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CAT LOOKS AT THE AUTOMATED AGGREGATE OPERATION

Editorial focus by Harold Hough Oct/Nov 2008

A Ford Hybrid Escape and a Chevrolet Tahoe hardly seem the key to the future of mining and aggregate operations, but they are definitely giving us a taste of the future. These two cars, “Boss” and “Odin” are automated vehicles that are using the equipment and software that may make the mine of the future less labor intensive.

Both of these cars were involved in the Defense Advanced Research Projects Agency (DARPA) Urban Challenge that tested automated cars in an urban setting; navigating around the town, moving with traffic, crossing intersections, and avoiding obstacles. Both of these cars were top finishers and were sponsored by Caterpillar, who is using the results of the research to develop automated heavy equipment for the future mine and aggregate operation. Odin was put through its paces at the Tucson test facility in September when Caterpillar was showing the technology to the media and customers.

"Caterpillar scientists and engineers have partnered with leading universities and top autonomy experts to enhance the core technologies for a fully integrated mine site operation," said Caterpillar Vice President of Electronics & Connected Worksite, Gwenne Henricks. "By aligning ourselves with the best and the brightest minds in the fields of science and engineering, Caterpillar continues to make sustainable progress possible around the world."

LOOKING TO THE FUTURE

Although automated mining equipment has been a real possibility for over a decade, low minerals prices in the late 1990s and early 2000s discouraged mining companies from investing in the new technology. However, now that profits are up, there are several reasons for looking seriously at automated mining.

One major factor in the push for automated equipment is the dearth of equipment operators. Although it pays well, few young people in North America aspire to become heavy equipment operators. The result is that the age of equipment operators is growing and the current boom in mining has depleted the pool of qualified operators. Although some companies and community colleges are aggressively trying to train more operators, demand continues to outstrip supply.

Another factor is safety. Mining has always been a more dangerous occupation and the manpower and material cost associated with accidents is huge. An automated vehicle means an operator isn’t around the equipment, which lessens the chance for falls or other accidents.

Safety is also enhanced by moving the human out of the loop. Operators get tired, haphazard, and bored; leading to many of the accidents on site. Computers and sensors do not get bored or lose concentration, which means that the chances of an accident are lessened. Of course, computers and sensors do fail, but software can shut the equipment down if there is any failure.

Another advantage to automated equipment is that an operation can maximize its output and increase efficiency. While human equipment operators might be tempted to cheat when it comes to running the equipment in the most efficient manner, a computer will carry out each maneuver precisely for as long as the mine desires. There will be no loss of efficiency as the shift comes to an end.

Automated equipment will also eliminate the discontinuities caused by bringing new workers in at the beginning of a shift. Unlike normal operations where work slows down as the shift nears an end and then slowly picks up as the new shift gets into the routine, there is no loss of efficiency with automation. Automated trucks can continue their routine of moving from the mine face to the crusher without interruption.

Cat is already moving towards the automated site. Systems like MINEGEM and AQUILA are already putting automated systems in the field. MINEGEM has brought some automation to underground mines and AQUILA is an automated blasthole drilling system that makes drilling more precise than ever before.

But, that is just the beginning. In July Caterpillar announced a groundbreaking alignment with BHP Billiton to develop an autonomous mining haulage system. The development program includes giving current trucks at the mine autonomous sub-systems. The companies plan to have autonomous trucks at selected mine sites by 2010. The program is developmental and not intended to be sold to other operations.

So, when will fully automated equipment come to your local mine or aggregate operation? The thought of a fully automated Cat 797 truck bearing down on miners with 400 tons of ore in the back still makes mine managers cautious. Even the diminutive Odin SUV had several watchers positioned around the Tucson test track who were able to turn off the car in case of any trouble. The test, however, went off without a flaw; avoiding obstacles put in its way, stopping when other vehicles moved into range and merging and moving with traffic as required.

But, as the fielding of AQUILA and MINEGEM has shown, automation is the way of the future. Don’t be surprised if Cat display at MinExpo 2012 has a couple of automated haulers ready to come to work at your site.