Open Cut

Improved Monitoring of Dragline Operation

ACIRL's Australian Dragline Performance Centre (ADPC) was contracted to undertake a comparison of different dragline process variables as project C3001 under the Australian Coal Association Research Program.

Objectives

The specific objectives of the project ....  read more

Dragline Bucket Filling Investigation

The aim of this project was to develop a method for obtaining quantitative data to characterise dragline bucket filling behaviour. This has been achieved and data has been collected for four bucket filling scenarios:

1. Conventional BE bucket (Howick mine)
2. Esco Mark IV (Newlands ....  read more

Improved Lubrication of Dragline Components

 When a dragline operator purchases a new machine, the specifications relating to lubrication tend to be general rather than definitive. Current practice, therefore, in the lubrication of dragline components requires the operator to select lubricants ....  read more

Dragline Automation

The objectives of the project were to:

• Demonstrate the feasibility of automatic sensing of bucket position.
• Characterise the electro-dynamic dragline system.
• Demonstrate closed-loop operation of the ADPC tenth scale dragline

Improved Dragline Spoiling Through 3D Simulation

The objectives of this project were:

• To conduct a field study at Peak Downs Mine to acquire the following data on the excavation of a typical block:
• Calibrated stereo pair photographs to produce digital terrain models (DTM's) of key

Modeling Dragline Bucket Dynamics and Digging (including Bucket Filling Animations CD)

The need to maintain and increase dragline productivity is widely recognised as a major priority by Australian dragline operators. Bucket performance is critical to dragline  ....  read more

Evaluation of GPS Technologies in the Open Cut Mining Industry

The global positioning system (GPS) is a satellite based system which can be used for positioning and/or surveying to 2cm accuracy horizontally and 3cm vertically anywhere on the earth's surface. There are 21 satellites currently in orbit with three ....  read more

Dragline Research Review

The existing ACARP program is a vast improvement over its predecessors. There is virtually no comparison in the quality of work, the expeditious performance of researchers, the applicability of the results and the technology transfer mechanisms. This is not to ....  read more

Dragline Training Simulator

The Issues

Productivity of operators

Operators are the key to dragline productivity. Performance of existing operators varies somewhere in the range 10-35%, so approaches to raising skills to uniform levels should be investigated.

Productivity loss in ....  read more

Improved Dragline Productivity Through Rigging Design

ACIRL Ltd was commissioned by ACARP to investigate and research aspects of dragline bucket rigging, (Project C4003). This project commenced in May 1995 and was completed in October 1996. The total project value was $195,000 of which ACARP provided funding for ....  read more

Improving Machine/Operator Interface for Draglines

The aim of this project was to develop modifications that can be installed in a dragline cabin to assist the operator in achieving maximum productivity and safety.

Results

The most important developments were concerned with providing the ....  read more

Hoist Control Project: Project Summary Economic Benefits of Hoist Control to Dragline Operation

Field tests on the hoist drive of draglines have shown "overshoot" and oscillations of the drive gearbox torque during the lifting stage of the cycle. These dynamics, ....  read more

Dragline Monitoring Using Acoustic Emission, Vibration, Strain and Operation Load

If a material or a structure is placed under stress, either mechanical, chemical or thermal, and if that stress is sufficient to alter the material's microstructure, a stress wave  ....  read more

Dragline Automation Implementation

Reduction in the cost of overburden removal from open cut coal mines has been identified as the most important means of improving the economic performance of Australian open cut coal mines. The  ....  read more

Development of Tools and Methods for Rigging Data Specification for use in Dragline Bucket Simulation

BHP Research and Technology Development has developed a rigging simulation model (PcDrag) and its associated tools for the assessment and design of bucket riggings. This software provides solutions of a set of non-linear equations for the static equilibrium of a dragline bucket and its ....  read more

