{"id":9811,"date":"2025-03-21T20:00:43","date_gmt":"2025-03-21T20:00:43","guid":{"rendered":"https:\/\/northamericanmining.com\/?p=9811"},"modified":"2025-03-21T20:14:20","modified_gmt":"2025-03-21T20:14:20","slug":"issues-in-collision-avoidance","status":"publish","type":"post","link":"https:\/\/northamericanmining.com\/index.php\/2025\/03\/21\/issues-in-collision-avoidance\/","title":{"rendered":"Issues in collision avoidance"},"content":{"rendered":"
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Mine safety is a journey, with each step building on and integrating with the previous steps. Implementing a Level-9 vehicle intervention system requires first adopting Levels 1-8. Photo: Wabtec<\/em><\/figcaption><\/figure>\n\n\n

North American Mining discusses collision avoidance in surface load and haul operations with experts from Hexagon, Matrix Design Group, and Wabtec.<\/em><\/strong><\/p>\n\n\n\n

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

Load-and-haul operations present \u201csignificant challenges\u201d for collision avoidance, as Mitch Tanzer, Wabtec Digital Mine\u2019s global commercial director, told North American Mining<\/em>. This is due to a mine\u2019s \u201ccomplex and dynamic nature\u201d with a high volume of vehicle interactions, particularly in dump zones and haul roads, where heavy equipment \u2013 haul trucks, wheel dozers, and shovels \u2013 operate in proximity.<\/p>\n\n\n\n

\u201cThese vehicle interactions increase the collision risk, especially when environmental factors like dust, rain, or fog compromise visibility. Changing road conditions, varying vehicle speeds, third-party contractors, and the presence of personnel on foot further add to the dynamic nature of mining operations and complicate collision avoidance efforts.\u201d<\/p>\n\n\n\n

These risks are compounded \u201cwhen factoring in human error,\u201d noted Josh Savit, principal advisor, Mining, Hexagon. \u201cOperators must maintain constant awareness of their surroundings, which can be challenging during long, monotonous shifts. Fatigue, distraction, and miscommunication can all contribute to collisions.\u201d<\/p>\n\n\n\n

Human factors can also prevent the effective implementation of collision avoidance technologies, added Brian Jones, Matrix Design Group\u2019s VP of sales and marketing, who noted that operator buy-in can be a challenge. \u201cCamera-based systems must also be kept clean in dusty mining environments to function correctly \u2013 which requires regular human intervention.\u201d<\/p>\n\n\n\n

\u201cIt is important to understand that collision avoidance systems (CAS) are, thus, only part of the answer,\u201d continued Savit. Any zero-harm strategy \u201cmust be backed by a proven change management methodology to ensure a meaningful safety culture prevails. Even the best systems integrating collision avoidance and operator awareness systems will never be 100% effective. Operators must still be engaged and re-engaged in a continuous improvement cycle.\u201d<\/p>\n\n\n\n

The best collision avoidance strategies \u201cinvolve a combination of advanced technology, robust operational practices, and human-factors engineering,\u201d agreed Wabtec\u2019s Tanzer, who provided the following breakdown of these three elements:<\/p>\n\n\n\n

    \n
  • Advanced CAS solutions include instant heading on take- off, curved beams, and accurate positioning that minimizes nuisance alarms. Real-time system health checks ensure the system\u2019s reliability. Diagnostics and fault reporting enable prompt maintenance and reduce the risk of system failure.<\/li>\n\n\n\n
  • Robust operational practices include implementing mining best practices, change management, training programs, and regular maintenance plans.<\/li>\n\n\n\n
  • Human factors engineering (HFE) involves designing
    products and systems so people can use them safely, comfortably, and efficiently. HFE is vital for operator acceptance and trust in the technology. Creating user interfaces that provide clear, context-specific alerts, such as
    voice instructions and simple graphics on the display monitor, enables operators to respond effectively to collision threats.<\/li>\n<\/ul>\n\n\n\n

    CAS and autonomous haulage systems<\/strong>
    Autonomous haulage systems (AHS) appear to offer a route to reduce the risk of collisions significantly, as they remove the primary contributing factor to most accidents: human error. According to Tanzer, however, the picture is more complex, firstly noting that there is no such thing as an entirely automated mine environment \u2013 and likely will not be anytime soon.<\/p>\n\n\n\n

