SURFACE LOADING
improvements of the first generation . It also offers a new feature to protect the rotating undercarriage by alerting the operator when the turning angle exceeds 20 degrees , so corrective action can be taken .
Other features within the new Operator Assist Technology Package include anti-swing in bank prevents damaging side-loading forces on the dipper when the operator attempts to swing the dipper through the bank . Hoist stall prevention monitors forces and optimises crowd / retract commands to avoid stalling the dipper and prevent detrimental forces on the hoist gearcase . Hoist rope slack prevention automatically adjusts crowd and hoist references to maintain rope tension when slack is detected .
Boom jack minimisation automatically adjusts hoist and crowd to maintain proper rope tension and improves cycle times . Rope crowd impact prevention measures the force on the crowd rope and automatically adjusts motor output to avoid shock loading . Rope crowd overspeed prevention eliminates unnecessary wear on the crowd brake by providing more braking power to avert overspeed situations .
By providing the foundation for support technology expansion and integration , the Integrated Technology Package helps to provide more robust and reliable reporting . New Cycle Segmentation establishes operating key performance indicators ( KPIs ) and identifies dwell time when idle . It divides cycle time data into digging , swinging to the truck , dumping and swinging to the bank segments . This allows miners to track machine performance across different shifts and operators .
With this introduction , legacy reporting technologies change to new Machine Health , Vibration Monitoring , Payload Management and Bearing Temperature Monitor technologies . Machine Health delivers improved reporting capabilities and provides remote real-time machine monitoring . Using sensors to capture data from the crowd , hoist , swing motors and gearboxes , Vibration Monitoring examines vibration signals for changes , allowing for proactive maintenance to reduce unplanned outage downtime . Payload Management provides real-time feedback on material moved to avoid truck over / underloading . Bearing Temperature Monitor keeps track of hoist , swing and crowd bearing temperatures and alerts the operator if figures rise beyond established thresholds .
The optional Integrated Technology Package will be available in standard and premium subscription levels . Standard subscriptions include all package technologies and push notifications for software updates . Premium subscriptions include all standard features plus vibration data analysis , monthly report generation from a Caterpillar engineer and inperson consultation to review the report ’ s findings and conclusions .
New Cat 7495 and 7495 HF shovel purchases
can be optionally equipped with the Integrated Technology Package and Operator Assist Technology Package as of 2023 . Availability of these technology packages as field retrofit kits is scheduled for mid-2023 .
Komatsu ’ s Track Shield 2
Repeated dipper-to-track strikes on electric rope shovels can reduce crawler shoe life and cause structural cracking and dipper damage , resulting in unplanned downtime and increased repair costs . Track Shield 2 is a new suite of control functions from Komatsu Mining that helps the operator decrease the number or severity of impacts between the dipper and the tracks or other parts of the shovel .
This solution calculates the position of the dipper and modifies controls to mitigate collisions . Komatsu says that Track Shield 2 is ideal for a variety of mining operations and applications including but not limited to oil sands with wide path tracks ; TRC dippers ; wider dippers ( 76 cubic yards or greater ); plus configurations where it is difficult to see potential strikes .
Komatsu states : “ Track Shield 2 has been engineered to substantially reduce the number or severity of costly collisions with the dipper on your valuable shovel asset . It ’ s a sophisticated technology upgrade that can help reduce maintenance costs and increase machine longevity from fewer incidents of damage or
Loader operation training & optimisation
Immersive Technologies offers human performance solutions for all makes models of surface mining loading equipment . The companies ’ simulator technology and services are deployed in mines in 48 countries around the world . Immersive Technologies states : “ Our products and services are driven by customer requirements and it is the voice of customer that has shaped our training solutions to deliver quantifiable value in key areas such as mine safety , productivity , reliability , and sustainability . Specific to surface loading , we are continually engaged with customers to improve how operators and supervisors make decisions to optimise the loading operation .”
Customer verified loader operation improvements cited in project references include 15 % improvement in shovel productivity ; 21 % improvement in truck payload ; 7 % reduction in cost per tonne ; and 6 % reduction in fuel use .
Immersive says familiarising new operators with machine controls and standard operating practices is necessary , but it is just the tip of the iceberg in terms of value that can be realised through training . “ Most of the long-term value resides in the optimisation of the operator behaviors and supervisor decisions that impact the load and haul circuit .” It adds : “ We know every mine has unique needs , which is why we partner with our customers and use data to pinpoint specific operational issues . Once needs are identified , we help the customer make improvements to their people , process or technology to ensure that training and development of mine personnel yields the highest returns for the customer .”
Field supervisors are the eyes and ears on the ground to ensure that the loading location is setup for optimum safety and productivity . Immersive Technologies has recently partnered with several Tier 1 mining
Rope shovel operator training in Immersive Technologies PRO5 mining simulator
operations to develop innovative tools and training products that improve Field Supervisor decision-making .
It told IM : “ For example , the company has developed an Operator Performance Analytics ( OPA ) dashboard that enables Supervisors to see near real-time metrics against their individual and crew performance . This allows the supervisor and operator to provide meaningful , data driven feedback . The company has also successfully delivered to mines a virtual reality training product named Mine Standards Training ( MST ) that trains field supervisors to make best practice decisions in line with the mine ’ s operational expectations . For example , the tool tracks decision making in complex situations for managing the loader position , payloads , digging technique and more .”
International Mining | MARCH 2023