Optimisation of Dragline Excavation

The objective of this project was to develop prototype software that would allow a mine to determine the optimum dragline excavation sequence, ie. where the dragline stands, where it digs from and dumps to, and when and where it moves. Currently, many of these decisions are made by the ....  read more

3d-Dig 2000

This project was conducted to enhance and further develop the 3d-Dig Version 1 Dragline Simulator. The Version 1 Simulator is a DOS-based system allowing dragline operations to be simulated and visualised. This system has proved to be a very effective tool for analysing and improving dragline ....  read more

Analysis of Data from Equipment Performance Monitors

This is a report of the outcomes of an ACARP sponsored research project that investigates data analysis techniques suitable for analysing the large volumes of data being generated by equipment performance monitors that have become widespread within the mining industry. The monitors are often ....  read more

Optimisation of Design Load Levels for Dragline Buckets

In this project CMTE developed a rigorous procedure to assist the dragline owner to identify the optimum operating point for a given dragline in terms of its bucket size. This optimum point is based upon the trade-off between two opposing factors: the increased instantaneous productivity that ....  read more

Modelling and Optimisation of Bulldozing

This project had the following aims:

• Monitoring of bulldozer operations and development of bulldozer productivity algorithms.
• Development of computer modelling software to allow the design, optimisation and graphical depiction of bulldozer operations. This software will use

Dragline Link Chain Field Trial

This project was for the trial of the link chain concept at Mount Thorley Operations. At the conclusion of the initial engineering difficulties were encountered with the MTO dragline in establishing the trial in an acceptable timeframe. An approach was made to ACARP to reduce the scope and ....  read more

Technical Diffusion of JKMRC Project Outcomes

The purpose of this project was to investigate the dissemination of outcomes from recent JKMRC ACARP projects, namely C5005 "Controlling Coal Damage due to Cast Blasting" and C5008 "Optimisation of Dozer Operations in Open Cut Mines"

Both these projects were released with computer ....  read more

Dragline Swing Assist

This report describes the CSIRO Dragline Swing Assist (DSA) technology and the performance of the proof-of-concept system installed on the BE1350 dragline at Boundary Hill. DSA is a radical new technology for dragline operation and can be seen as an addition to any other dragline technology ....  read more

Dragline Rigging and Control System for Universal Dig & Dump

This report presents the results from the fast track version of the original ACARP project submission "Dragline Rigging and Control System for Universal Dig and Dump". The project was designed to investigate and quantify productivity data and machine loads, to assist in the assessment and ....  read more

Improved Understanding of Shovel Dippers & Processes

p>After draglines, rope shovels are the most important part of coal uncovery and yet up until now, the process of excavating with a shovel has been largely based on experience and intuition. The work done during this project has advanced understanding of dippers and processes greatly. This ....  read more

Optimised Bucket for Parallel/Universal Rig

The goal of this project was to investigate the way the bucket connection points could be varied to reduce the rope load variations, increase the dumpability of the bucket, and identify an approach for retrofitting an existing bucket and/or developing a new bucket ....  read more

Development of Slope Stability Radar

This report describes the recent developments of the Slope Stability Radar (SSR). It covers the engineering development and testing of the early production standard, or beta prototype, as required by this project. This work followed the successful proof of-concept model ....  read more

Automated Digital Terrain Mapping for Draglines

Draglines are the most important means of coal uncovery in open cut mines. The key problem is that we do not know what a dragline is doing. 3D plans can be developed, but we can not tell how good the plan was, or how well it was followed. A dragline monitor can measure how the dragline has ....  read more

Dragline Automation through Automatic Control of Bucket Carry Angle

The aims of dragline automation are to:

• increase average bucket content by maximising fill and reducing spillage,
• decrease average cycle time, by improving repeatability,
• reduce maintenance down-time by reduction of dynamic overloads.

