2011_2_01.pdf
TRANSCRIPT
Systemy Zarządzania w
Inżynierii Produkcji
2011, Nr 2 (2), s. 3‐7
2011, No 2 (2), pp 3‐7
Management Systems in Production Engineering
Abstract: VŠB‐Technical University of Ostrava, ins tute of geodesy and mine surveying has been coopera ng with Severočeské doly j.s.c. (SD) in important research project since 2007. The main goal is improve control system for opencast mining. Two bucket wheel excavators (K800/103 and KU300/27) were equipped with measurement hardware at the Libouš Li‐gnite Mine (North Bohemia brown coal basin). The posi on of the bucket wheel centre is computed by means of GPS data, inclinometer and incremental measurements. Data is transferred to a base. All the values measured are saved in this database. The surface layout of the mine as well as posi ons of underground geological layers are updated on a regular basis in the digital model of the mine. The main aim of the research is verifying the system in connec on to digi‐tal model for short me prognosis of qualita ve parameters of coal (Ad, Sd, Qr, Wr and MS), con nuous automa c com‐puta on of mined materials (m3, tons) and con nuous checking of crea on of the movement surface/plane of the exca‐vator and mining goals. Mine surveyors have a lead role in the working team. The paper describes possibili es of using the GPS for mine surveying and for produc on planning.
THE UTILISATION OF GNSS TECHNOLOGY FOR MINING PROCESS AUTOMATION
WYKORZYSTANIE TECHNOLOGII GNSS DO AUTOMATYZACJI PROCESU WYDOBYWCZEGO
INTRODUCTION
The fact that the satellite system provides data inde‐pendently of weather condi ons, round the clock and anywhere in the world is a major advantage of the system. During the last two decades the satellite technology has been undergoing fast developments worldwide, which has resulted in the use of GPS technology in many fields. In the surface mining industry the GPS has proven to be useful mainly at resolving usual surveying tasks. The op on is now inves gated of u lisa on the GPS technology also for facili‐ta on of the mining process.
USE OF THE GPS FOR DETERMINATION OF EXCAVATOR BUCKET WHEEL POSITION
It is obvious that if the 3D posi on of excava on ele‐ments of mining machinery and associated mining mecha‐nisms can be determined rela vely accurately, mul ple task can be successfully resolved in terms of control of this hardware (fig. 1). As far as brown coal surface mines are concerned, the following topics are of prime interest:
Facilita on of the process of control of excavator opera on (e.g. prognoses of qualita ve parameters of coal being mined).
Calcula ons of volumes of mined materials in nearly real me.
Very accurate control of crea on of the movement plane of the excavator and immediate control of mi‐ning targets.
Control and checking of associated mining mecha‐nisms (e.g. dozers).
In 2006 Severočeské doly j.s.c. launched a research pro‐ject tled “GPS‐Aided Determina on of the Posi on of the Bucked Wheel of the K800/103/N1 Excavator”. A project was developed, in which all the components of the system were designed, including their posi ons, as well as systems of data transfers and data evalua on.
The system consisted of three basic elements [6]: Measurement segment (GPS, iner al sensors, control
unit), Communica on segment (radio or GPRS communica on
for recep on and transmission of data), User segment (evalua on so ware).
On bucket wheel excavator K800/103 (fig. 2) the measu‐rement segment originally (2006) consisted of 2 DGPS devi‐ces Trimble DSM 232 (Dot 1, Dot 2), 2 inclinometers (Dot 3, Dot 4) and one incremental rota on speed sensor (Dot 5). Correc ons for DGPS were transferred from the reference sta on to the excavator employing a radio‐modem.
Dana SLÁDKOVÁ VŠB – TU Ostrava
Key words: analysis, bucket wheel excavator, digital model, gps, inclinometer, incremental measurements
Słowa kluczowe: analiza, koparka wielonaczyniowa, model cyfrowy, GPS, inklinometr, pomiary przyrostowe
4 Systemy Zarządzania w Inżynierii Produkcji/Management Systems in Produc on Engineering 2(2)/2011 D. SLÁDKOVÁ — Wykorzystanie technologii GNSS do automatyzacji procesu wydobywczego
Fig. 2. K800/103 excavator Rys. 2. Koparka K800/103
A control unit controls the opera on of the en re sys‐tem. The posi on of the centre of the bucket wheel axis (Dot 6) is computed from X, Y, Z coordinates acquired from the GPS devices and on the basis of sensors’ data (inclina ons, rota on speeds) on a 5‐second basis. Using radio‐modems, the data is transmi ed to the headquarters building of the Surveying and Geology Department, where it is saved. Then the data is processed by evalua on so wa‐re (Kvas Prognosis Models). The system has been operated since December 2006.
