There’s a new member of the ControlMaster® family and it is automating surface drills.
Classic red in colour, this creation came about thanks to the Polyus project, but it looks to be a permanent member of the family when it was redesigned to be rolled out across all models of surface drills.
Although RCT has remoted surface drills in the past, the decision was made to reinvent the existing drill console.
“The original consoles were very big and took up a lot of space so we jumped at the chance at redesigning it for the Polyus project,” said RCT Custom’s Design Technician Jayden Rickert.
“RCT are constantly innovating and improving its solutions to ensure we are ahead of the curve and this project was no exception.”
Concept
The concept stage is one that involved extensive research and had Jayden reviewing numerous sources for more information.
“The Atlas Copco DML Series drill that the console would be installed on wasn’t available to me here so I had to improvise which was by far the hardest aspect of the project,” he said.
Jayden had to ensure the console would mimic all the functions of the model drill to ensure the progress was a success.
“RCT’s main goal with projects like this is to enable operators to control the machines with the same functionality as if they were sitting in the cab of the machine,” he said.
“There were a lot of factors to be taken into consideration with this project.”
“As technology has advanced, so has the ability to condense our ControlMaster® technology into a smaller console and still have the same functionalities we had previously.”
Once Jayden had drawn up the required specification in a detailed document and he was certain that they were in order, and then the Custom team knew exactly what was needed to carry out this project successfully.
“This included knowing the hardware required to fit out the new drill console, number of joysticks, display, inputs, parts etc.”
Jayden described the surface drill project as somewhat unique for RCT.
Outcome
The redesigned console consists of multiple joysticks and HMI (Human Machine Interface) which can be used over four different modes to perform 70+ functions.
It was an important requirement that the icons met ISO Standards and that they would translate well to into Russian but also have a universal meaning for future projects.
“Everything that we implemented on this console was to serve a specific function; it was important that we covered
for every eventuality, also to ensure that we had catered to every function and requirement that the operator would need.”
To further ensure operators have the same vision, if not a better view of the operating area, Jayden and the team added a full camera system which includes 5 fixed cameras and pan-tilt-zoom camera which are capable of remote directional and zoom control.
Although Jayden was the brainchild behind the project, he recognised the project was a team effort and it wouldn’t have been possible without the assistance of the Custom, Drafting and Marketing departments.
“In particular, RCT’s Technical Document Coordinator Clint Wilmot and his team – his Auto CAD drawings are so precise, which is exactly what I needed in order to make these concepts a reality,” he said.
“RCT’s Graphic Designer Gemma Twidle helped to create the drill ISO icons and designing a user interface for the console to ensure a seamless user experience, which turned out exceptionally well. It was easy to communicate what we wanted and Gemma had some great ideas.”
Of course, RCT’s Custom team were also heavily involved.
“I had an amazing team working with me to achieve this task which included Embedded Software Engineer, Tam Nguyen, Senior Embedded Software Engineer Nick Stanley, Design Technician Michael Godfrey and Apprentice Auto Electrician, Blake Laidler."
The end result was a modernised console that met all the criteria for this particular drill project but also lay down the foundations, to be adapted to various drills for years to come.
Installation
As well as leading the design and manufacture of the console, Jayden literally went the extra mile and flew to Polyus’ site in Russia to ensure the successful deployment of the console once it was installed on the drill. Jayden played an integral role in this project from start to finish and his exemplary diligence and capabilities were noticed. This project was a great example of a team member that went above and beyond to deliver our client the best solution possible.
The end result of this project was that the operator was able to match/improve on manual production times. From a safe, clean control station environment free from rock falls, explosives, constant machine vibration, diesel fumes, and dust and extreme weather conditions.
RCT is proud to announce its latest project with Tasmanian-based Caterpillar OEM, Elphinstone for its client in Indonesia.
This project will be carried out by bespoke department, RCT Custom who were engaged to implement a ControlMaster® Portable Teleremote solution for an Elphinstone-manufactured WR820 Articulated Underground Water Truck.
RCT’s Portable Teleremote solution works by utilising cameras on board the machine to relay vision of its movements to the operator; who can then oversee the machine via remote control.
The machine’s tramming and the articulation of the water cannon mounted on the crane will be controlled by RCT using looms and hydraulics installed and manufactured by Elphinstone to RCT specifications. This wasn’t a straightforward installation, hence why RCT Custom was tasked with the job.
This is the second project where RCT Custom has applied this technology to a water cart for the same clients.
Stay tuned for more on this project…
A coal mine site in America has employed RCT’s Smart Technology in order to adhere to Mine Safety and Health Administration (MSHA) regulations.
The regulations highlighted the need to further safeguard dozer operators by removing them from the cab of the machine that was responsible for pushing residual coal material into a tailings pond.