    \u201cBy the end of 2025, more than 1,800 haul trucks are expected to be operating in AHS. However, that still leaves many manned haul trucks in operation,\u201d the Wabtec expert reminded us. \u201cEven if a mine\u2019s haul trucks are all automated, many other vehicles operate at a mine, such as light vehicles, dozers, scrapers, graders, and fuel trucks, that are not automated. From an operational point of view, there will also be times and areas within a mine that do not allow for AHS functionality, such as maintenance areas and areas beyond the geofence.\u201d<\/p>\n\n\n\n

    Tanzer explained that these hybrid environments \u2013 where some vehicles are automated and others are not \u2013 pose additional challenges for collision avoidance. \u201cCurrent AHS solutions often use proprietary protocols that prevent interoperability with third-party CAS technologies. This creates duplication and potential failure modes, such as when an AHS machine switches from autonomous to manned operation, but the operator fails to activate the CAS.\u201d<\/p>\n\n\n\n

    Mining autonomy involves \u201cmore than deploying the latest sensors and machine learning algorithms,\u201d added Hexagon\u2019s Savit, who described it as \u201corchestrating the fleet and understanding the broader mission and daily production goals.\u201d In that context, \u201ceach truck\u2019s payload, interactions with other equipment, and ultimate destination are critical data points in ensuring it arrives at the right place, at the right time, with the right payload.\u201d<\/p>\n\n\n\n

    According to Savit, Hexagon believes better situational awareness is the key to interactions between autonomous and manned machines. \u201cMany existing AHS are rules-based systems, moving the truck from point A to point B on a defined route. We are working on more aware autonomy at several projects, which include autonomous world perception to enable object detection and operator vehicle-to-vehicle and vehicle-to-person awareness. Ultimately, Level-9-type vehicle interactions will likely evolve into advanced driver assistance systems (ADAS) capability in mining and remove some current limitations around AHS and manned fleet interactions.\u201d<\/p>\n\n\n\n

    This could mean \u201cnon-autonomous vehicles being able to maintain greater optimum speeds when in the autonomous zone, for example, or having shorter following distances than are currently allowed,\u201d continued Savit. \u201cThe situation today is more often full autonomy or manned operations, but technology should allow us to move towards mixed, assisted decision-making for operators, combined with semi-autonomous operations. That said, unlike for road users, there is a production mission involved in mining, so everything must be done with productivity in mind \u2013 and all the fleet orchestration that entails.\u201d<\/p>\n\n\n\n

    The age of artificial intelligence<\/strong>
    One of the technologies that may facilitate this improved situational awareness is artificial intelligence (AI). According to Chris Adkins, mining sales manager at Matrix Design Group, \u201cadvances in AI modeling and algorithms, along with hardware evolutions, will improve the performance and customization of CAS. This may materialize in the speed, distance, and accuracy in which people, vehicles, and items are detected.\u201d<\/p>\n\n\n\n

    An example is AI smart cameras, which are \u201cenhancing the landscape in which CAS operate,\u201d according to Wabtec\u2019s Tanzer. \u201cFunctions such as edge and void detection, fatigue monitoring, and the ability to detect people and objects without tags elevate workplace safety to a new level. With good interoperability, customization, and open APIs, these solutions offer a reduced time to value because, as a system is commissioned, it can derive immediate benefits from increased proximity detection.\u201d<\/p>\n\n\n\n

    However, as a CAS solution for mining, \u201cAI smart cameras have limitations and compromises,\u201d added Tanzer. \u201cThey are yet to deliver the range capability required for heavy vehicles and lack the functionality of advanced features, such as curved beams, system health checks, and voice-based alerts. There is also a tendency for AI smart camera companies to offer limited support and services, so there are trade-offs like most products and services in the technology space.\u201d<\/p>\n\n\n\n

    Hexagon\u2019s Savit noted that \u201cwith good data and analytics, the time between system implementation and measuring value can be shortened from years to months or weeks in some cases.\u201d AI can also provide additional insight when identifying data correlations that might not otherwise have been noticed, for example, between a safety event or breakdown in a particular location and the equipment or road condition. \u201cOften, mines never identify the root cause of such issues, but the extra level of insight that connected processes provide can help address this.\u201d<\/p>\n\n\n\n

    According to Savit, \u201cHexagon believes that AI and the capabilities it provides will have a growing impact on mine fleet management and safety. Optimizing engines, predictive maintenance, user-experience workflows, and processes, such as short interval control, will be significantly enhanced by AI in the future. Advanced sensors and sensor fusion are also expected to unlock value in fleet management and performance, particularly for autonomous operations.\u201d<\/p>\n\n\n\n

