{"id":7279,"date":"2024-05-07T18:24:10","date_gmt":"2024-05-07T18:24:10","guid":{"rendered":"https:\/\/northamericanmining.com\/?p=7279"},"modified":"2024-05-15T16:49:02","modified_gmt":"2024-05-15T16:49:02","slug":"state-of-the-autonomous-haul","status":"publish","type":"post","link":"https:\/\/northamericanmining.com\/index.php\/2024\/05\/07\/state-of-the-autonomous-haul\/","title":{"rendered":"State of the (autonomous) haul"},"content":{"rendered":"\n

North American Mining<\/em> investigates the world of mine haulage automation, asking where we are and where we are heading next.<\/strong><\/p>\n\n\n\n

By Jonathan Rowland<\/em><\/p>\n\n\n

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In the near future, excavators and dump trucks will exchange information with other equipment and machinery to realize autonomous operation and improve safety and productivity at mining sites. Photo: HCMA<\/em><\/figcaption><\/figure>\n\n\n

The mining industry has \u201cincreasingly adopted automated haulage solutions as the technology is beginning to be more commercialized,\u201d Masayoshi Ota, vice president of Mining Sales at Hitachi Construction Machinery Americas (HCMA) told North American Mining<\/em>. \u201cNumerous autonomous fleets have been successfully implemented in large copper, iron ore, and oil sands mines; however, many of these fleets are still in the testing phase.\u201d<\/p>\n\n\n\n

As mines operate 24\/7, 365 days a year, it is \u201cunderstood that an autonomous haulage system can improve both productivity and safety,\u201d Ota continued. \u201cThis is particularly true where there is increased risk due to the terrain and\/or a competitive labor market. In these situations, the automated haulage solution is often a better alternative.\u201d<\/p>\n\n\n\n

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\u201cAutonomous haulage systems are rapidly gaining traction, due to their potential to enhance consistency, productivity, and safety,\u201d said Sam Wood, head of product management for AI and Autonomous Vehicles, at Navtech Radar. In short: they are helping keep mining companies stay competitive in a market made increasingly challenging by declining ore grades, more complex geology, and growing demand for key metals and minerals \u2013 not to mention social and environmental sustainability issues.<\/p>\n<\/blockquote>\n\n\n\n

There are also \u201cpromising signs of wider adoption outside traditional mining hubs, such as Canada and Australia,\u201d continued Wood. \u201cAutomation technologies are also expanding beyond large haul trucks to smaller loaders and water trucks, demonstrating a widening scope for adoption and integration. Additionally, the automation of smaller loaders in confined shows growing confidence in these systems.\u201d<\/p>\n\n\n\n

As an example of this: Caterpillar\u2019s autonomous truck fleet currently spans the 190- to 370-tonne (210- to 410-ton) class sizes, but it will soon be expanding to the smaller 139-tonne (153-ton) class size as well, the company told NAM.<\/p>\n\n\n\n

In 2022, the Irving, Texas-based OEM also announced a collaboration with Luck Stone<\/a> to deploy Command for hauling at the Bull Run Plant in Chantilly, Va. This is Caterpillar\u2019s first autonomous deployment \u2013 technology, processes, and people \u2013 in the aggregates industry and will expand the autonomous truck fleet to include the 90-tonne class (100-ton class) Cat 777.<\/p>\n\n\n\n

It is not just the size of the equipment that is shrinking; we are starting to see far smaller fleets automated than previously, according to Sean McGinnis, vice president and general manager of Technology and Global Sales Support at Caterpillar Inc.<\/p>\n\n\n\n

\u201cIt is no longer only for mine sites with fleet sizes of more than 70 trucks, which was initially the case of the technology\u2019s early adopters, when we deployed our first autonomous trucks more than 10 years ago. Today, we are seeing viability for autonomy at smaller mines with a fleet of less than 15 trucks.\u201d<\/p>\n\n\n

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Autonomous haulage is the future of mining. But it\u2019s a future that is already here with autonomous trucks and other equipment hard at work at mine sites around the world. Image: Caterpillar.<\/em><\/figcaption><\/figure>\n\n\n

Upcoming challenges<\/strong>
<\/strong>The implementation of autonomous haulage solutions is \u201cnot only about the technology,\u201d said McGinnis.<\/p>\n\n\n\n

\u201cOne of the biggest challenges with autonomy is getting the processes and people ready for autonomous mining. The foundation of Caterpillar\u2019s long track record of success in autonomy stems from bringing the three critical components together: deeply integrated technology, correct processes for the specific mining operation and change management with the people.\u201d<\/p>\n\n\n\n

