SIMS & TRAINING
autonomous operations . The program delivers high-quality training anywhere in the world , with both virtual and in-person teaching methods available . The AutoMine simulator enables mining personnel to practice in a realistic setting , saving money and production time while allowing operators to run AutoMine for loaders and trucks without tying up machines or production . It uses the same controls and software as the AutoMine system and comes in portable trolley cases or a full-sized station version ( with operator chair ).
And ahead of course Sandvik is working on simulators for its battery-electric machines – with the first being for Toro LH518iB . As these machines are new in the market , it is a big priority for mines using these units to get operators trained quickly as there will be no previous experience to rely on . These BEV simulators are set to be launched in Q1 2024 . BEV LHD sims will be followed by BEV trucks at a later date . “ The biggest challenge has been the simulation of the AutoSwap battery swapping technology . For diesel equipment we already have highly advanced engine simulations available and all the data from real engines . We have had to recreate the effect of the battery , inverters on power delivery to the machine and how that is shown on the operator screen , plus for AutoSwap how to represent the used battery drop and new battery being attached . Not only that but creating errors and situations within the BEV simulation as that is what you need when you are trying to train someone – you need to create some real-life situations . We are learning from real field results and our experienced teams in Camarillo and Turku what types of issues arise in the real machine so we can do our best to replicate those .” Up until now , training of BEV operators has been done directly by Sandvik trainers onsite at the mines , as well as at Sandvik locations .
Looking at Load and Haul as an example , the Load and Haul Learning Solutions offering is quite extensive . It includes LH517i and LH621i Cabin Digital Trainers , LH517i and LH621i portable Digital Trainers , plus an LH515i Cabin Digital Trainer and the Digital Trainer – TH for underground trucks . Along with that the retrofit kits are available for LH517i / LH621i and LH515i simulators . But at the same time , simulators are not Sandvik ’ s primary business , they remain firmly an advanced training tool for customers . These simulators as well as those for drilling , both underground and surface , are all built in Finland working together with an external company in Tampere – Gofore ( Creanex ) – who work with a range of industries , not just mining .
Shiv Kumar , Sandvik Training Manager , Load and Haul Division : “ We are not a simulator company , we are specialising in products and services for mining , rock excavation , rock drilling , rock processing , metal cutting and machining .
Sandvik Digital Trainer LH - Loader Simulator
But we wanted to make our own simulators so that we can provide them as a valuable tool for our customers along with the machines . The primary driver of our simulator program was not profit but to support our customers in their operations . For example , if the operator knows the machine better and operates it better , then the effective reliability of our machine increases .”
The Sandvik simulator teaches how to use the machine – it is a replica of the machine in a smaller form ; with the real controls and control system plus the real seat , dashboard and display . This all adds to a better feel and insight . Also , Sandvik mining machines are state of the art and big investments – it is preferable that the customer does not put an inexperienced operator directly on the machine as it could cause unnecessary damage to the machine early on plus there are added safety considerations . Another good reason for having the simulator from Sandvik is to prepare for potential disturbances or delays in global supply chain – which could happen eg for logistical or customs reasons . “ If we can deliver the simulator beforehand , and they are small enough to airfreight , then the customers have time to train their operators and prepare them before the real machine arrives . We can also incorporate any new technologies or upgrades into the simulator . Ultimately the time taken to train the operator when you factor in equipment lead times can be reduced drastically . And when the machine arrives , it can start doing the job the customer paid for it to do as opposed to it being used as a training tool .”
Kumar says Sandvik is seeing unprecedented demand and now has simulator customers all over the world including Australia , Africa , North and South America and in Asia . “ They are often offered as part of a package with many new machine sales , so this alone has meant a huge
increase in their population . In the overall scheme of things , compared to the real machine and benefits it brings to the customer , it is not a major cost , but it greatly increases our value proposition . The customer understands to an even greater degree that we are here to support them .”
By 2023 , Sandvik had delivered more than 25 load and haul simulators . In general the demand for loader sims is higher , given that there is a steeper learning curve in terms of skills needed to operate a loader versus a truck , which involves a more standard seating position and less variation in duty – for loaders have sideways seating and may load material from a muck pile or draw point , and may deliver material to an ore pass or a truck .
The simulators are used by the Sandvik training department in the sales area themselves but also by the end customers .
One of the other advantages of the Sandvik simulators it says is their portability – there are both cabin versions , which have some extra expense but also tabletop versions that can be used with portable screens . Both types can be stored in normal office premises , for example . In Australia , the Sandvik office also has simulators that are regularly sent to the mining customer sites . In other parts of the world , Sandvik has also rented simulators to customers for a fixed period , but the customer has chosen to buy them at the end of that time .
Most of the sims Sandvik delivers today have its control system in-built . It generates all the alarms in certain situations and allows you to simulate a lot of troubleshooting of problems that the operator in the real machine might have to deal with and how they should respond , even if that means putting in a call to technicians on the surface . Kumar : “ We are updating this control system and software on the simulators all the time , including the first we delivered all the way back in 2019 . The control system software is the same as we have in real machines . Independent simulator companies cannot offer this . Also , there are the safety and sustainability factors as well . As mentioned , new operators can make mistakes using the simulators safely without risk to themselves or others in the real mine .” He adds : “ It is more sustainable and minimises environmental impact , as human trainers don ’ t have to travel as much to sites ; plus , you aren ’ t burning fuel using a simulator . Finally , it is also much more efficient as a training tool , as while one operator is on the simulator , others are watching and gaining knowledge as well . And while a real machine is limited by availability for training , the simulator can continually host new operators , up to 20 a week in some cases . You are also saving money if the real machine is not having to be used for
16 International Mining | NOVEMBER / DECEMBER 2023