HIGH PROFILE
telltale that uses coloured bands as visual markers. Digital systems, such as those based on LiDAR scanning, are also available, but they come at a high cost and require regular, scheduled surveys to track changes over time. They work by comparing 3D scans taken at different points in time. Generally, LiDAR scans are taken via portable units maybe only once a month or even once a quarter. While there is a lot of publicity about drone-based LiDAR scans, the realities of operational mining mean this is rarely a realistic option.
Vallati:“ At Sandvik, we saw that there was this gap in the industry for a simple device to monitor convergence that is easily deployable and scalable and can provide real time data as soon as any excavation is opened. It had to be remotely operated, wireless and able to take continuous measurements without user intervention – in other words as self-sufficient as possible. A system that can be left in place taking its own measurements.”
28 real-time access to the data.
How is the sensor mounted in the mine? On the back, the xCell Cyclops has a socket that allows it to be installed directly onto existing rock bolts. The socket works with Sandvik’ s MD, MDX and Kinloc bolts, but with adapters it can also be retrofitted to other types of thread bars. A lock nut is used to lock the device in position and once it starts operating it takes distance measurements from one side of the excavation to the opposite side.
The xCell Cyclops can be oriented with a flexibility of +/- 15 degrees using the built in ball pivot mechanism. It can be configured to measure at a user defined rate, with convergence calculated relative to installation date as the initial reference point. Accuracy is +/- 2mm and it has a maximum measurement span of 20 m. Then longevity- using the latest chip technology, the battery is enough to last three years based on hourly measurements and a daily upload. It has a low profile to reduce the potential of
Underground drift wall with shotcrete, wire mesh and standard bolts, two of which are equipped with xCell Cyclops
The nuts and bolts of xCell Cyclops
So Sandvik came up with the xCell Cyclops system, consisting of the sensor itself, the data gateway device, and finally the user application. The xCell Cyclops is the sensor- a laser-enabled device that measures distance and links to Wi-Fi comms to upload its data automatically to the cloud. If Wi-Fi is not available, the xCell Professor is used. This gateway, typically mounted in mine vehicles, collects data from the xCell Cyclops via Bluetooth during drive-by passes at up to 30 km / h and then uploads it once comms are available. Finally, there is a user platform, which is accessible via web browser as well as a dedicated app for iOS devices, giving impact damage from vehicles plus is IP66- rated which allows it to be washed if it is covered in dust. Sandvik did look at options for self-cleaning devices, but the cost did not justify their use.
For the xCell Professor, which is installed in mine vehicles, the unit powers up automatically when the vehicle ignition is switched on. The range between the xCell Professor and the xCell Cyclops is up to 700 m in open air, but in underground environment, due to mine geometry it is limited to around 300 m line-of-site. There is also potential in the future to equip all vehicles with the xCell Professor- maybe deploying it along with a collision awareness
or avoidance system.
In the online application, users can set up trigger points for both total convergence and millimetres per day movement. If the ground moves too much or too quickly, the user will receive a notification. Notifications are also sent for hardware related problems such as low battery or required maintenance. Data can be exported to a CSV file for filing and third-party software processing as well.
The deployments so far
So where has xCell Cyclops been deployed to date? One example is at the Fosterville Gold Mine in Australia. They have squeezing ground conditions where interbedded layers of shale and sandstone undergo shear deformation causing buckling and bulking of the walls. In one case, the mine deployed three xCell Cyclops in a drive that was mined parallel to the bending to monitor deformation caused by a nearby stope firing, around 20 m away. The xCell Cyclops data was coming in hourly and showed a peak where the ground moved quite quickly after the firing. After a couple of weeks, it could be seen that the displacement had stabilised, so the firing had caused a quick ground movement, but was ultimately not an immediate concern, and only xCell Cyclops was able to help the client realise that.
If the lens gets covered by dust, for example from operating loaders in the area, then there could be noise in the measurements, but the xCell Cyclops is also smart enough to detect when it is dirty and sends a notification to the user that cleaning is required. This also happened at Fosterville and was quickly resolved.
Moving to another Australian gold mine- Sunrise Dam, characterised by poor rock type and a shear zone which cause ground movements. Here, xCell Cyclops has been used in the faulted area to detect movement of this high fractured ground, as well in other areas just to measure the natural creep of the rock in large intersections and around critical assets. If xCell Cyclops recorded a ground movement that was a concern or was unusual for a particular area, then a geotech went there to further investigate.
The xCell Professor module is mounted in mine vehicles to gather data from the xCell Cyclops’ via Bluetooth when Wi-Fi is not available
International Mining | JANUARY 2026