SURFACE AUTOMATION
and individual mines start their journey in
different places. “Some will begin with a
technology product such as Cat ® Terrain, which
uses guidance technology for drilling, grading
and loading operations. Others start with Cat
Fleet, which serves as an operational ecosystem
that provides real-time tracking of machines and
material movement.”
There are different levels of a utomation, as
well. For example, Caterpillar offers truck-
spotting and load-positioning technologies that
leverage pieces of Cat Command automation to
improve manned operations. In the semi-
autonomous realm, remote-control dozing allows
operators to take control of machines that
perform production dozing autonomously.
“We’re committed to delivering technology
solutions that can make a difference for mines of
every size and with every type of equipment,”
says Craig Watkins, Caterpillar Mining Technology
Manager. “There’s something for everyone, no
matter where they are on their autonomy journey.
We want to help them get started down that
path, wherever it makes sense for their
operation. The significant benefits of automation
can be realised with even the simplest of
applications. While full autonomy may be the
ultimate goal, individual technologies can be
used alone or combined in multiple ways to take
advantage of immediate productivity, efficiency
and safety gains and serve as the building blocks
leading to autonomous mining operations.”
The modularity of Cat technology products
helps in this effort. The operating system for
Fleet is the same for Terrain and the same for
Command. The products are also fully scalable.
“The technology products work individually, and
they grow alongside mines as they follow their
own path to autonomy,” Watkins says.
Caterpillar started with three autonomous
mining trucks for testing and validation in 2011,
and six autonomous trucks were deployed
commercially in 2013. By the end of 2017, 100 Cat
autonomous trucks will be operating on three
continents and in three different applications.
The total includes 56 trucks that constitute the
largest single fleet of autonomous trucks, which
have achieved 20% greater production than
manned trucks operating in the same mining
complex. This fleet of autonomous trucks
operates in a space with more than 150 manned
vehicles – graders, loaders, water carts, light
vehicles, dozers – and all dispatched through the
Cat MineStar System.
“There have been no lost time injuries
associated with the autonomous trucks in the
field during the 4.5 years since operations began.
The Cat Command for hauling system obviously
reduces the number of people working in the
active mining area, which reduces exposure to
risk. Additionally, the system offers a minimum of
2+1 layers of protection to help ensure safe
operation, and additional reporting capabilities
available with the autonomous system help drive
a robust safety culture and process
improvements.”
The autonomous trucks system has also
proven reliable – with greater than 99.95%
system availability. “In short, the system is
productive, safe and reliable. These mining
industry results are further validated by the
commercialisation of autonomous vehicles for
consumer use and business use in other
industries.”
Another recent autonomous mining trucks
application Cat says “is reassuring for those who
view autonomous truck operations as daunting.
Caterpillar deployed the system for a contract
earthworks operation within 30 days of contract,
and the fleet exceeded all goals for production
within 45 days of the initial truck operation.”
Autonomous trucks achieve performance
advantages over manned operations by working
more hours each day and by working faster.
“Higher utilisation of 2.5 hours a day on average
results from no shift change, no breaks and no
lunch. Refuelling and inspection is the only stop
on most days.”
The Cat autonomous trucks system ensures
that the trucks operate consistently – with no
difference in operator skill level slowing down
truck cycles. “All trucks react the same way to
environmental variables and drive to the design