An automated mine is \u201cmore like a factory,\u201d McGinnis continued. \u201cWhile it still has all the variables of a mine site, the mine now knows how to make the processes leaner, how to get more productivity, how to link their processing plant and the autonomous trucks to build a system, like a factory. Having a consistent process is one of the biggest advantages of autonomous haulage.\u201d<\/p>\n\n\n\n

Other barriers include deployment costs, complexity, and the speed of workforce upskilling, added Navtech Radar\u2019s Wood, as well as an overreliance on Global Navigation Satellite Systems (GNNS), which Wood described as an \u201cimpending challenge.\u201d<\/p>\n\n\n\n

\u201cFactors like increased solar activity, proliferation of low-cost jammers, and spoofing equipment pose risks to GNSS reliability,” Wood continued. \u201cAdditionally, the cost associated with deploying corrections services \u2013 which are required for position accuracy for control across vast mining sites \u2013 adds complexity. At the same time, mining environments differ significantly from regular roads, requiring robust sensor systems tailored for feature-sparse, dusty conditions with oversized vehicles. The quality of automation decision-making hinges largely on the accuracy and reliability of sensor data.\u201d<\/p>\n\n\n\n

To address these challenges, \u201congoing innovation in radar navigation technology presents a promising solution by reducing dependence on GNSS and enhancing perception capabilities in adverse mining conditions,\u201d added Wood.<\/p>\n\n\n\n

\u201cInteractions between GNSS and radar-based systems has the potential to create a dynamic scene that is far more reflective of the mining environment scene. Communication between systems would have challenges but obvious benefits and is essential for the safe integration of robotics into mining operations.\u201d<\/p>\n\n\n\n

Additionally, \u201cthe evolution of intelligent sensors towards adaptive machine learning-driven systems offers exciting opportunities for automation,\u201d concluded Wood.<\/p>\n\n\n\n

\u201cBy leveraging machine learning advancements, sensors can dynamically learn and adapt, optimizing mining processes and enhancing operational efficiency.\u201d<\/p>\n\n\n

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Successful autonomous solutions bring together technology, the right processes for the mine site, and strong change management. Image: Caterpillar.<\/em><\/figcaption><\/figure>\n\n\n

Let\u2019s talk interoperability<\/strong>
Interoperability is another challenge, as Hitachi\u2019s Ota explained. \u201cMines have already committed resources to existing trucks and infrastructure at the mine site, most often from a mix of OEMs. This makes interoperability a requirement to maximize their return on investment.\u201d<\/p>\n\n\n\n

Addressing this need, several OEMs and mining companies \u2013 including HCMA \u2013 are involved in the implementation of a new ISO standard (ISO 23725) aimed at progressing autonomous system and fleet management system interoperability.<\/p>\n\n\n\n

According to the draft standard, the goal is to \u201cdefine a reproducible integration of an autonomous haulage system and a fleet management system to avoid customized implementations at every site [allowing] a supplier with a narrow product coverage but highly valuable core mining competencies to participate and deliver open-autonomy components in the overall autonomy technology stack.\u201d<\/p>\n\n\n\n

\u201cWe are championing open standards, including implementing ISO 23755,\u201d continued Ota. \u201cThis standard decouples fleet control from OEM systems and enables customers to use existing haul trucks, fleet management systems, hardware, network, and other infrastructure already in place. The open systems platform provides the necessary fleet management system, spotting, mapping, traffic management, situational awareness, and controls to enable autonomous operation of both traditional ultra-class trucks and smaller electrified trucks.\u201d<\/p>\n\n\n\n

As an example: Wenco International Mining Systems, a HCMA group company, provides \u201copen platform fleet management systems necessary for spotting, mapping, traffic management, situational awareness, and control, to enable the autonomous operation of both ultra-class trucks and smaller electrified trucks, regardless of make, and is scalable up to 100 vehicles,\u201d concluded Ota.<\/p>\n\n\n

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A Caterpillar autonomous truck is loaded by a 7495 electric rope shovel. Image: Caterpillar.<\/em><\/figcaption><\/figure>\n\n\n

Future-proof autonomation?<\/strong>
If the last few years are anything to go by, automation solutions have the potential to advance quickly. How can mining companies ensure the decisions they are making now future proof their mine sites against new developments? Interoperability surely has a role to play here. But so too does communication between mines and technology providers.<\/p>\n\n\n\n

\u201cCaterpillar has learned the importance of being heavily engaged on site,\u201d said McGinnis. \u201cWe have truck and mining engineers who know how to optimize autonomy and are available to work with customers on site. Onsite personnel give us quick feedback about how the product is performing and what software changes are necessary. We believe having our people on site is critical.\u201d<\/p>\n\n\n\n