THE RESEARCH PROGRAMME
The data transferred is saved in database file *.DB. All the values measured are saved in this database. On a five‐second basis the database should be updated with a series of newly measured values. The first tools have already been
developed in the “KVAS ‐ Prognosis Model” programme for visualisa on of the excavator and u lisa on of the results of computa on of the posi on of the centre of the bucket wheel axis.
The sec on of digital opera onal map in fig. 3 shows the posi on of schema zed K800/103 excavator. On the le hand side, the ver cal geological profile is shown in simpli‐fied terms. The posi on of the bucket wheel in rela on to the profile in the relevant site can be seen. The individual types of coal are colour–discerned on the basis of quali‐ta ve parameters. Mining plan for excavator is also shown (red lines) as well as boreholes. Another view is on fig 4. The current status and the history of qualita ve parameters of the coal (Eleva on of bucket wheel ‐ 1, Hea ng Value Qr – 2 and sulphur content Sd – 3), as derived from the model, can be seen in the le part of the figure.
Fig. 1. Surface mining – Libouš mine Rys. 1. Kopalnia odkrywkowa ‐ kopalnia Libouš
Systemy Zarządzania w Inżynierii Produkcji/Management Systems in Produc on Engineering 2(2)/2011 5 D. SLÁDKOVÁ — The U lisa on of GNSS technology for mining process automa on
Fig. 3. The posi on of the bucket wheel excavator in real me (map and profile) Rys. 3. Pozycja łyżki koparki kołowej w czasie rzeczywistym (mapa i profil)
Fig. 4. Eleva on of bucket wheel and qualita ve parameters of the coal (le part of the figure) Rys. 4. Podwyższenie koła czerpakowego i parametrów jakościowych węgla (lewa część rysunku)
6 Systemy Zarządzania w Inżynierii Produkcji/Management Systems in Produc on Engineering 2(2)/2011 D. SLÁDKOVÁ — Wykorzystanie technologii GNSS do automatyzacji procesu wydobywczego
The measured data also serves for detailed analysis of the en re process. The analysis is developed by the Ins tu‐te of Geodesy and Mine Surveying of the Technical Univer‐sity – VŠB Ostrava. The following is carried out in par cular:
Analysis of data transfer (number of measurements received)
Analysis of accuracy of individual meters Analysis of gross errors Analysis of the mean errors of individual measure‐
ments and iden fica on of the cri cal point Comparison of computed mean errors with values
iden fied by the manufacturers of all the used me‐ters
Analysis of the accuracy of the calcula on of the buc‐ket wheel axis centre (mean error propaga on)
Analysis of data during opera on of the excavator The basic equa ons for determina on of 3D (XK, YK and
ZK) bucket wheel axis posi on were derived from geometry of excavator and posi ons of GPS and iner al sensors at the K800/103/N1 (fig. 5) excavator:
Accuracy of calcula on 3D bucket wheel axis posi on
was derived using of mean error propaga on method:
The equa ons (4‐6) for mean errors mxk myk and mzk of XK, YK a ZK calcula on we got using par al deriva on. The final equa ons are quite extensive therefore we do not bring them in the ar cle. We appointed values of mean errors individual measurement instruments to equa ons (4), (5), (6) (final version) and have obtained mean errors
and influenced by accuracy of individual measurement in‐struments.
PARTIAL CONCLUSIONS FROM THE RESEARCH PROJECT (2007)
The accuracy of determina on of the posi on and eleva on of the centre of the wheel axis depends also on the reliability of transfer of correc ons from the reference sta on to the excavator as, unless the correc ons are transferred from the reference sta on to the excavator, GPS receivers switch automa cally from the DGPS mode to the “naviga on” mode ‐ with considerably compromised accuracy. The first results of data analyses showed that it would be necessary to ensure be er quality transfer of correc ons from the base to the excavator and vice versa – the success rate was about 70%. This, consequently, had a nega ve impact on the accuracy of the GPS measurements.
The first results already suggest that for the purpose of rou ne applica on, the RTK regime will have to be used and the GPS receivers will have to be upgraded, par cularly due to the need to increase the accuracy 3D posi on deter‐mina ons. Using D‐GPS technology we achieved average accuracy of determina on of the posi on and eleva on of the centre of the wheel axis:
mxk = ±0,164 m myk = ±0,143 m mzk = ±0,265 m
THE RESULTS OF DEVELOPMENT IN 2009
On the results of our analysis, SD Company has realized two important changes:
radio communica on for recep on and transmission of data was displaced by GPRS system,
2 DGPS devices Trimble DSM 232 were changed by 2 RTK Leica MNS1230 GG. The Leica MNS1200 GNSS is specifically designed for construc on and mining ma‐chine opera on at toughest condi ons.
