, Brendon Cullen.
“Before the introduction of these features, one operator would only be able to concentrate on the activity of one mobile machine. The new features allow them to attend to multiple machines safely and effectively thanks to Guidance Automation which will keep the machine on the correct path, to avoid machine damage and to ensure faster tramming.”
These latest automation features are made possible by digitising the mine’s work area with RCT’s Bridge, the company’s own communication network; essential in supporting the latest autonomous features.
“RCT Bridge is the stepping stone solution to bring a mine site to full digitisation and is simply integrated into the site’s existing system,” said Cullen.
In addition to this, RCT’s Area Access Control (AAC) units have also been deployed. This relatively new system acts as an extension of the Automation Control Centre and interfaces between the work areas and machines.
“These lightweight, cost effective and portable solutions are
the ideal alternative to installing a cabin on site,” said Cullen.
Operators will not only have all these innovative features at their fingertips, but they will also be utilising them from the comfort of an Automation Control Centre on the surface of the mine which has been upgraded with operator ergonomics in mind.
“The control centre was overhauled to ensure improved functionality with a new operating system which includes the MMC and MMS features to make it more comfortable for operators.”
These additions are designed to help increase the mine’s overall efficiency and to increase productivity.
”This project is a great example of RCT’s interoperability capabilities; highlighting the company’s abilities to integrate with different brands of machines and a site’s information system,” said Cullen.
The implementation of RCT’s state-of-the-art features is part of Sunrise Dam’s technology transformation.
RCT’s Smart Technology solutions are helping to improve safety at Newcrest’s Lihir open cut mine in Papua New Guinea.
The company’s ControlMaster® Teleremote solutions were installed on two CAT 6050 (Terex RH200) hydraulic shovels and two CAT D11T dozers. While RCT’s dealings with dozers are extensive, it is believed to be the first time a company has remote controlled a CAT 6050 (Terex RH200) on Teleremote. The solution removes the operator from the cab of the machine and relocates them to an air-conditioned cabin located outside of the open pit operations, enabling them to carry out work away from the mine face.
Lihir is not only one of the largest gold deposits in the world; it is also located at Luise Caldera: an extinct volcanic crater that is geothermally active. Therefore Newcrest selected RCT’s technology to safeguard operators during the mining process.
In this instance, Newcrest has installed a Control Centre, designed and manufactured by RCT’s Custom department. The station consists of two operator chairs, one equipped with shovel controls and the other with dozer controls to ensure that the machines can be operated simultaneously. Providing operators with a comfortable environment to work in also reduces fatigue and increases productivity. They are still armed with all the functionality and vision they would have if they were actually in the driver’s seat.
“RCT’s level of support and response to our needs during the installation phase, and then afterwards, has been impressive.
This was a pioneering project with many challenges, and this technology has successfully delivered improved levels of safety for our employees,” said Newcrest’s Group Manager Mining Technology, Tony Sprague.
This project is just the start of an overarching mining technology strategy for Newcrest Lihir, and RCT is excited to be part of it.
“It wasn’t a standard installation by any means. It’s a great example of RCT’s extensive capabilities and flexibility when it comes to projects,” said RCT’s Account Manager, Wayne Carrington.