McGinnis continued: \u201cWe deployed our first autonomous trucks at customer mine sites more than 10 years ago. Our engineers keep in close contact with the mining customers and continually upgrade the autonomous haul product. The software looks quite different from the original version developed more than 10 years ago.\u201d<\/p>\n\n\n\n

The theme of cooperation between mine and technology supplier was also taken up by Navtech\u2019s Wood. \u201cBy developing a collaborative relationship with suppliers, mining companies can leverage technologies that adapt to evolving needs. Key considerations when selecting technology partners include their commitment to innovation, ability to customize solutions, focus on knowledge transfer, and long-term support beyond mere transactions.\u201d<\/p>\n\n\n\n

Investment in such strategic partnerships \u201cenables continuous improvement and adaptation to new technological advancements, ultimately enhancing mine site efficiency and safety,\u201d Wood concluded.<\/p>\n\n\n\n

\u201cIn addition, an ability for end users to respond and adapt quickly to changing needs without being bound to a supplier\u2019s methodology is a powerful way forward within those partnerships.\u201d<\/p>\n\n\n

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The mining industry in increasingly adopting mine haulage automation solutions to help solve some of the industry\u2019s most pressing challenges. Image: HCMA.<\/em><\/figcaption><\/figure>\n\n\n

Autonomy in the future of mining<\/strong>
Autonomous haulage solutions are also likely to have a key role to play in assisting mining companies to navigate other industry trends, such as electrification. \u201cDue to the complexities of managing a battery-electric haul fleet, we believe systems, such as MineStar Command for hauling, will be essential to optimize the performance and efficiencies during operation,\u201d said Caterpillar\u2019s McGinnis.<\/p>\n\n\n\n

Such systems \u201cwill likely need to help monitor and orchestrate the complex balance of onboard energy, available charging assets, and production targets to achieve the lowest operating costs,\u201d McGinnis added.<\/p>\n\n\n\n

Haulage is also only one component of a fully autonomous operation at mine sites. Mine automation will thus \u201cextend beyond haulage to encompass the entire operation,\u201d said HCMA\u2019s Ota. For example: HCMA is currently developing a \u201cwide range of technologies\u201d to automate ultra-large excavators.<\/p>\n\n\n\n

\u201cThe sharing of data is a critical piece of the automation puzzle here,\u201d continued Ota.<\/p>\n\n\n\n

\u201cIn the near future, ultra-large hydraulic excavators and dump trucks will exchange information with other equipment and machinery to realize autonomous operation and improve safety and productivity at mining sites, while ushering in the digital mine site future. The ultimate challenge is to harness Level 5 autonomy. This will allow customers to capture the full potential return on investment through reduced need for human intervention.\u201d<\/p>\n\n\n\n

\u201cMine site automation will play a critical role in the future of surface mining, but it is already making significant impacts, and not just with autonomous haulage,\u201d concluded McGinnis. \u201cAutonomous machines are hard at work around the globe every day: autonomous drilling, loading, dozing and hauling with the autonomous sites of tomorrow already underway.\u201d<\/p>\n\n\n\n

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<\/p>\n","protected":false},"excerpt":{"rendered":"

North American Mining investigates the world of mine haulage automation, asking where we are and where we are heading next. By Jonathan Rowland The mining industry has \u201cincreasingly adopted automated haulage solutions as the technology is beginning to be more commercialized,\u201d Masayoshi Ota, vice president of Mining Sales at Hitachi Construction Machinery Americas (HCMA) told North American Mining. \u201cNumerous autonomous…<\/p>\n","protected":false},"author":8,"featured_media":7280,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"om_disable_all_campaigns":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"_themeisle_gutenberg_block_has_review":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_feature_clip_id":0,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_publicize_message":"","jetpack_publicize_feature_enabled":true,"jetpack_social_post_already_shared":false,"jetpack_social_options":{"image_generator_settings":{"template":"highway","default_image_id":0,"font":"","enabled":false},"version":2},"jetpack_post_was_ever_published":false},"categories":[4],"tags":[769,716,2088,1204,40,1081,2885],"coauthors":[1635],"class_list":["post-7279","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-features","tag-aggregates-industry","tag-autonomous-haulage","tag-autonomous-haulage-system","tag-autonomous-trucks","tag-caterpillar","tag-hitachi-construction-machinery-americas","tag-luck-stone"],"aioseo_notices":[],"aioseo_head":"\n\t\t\n\t\n\t\n\t\n\t\n\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t