The site’s mine maintenance supervisor acknowledged that the coal industry can be dangerous business.
“The introduction of MSHA’s regulation would enhance operator safety in the coal industry across the country. Anytime you can take the human factor out of a dangerous situation is a good thing,” he said.
RCT’s ControlMaster® Line-of-Sight (LOS) dozer package answered the client’s direct needs; ensuring the site adhered to the regulation.
However, this wasn’t a standard installation as the system would have to be adapted to fit the site’s electric Caterpillar D7E.
“This model of dozer has virtually no hydraulics and carries upwards of 400 volts of electricity,” said RCT’s USA Service Manager, Thomas Laverty who completed the install.
“This particular model of dozer was unlike anything RCT had fitted previously,” he added.
As a result RCT Custom delivered this project. The system was installed within five days and on the sixth day the dozer was in operation.
Operators were more than impressed with the system which took them from the uncomfortable seat inside the cab of the dozer, to remoting the machine from a safe distance.
One of the operators described sitting inside a dozer for the duration of a shift as an uncomfortable experience.
“I’ve gone from sitting in a piece of equipment that is travelling over uneven rocks and material for up to 10 hours a day to remoting the dozer from a distance and now I can’t feel a thing,” he said.
Not only does the LOS solution create a more comfortable working environment for the operator but it has proven to be a time saver at shift changes.
“Switching operators during a shift change used to be quite time consuming, but now there’s no need to stop the dozer for long during handover,” he added.
“The LOS reduces changeover time significantly as no one physically has to enter the dozer and I can explain what I’ve been doing and where I’m up to, while I continue to operate it.”
Of course, the biggest benefit for the operators on site was that the system not only improved safety but it now met MSHA standards.
“This way I can run the dozer and do the job and be completely away from the dozer and potential danger,” he said.
The mine maintenance supervisor stated “the next generation was going to love it. It’s just going to make the job much safer.”
RCT‘s remote control solution is safeguarding mobile elevated work platform operators after a near fatality at a mine site highlighted the need to reform the process.
The operation of mobile elevated work platforms currently requires two-people; one in the basket and one operating the movements from the ground. RCT’s ControlMaster® MTX1000 pendant remote is mitigating the risk, giving the control to the person in the basket. This enables the person working at a hazardous height to control the lifting, lowering, crowning and tilting functions. Further safeguarding this procedure is the MTX1000’s safety interlock feature.
This popular solution has already been sought after by one mining contractor who required a simple and cost-effective solution to ensure operator safety, that wouldn’t require extensive machine modifications or ongoing service and maintenance.
“The MTX disparity checks all proportional outputs, making it safer than a conventional hardwired solution. If an incident was to occur, our remote control will shut down straight away rather than move the basket back to its original position,” said RCT’s Automation and Control Product Manager, Brendon Cullen.
In addition the solution provides a master control in the operator station cabin for a second operator to be able to resume control if required; further safeguarding operators.
“With ultimate control moved to the operator in the basket, the risk of crushing and pinching incidents is vastly reduced,” he said.
The MTX1000 is the latest addition to the ControlMaster® radio remote control range. It is designed with the same operating platform as RCT’s leading ATX2200, but conveniently packaged into an even lighter remote control. The remote control includes a graphical display, proportional joysticks, dead-man and control buttons. It can be operated continuously for more than 16 hours before it requires recharging.
The introduction of RCT’s ControlMaster® Teleremote and Guidance systems has seen productivity and safety increase at a mine site in Egypt.
“The company’s main aim was to extract as much metal from the large porphyry body while eliminating damage to the site’s mining equipment in the process,” said RCT’s African Business Development Manager, Mike Thomas.
Two of the site’s Caterpillar R2900 loaders were equipped with RCT’s Smart Technology. The Teleremote solution has removed the operator from the cab of the loader, allowing them to control the machine from a safe location. At this particular site, the Automation Centre is on a skid, positioned in the back of a light vehicle, allowing for a mobile operation. Guidance has automated the loaders ensuring they avoid all walls and obstacles while tramming. Paired together, the two systems are designed to not only ensure operator safety, but significantly increase productivity by allowing machines to reach greater speeds and eliminating unscheduled downtime associated with machine collisions and shift changes.
In addition to installing the systems, RCT delivered training to operators and maintenance staff which took place both on site and at RCT’s Perth office.
“The specialised skills training has empowered staff with the knowledge, and know-how to maintain and troubleshoot the solutions installed,” added Mr Thomas.
“Training ensures the site can be self-sufficient when it comes to our solutions which in the long term reduces downtime as maintenance can be undertaken on site, there’s no need for it to be carried out overseas,” he said.
The ability for operators to control the loader on Teleremote and Guidance solutions has increased productivity and eliminated machine damage at the site – directly meeting the client’s requirements.