    This last point highlights the wider operational benefits a CAS provides. \u201cWhile a safer workplace inherently minimizes personnel downtime and boosts productivity, protecting equipment from collisions also enhances its availability, lowering downtime due to incidents,\u201d said Matrix VP Brian Jones. \u201cThe data acquired from these platforms can also be used for production reporting and optimization efforts without additional hardware or software systems.\u201d<\/p>\n\n\n\n

    \u201cCollision avoidance is not just about keeping vehicles from interacting too closely for safety reasons,\u201d agreed Savit. \u201cMaintaining distance between machines also makes for a much more fluid operation, which benefits traffic flow, cycle time, and overall productivity. For example, we have seen users decide rights of way based on CAS data; other mines have increased speed limits, confident they can appropriately and safely manage this through the system.\u201d<\/p>\n\n\n\n

    \u201cThe data and analytics derived from continuous monitoring also allow mines to anticipate potential hazards and make better decisions, further enhancing operational efficiency,\u201d concluded Tanzer. \u201cFor instance, CAS analytics can identify risky operator behavior, enabling corrective actions that improve overall site safety and productivity.\u201d<\/p>\n\n\n

    \"\"
    Advances in AI modeling and algorithms, along with hardware evolutions, will improve the performance and customization of CAS systems. Image: Matrix Design Group.<\/em><\/figcaption><\/figure>\n\n\n

    The costs of CAS<\/strong>
    Although implementing a CAS at a mine requires significant upfront costs, all our experts agreed on the substantial long-term returns such a system provides, especially when weighed against the costly disruption and reputational harm caused by equipment damage and injury.<\/p>\n\n\n\n

    \u201cPrimary costs include purchasing and installing hardware and software and integrating these systems with existing mine site controls,\u201d noted Tanzer. \u201cAdditional ongoing costs are related to system maintenance, operator training, and software updates to ensure the system remains effective and reliable.<\/p>\n\n\n\n

    According to Matrix\u2019s Chris Adkins, specific expenses that a CAS can mitigate include:<\/p>\n\n\n\n

      \n
    • Safety violation penalties. The U.S. Mine Safety and Health Administration (MSHA) has implemented a 2.6% increase in civil penalties to account for inflation. A willful violation now carries a fine of $11,823, while the maximum penalty for a flagrant breach has skyrocketed to $332,376.<\/li>\n\n\n\n
    • Injury-related costs. The financial burden of injuries is substantial. On average, a medically consulted injury costs $42,000, while a fatality costs $1.39 million, according to the National Safety Council.<\/li>\n\n\n\n
    • Indirect costs of injuries. These often comprise the bulk of total injury-related expenses and are typically uninsured
      and unrecoverable. Examples include benefits paid to injured workers for absences not covered by workers\u2019 compensation, wage costs related to time lost through work stoppage, related overtime costs of other workers, administrative time, training costs for replacement workers, and lost productivity.<\/li>\n\n\n\n
    • Insurance premium increases. Accidents may significantly raise premiums for liability, workers\u2019 compensation, and business interruption insurance, further compounding the financial impact.<\/li>\n<\/ul>\n\n\n\n

      Regulations and CAS<\/strong>
      While MSHA has not directly mandated CAS in U.S. surface mines, the agency\u2019s Powered Haulage and Equipment Program includes several relevant requirements for mines to:<\/p>\n\n\n\n

        \n
      • Identify and analyze hazards and reduce the resulting risks related to the movement and operation of surface mobile equipment.<\/li>\n\n\n\n
      • Identify currently available and newly emerging feasible technologies that enhance safety at the mine and evaluate whether to adopt them.<\/li>\n\n\n\n
      • Train miners and other persons at the mine to perform work to identify and address or avoid hazards related to surface mobile equipment.<\/li>\n<\/ul>\n\n\n\n

        \u201cCAS can be used to fulfill each of these requirements,\u201d noted Matrix\u2019s Jones.<\/p>\n\n\n\n

        Regulation in other parts of the world is also driving adoption. \u201cSouth Africa has established safety standards and guidelines that mining operations must adhere to, while, in other parts of the world, governments and regulators have provided guidelines and frameworks to encourage companies to self-mandate,\u201d said Wabtec\u2019s Tanzer. \u201cMining companies outside South Africa must recognize the advantages of operating without a mandate by proactively implementing best practices and safety improvements at their mine sites. Such steps will help satisfy governments and regulators without establishing a formal mandate.\u201d<\/p>\n\n\n\n