Real Time Shovel Operator Feedback System

This project endeavoured to determine whether real-time knowledge-of-performance information would favourably influence the behaviour of a rope shovel operator. Previous work done by CMTE had established that overall machine performance was profoundly dependent on individual ....  read more

Open Cut Automation Scoping Study

The objective of this project was to develop a roadmap that identifies how ACARP expenditure on automation based research for surface coal mining should be invested to achieve maximum benefit for the Australian Coal Industry over the next 3 to 10 years.

The roadmap developed is equipment ....  read more

Rope Shovel Automation

This project has demonstrated a number of technologies that are critical to automating rope shovel operation. They are:

• Computer control of all three drives of a model rope shovel (crowd, hoist and swing).
• Reliably detecting the onset of stall and two

Rope Shovel Operator Information System

This project endeavoured to expand the capabilities of the existing data acquisition, processing and feedback system developed under ACARP project C11047 to include GPS machine position, dig face profile, shovel distance to the face and tactile feedback.

Previous work done by ....  read more

Advanced Duty Detection System

An advanced duty detection system has been developed and demonstrated that will continuously monitor dragline operation and identify and classify operating practices that cause excessive amounts of incremental damage or duty on the machine. The system will form part of and extend the ....  read more

Dragline Operational Enhancements through the use of Digital Terrain Maps

Digital Terrain Maps (DTMs) offer the next logical step in monitoring the performance of a dragline and the overburden removal excavation process. Online knowledge of the local terrain and how it changes with time would allow measurement of the real productivity (coal ....  read more

Refinement of Automated Dragline Swing Control Algorithms

The control of the swing cycle of a dragline a key component of the dragline automation roadmap presented in the ACARP Open Cut Automation Scoping Study (C11054). The CSIRO team in partnership with ACARP and mining companies have been progressively developing a Dragline Swing Assist (DSA) ....  read more

Swing Loader Traffic Control

This project has successfully demonstrated (on a 1/7th scale model swing loader and haul truck) the technology to direct drivers to a recommended loading position. It does this in two phases. In the first phase, a scanning range laser on the swing loader is used to generate a digital ....  read more

Real-Time Dragline Production Enhancement System

The enhanced sensing of machine and operator performance is crucial to the automation of dragline operations and for improving safety in the dragline working area. The determination of a reliable and accurate measure of the terrain surfaces in the region around the dragline, ....  read more

Accurate Guidance and Measurement for Excavators using a Laser Scanner

This project has successfully developed and demonstrated a proof-of-concept system that is able to simultaneously
track the bucket of a mining excavator and map the terrain under the boom.

Over a 12 month period, a number of trials were conducted at Blair Athol Mine ....  read more

Improving Operator Support and Selection Processes

Variations in dragline operator performance have major maintenance and productivity implications for mines.  The value of replacing operators who achieve below average performance, with operators who achieve higher productivity and lower damage costs through better selection and  ....  read more

Shovel Automation - Phase 2: Autonomous Excavation and Truck Loading for Mining Shovels

In this project, we have progressed the results from ACARP project C12030 through addressing the second phase of the mining rope-shovel automation roadmap by successfully demonstrating complete automatic cycles on a 1/7 scale-model rope shovel. The primary achievements include the ....  read more

Load, Haul, Dump (LHD) Analyser and Landform Management System

This project has developed a computer-based system for the study, design and optimisation of truck-and-shovel overburden removal. It includes functionality to allow the quick and approximate modelling of long term dragline spoil and incorporation of truck and shovel pre strip.

Identifying the Determinants of Reduced Dragline Operator Performance Over Time

The purpose of this report is to investigate factors that may impact the productivity and performance of dragline operators in the Australian Coal Industry. Central to the effective operation of the coal mine is the dragline and it is argued that as little as a 1% increase in dragline ....  read more

Increasing Dragline Prime Output

This project was about the effective use of the dragline productive capacity. The dragline has a certain productive capacity which is made up of prime and rehandle. It is the prime, not the total, which dictates how much coal is uncovered.