The results of accuracy analysis are be er now and for main future purpose – prognosis of qualita ve parameters of coal to be mined in near future (short term prognoses) – are sa sfying. Data transfer success rate is be er than 99% and average accuracy (RMS) of determina on of the 3D posi on of the centre of the wheel axis:
mxk = ±0,025 m myk = ±0,012 m mzk = ±0,041 m
THE MAIN GOALS
A er the research programme is completed, a complex system can come into being of measurement of posi ons of mining mechanisms, which could be beneficial in mul ple areas:
Mining of coal, striping and combined haulage levels: Visualisa on of the posi ons of excavators and their movements and eleva ons in real me at earmarked computers connected to the network and provided with relevant so ware.
Informa on on the posi on of the wheel in rela‐onship to the stratum profile or stripping level.
Saving of mining procedures and their retroac ve retrieval in both graphic and numerical forms (checking and analy cal purposes).
Control of crea on of movement surface/plane in real me and its immediate checks.
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Systemy Zarządzania w Inżynierii Produkcji/Management Systems in Produc on Engineering 2(2)/2011 7 D. SLÁDKOVÁ — The U lisa on of GNSS technology for mining process automa on
Computa on of qualita ve parameters of coal in real me with all excavators and simula on of the func ons of the qualita ve parameter meters.
Development of prognosis of qualita ve parame‐ters of coal to be mined in near future (short term prognoses).
Computa on of volumes of mined materials in real me (the volumes of mined materials will be
known with almost “surveying” accuracy immedia‐tely a er the relevant period – day/month).
Measurement of extension of the wheel boom. Facilita on of the Opera ve Control of Mining: In a modified form, the applica ons can also by
used in notebooks and PDA. The data can hence be available anywhere in the field.
Mine planning: Automa c and con nuous updates of the condi on
of haulage levels in the mining model. Checking of adherence to technical regimes, inclu‐
ding mine planning maps or long term mining goals (posi on and eleva on parameters of advances).
Determina on of the ini al condi ons for prepara‐on of next month’s advance on the basis of actual
advance in the ongoing month. Con nuous calcula‐on and detailing of the limits of start and end of
advance in the next month (period).
CONCLUSIONS
The process of mining of industrial minerals in rather complicated geological condi ons (variable morphology and qualita ve parameters – both ver cally and horizontal‐ly, occurrence of idle underground mines etc.) cannot be presently fully automated, as is nowadays commonplace in. e.g. electrical engineering, in industry of manufacture of simple mechanical engineering products or in the food in‐dustry. Nevertheless, the developments in informa on
technologies as well as in other technologies enable to expedite the feedback within the line of “planning – imple‐menta on‐check”. Informa on on where an excavator ope‐rates and what is being mined can be acquired (with some degree of inaccuracy) immediately. It is cri cal now if such mechanisms can be created that can exploit this data and influence the produc on process. In the mean me we are at the beginning of resolving the task, to which mul ple disciplines will have to contribute. Through resolving the issue of accurate and reliable determina on of the 3D posi‐on of the opera ng machineries and associated mecha‐
nisms in mines, the mining engineers, surveyors, geologists, reclama on engineers and managerial staff will acquire a tool for be er control and ensuing checks of produc on processes during open cast mining of industrial minerals.
REFERENCES
[1] Rucký P., Blovský J., Vrubel M.: Některé zkušenos s aplikací GPS v povrchovém dobývání na DNT–SD a.s. a v Porýnském revíru. Uhlí ‐ Rudy ‐ Geologický Průzkum. Nr 2, 2004.
[2] Rucký P.: Výzkumná zpráva VÚHU č.262/97 „Komplexní ověření aplikace systému GPS na kole‐sových rýpadlech DNT‐SD, a.s. pro opera vní řízení a kontrolu těžby uhlí a skrývky“. 12.1997.
[3] Vrubel M.: Geologický model. Zpravodaj SHD. 03.1991. [4] Vrubel M.: Objemový a báňský model lomu. Zpravodaj
SHD 03.1992. [5] Vrubel M.: Prognózní model a možnos jeho. Procee‐
dings of conference „Brown coal 1994“. 10.1994. [6] Talácko M.: Systém pro sledování prostorové polohy
kolesa rypadla K 800/N1. Technical Report. 03.2007. [7] Vrubel M., Sládková D., Talácko M.: New possibili es
of GPS technology in mine surveying. Proceedings of the 13th Interna onal Congress of ISM. Budapest 09.2007.
Ing. Dana Sládková, Ph.D. VŠB – Technical University of Ostrava Faculty of Mining and Geology Ins tute of Geodesy and Mine Surveying 17. listopadu 15/2172, 708 33 Ostrava‐Poruba e‐mail: [email protected]