        For example, in Australia, the New South Wales government has introduced the MDG-2000 Guideline, which \u201coutlines what is required when selecting and implementing collision management systems, ensuring compliance with safety standards,\u201d Tanzer continued. \u201cBesides the framework, regulatory bodies emphasize the need for functional safety and operational integration, pushing mining companies to adopt capable solutions that align with global initiatives such as EMESRT, the Earth Moving Equipment Safety Round Table, and ICMM\u2019s Innovation for Cleaner, Safer Vehicles. These standards ensure CAS technologies are effective and operationally integrated with existing mine site controls, enhancing their reliability and performance.\u201d<\/p>\n\n\n\n

        Selecting and implementing a CAS<\/strong>
        Several critical considerations should guide CAS selection and implementation to ensure alignment with industry best practices. First is the level of existing vehicle interaction at the mine site. \u201cSuccessful implementation of any CAS depends on the readiness and maturity of the baseline controls at the mine site,\u201d explained Tanzer. \u201cUnderstanding EMESRT Levels 1-6 controls is essential, as inadequate baseline controls can render the technology less effective or even introduce additional risks.\u201d<\/p>\n\n\n\n

        \u201cWe see safety as a journey with the customer,\u201d said Hexagon\u2019s Savit, taking up a similar point. \u201cFor example, we would not offer our Level-9 vehicle intervention system to any mine that has not already been on that journey. We recommend that operations use Levels 7 and 8 for at least six months to a year to understand those systems before taking the final step.\u201d<\/p>\n\n\n\n

        \u201cThe system\u2019s functional performance and technical requirements must align with industry standards such as EMESRT and ICMM,\u201d continued Tanzer. \u201cThe system must also be integrated with existing controls rather than functioning as a standalone solution. The installation process should follow a structured project approach. Thorough scoping exercises, stakeholder engagement, change management, and training programs for operators and maintenance crews are critical success factors. Finally, the mine site should consider the long-term maintenance and scalability of the system, ensuring it can adapt to changing operational needs.\u201d<\/p>\n\n\n\n

        \u201cWhile EMESRT is a linear process, we view layered safety as a cyclical, continuous improvement process,\u201d added Savit. \u201cRevisiting customers helps increase \u2018stickiness,\u2019 meaning keeping up with the latest technology and ensuring it is used and applied most effectively. Supporting customers with change management and data delivery is essential to a layered safety offering.\u201d<\/p>\n\n\n

        \"\"
        User interfaces should provide clear, context-specific alerts, enabling operators to respond effectively to collision threats. Pictured: Hexagon\u2019s Core display.<\/em><\/figcaption><\/figure>\n\n\n

        Critical, yes, but not a silver bullet<\/strong>
        \u201cThe mining industry tends to be conservative, but once something is proven, adoption can be swift,\u201d said Savit. \u201cRegulation, like that being adopted by South Africa\u2019s Department of Mineral Resources and Energy mentioned earlier, is also moving fast. As an indication of adoption, the EMESRT standards, including Levels 7, 8, and 9, are now commonly used and understood in mining.\u201d<\/p>\n\n\n\n

        While this is positive for mine safety and operational effectiveness, it\u2019s essential to understand that simply installing CAS technology is insufficient. Wabtec\u2019s Tanzer concluded that \u201csuccessful collision avoidance requires a holistic approach integrating technology with people, processes, and existing controls. Continuous monitoring, maintenance, and optimization are also essential to ensure long-term effectiveness and operator trust in these systems.\u201d<\/p>\n","protected":false},"excerpt":{"rendered":"

        North American Mining discusses collision avoidance in surface load and haul operations with experts from Hexagon, Matrix Design Group, and Wabtec. by Jonathan Rowland Load-and-haul operations present \u201csignificant challenges\u201d for collision avoidance, as Mitch Tanzer, Wabtec Digital Mine\u2019s global commercial director, told North American Mining. This is due to a mine\u2019s \u201ccomplex and dynamic nature\u201d with a high volume of…<\/p>\n","protected":false},"author":8,"featured_media":9812,"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":[2936,3683,633,524,1066],"coauthors":[1635],"class_list":["post-9811","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-features","tag-autonomous-haulage-systems","tag-collision-avoidance-systems","tag-mine-safety","tag-surface-mines","tag-wabtec"],"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