While many millions of dollars ....  read more

Real Time Continuous Measurement of Blasted Dragline Overburden Bulk Density

This report presents a method for measuring the in-bucket material volume on a dragline for the purpose of estimating the material's bulk density in real-time. Knowledge of the blasted overburden bulk density can provide instant feedback to mine planning and scheduling, enabling better ....  read more

Advanced Dragline Performance Analysis

The ability to automatically classify and report swing cycles according to their limiting motion (swing, hoist or drag) is an essential capability in order to flag potential dragline performance losses and drive continuous improvement efforts.  

This project uses data ....  read more

Theory of Constraints in Strip Mining

This research project was commissioned to investigate the feasibility of using Theory of Constraints to assist in planning the stripping process of a coal mine. The explicit aims were:

· Investigate how Theory of Constraints might be used in the stripping process;

· Model ....  read more

Real Time Continuous Measurement of In-Place Blasted Dragline Overburden Bulk Density

This report presents a method for measuring the in‐place bulk density through comparisons of digital terrain models and machine monitor data. For the context of this report in-place refers to the original place of blasted material after the blast and before being handled by the dragline. ....  read more

3D Scan Matching And Registration For Improved Mine Survey

ACARP project C20028 entitled "3D scan matching and registration for improved mine survey" endeavoured to reduce survey costs and improve the timeliness of survey data via the introduction of CSIRO's 3D mapping technologies to the survey process. It was intended to demonstrate the ....  read more

Automated Design of Multi-Pass Dragline Strips Using 3d-Dig

This project aimed  to research, develop and implement a design methodology to automate the design of a complete, multi-pass dragline strip. The design methodology was implemented by extending the capabilities of the 3d-Dig dragline simulation system.

The 3d-Dig system has been ....  read more

Enhanced Reporting of Advanced Dragline Analytics

Dragline repositioning is a major source for the loss of productive dig hours. A trade off exists in any decision to remain digging at a particular location or to reposition the dragline in order to obtain more favourable dig conditions, spoil room or swing angles.

This ....  read more

Dragline Automation System: Optimal Excavation Sequencing

Dragline excavation sequencing describes the complex problem of determining the sequence of tub positions and the associated material movement task for each tub position for dragline strip mining. This project has examined computational methods for computing excavation sequences. It is thought ....  read more

Quantifying Development Risks for a High Capacity Surface Mining Continuous Cutting System in Waste

This project enabled investigation of potential cutting technologies for use in a High Capacity Surface Continuous Cutting (HCSCC) system for coal mine overburden, identifying technology gaps and risk mitigation strategies for commercial implementation.

Key ....  read more

Automated Bulk Dozer Push - Reducing the Cost of Overburden Removal

Caterpillar Command for Dozing is a Semi-Autonomous Tractor System for D11T dozers that can perform bulk dozing. The first deployment of this technology was at Black Thunder Coal Mine in Wyoming where it was demonstrated to be capable of executing push-to-an-edge bulk dozing as part of a ....  read more

Dragline Excavation Sequencing

It has long been recognised that optimising the positioning and material movement tasks of dragline operation has the potential to reduce excavation times and improve spoil management. The challenges to building a system capable of realising these benefits are many and varied, and include the ....  read more

Dynacut Fundamental Development and Scalability Testing

The previous project outcomes (C25041) supported the potential for DynaCut technology to be effective and economically competitive at a large scale for surface coal mining. This phase aimed to progress the de-risking process through additional cutting trials with a modified cutting ....  read more

SATS Automated Mission Planning

The Caterpillar Semi-Autonomous Tractor System (SATS) enables autonomous bulk push mining operations for overburden removal. It can execute various bulk-movement methods including Push-To-Edge, Tip-Head, and Pivot-Push.  The SATS system in its current commercial form autonomously and ....  read more

Dragline Excavation Sequencing

This project achieved an important step toward realizing 'live' excavation sequencing as a tool for real-time management of dragline excavation. The sequencing system guided excavation for a blocks pass operation, planning the operation sequence and having operators follow the guidance ....  read more