modern trends in drill navigation and case studies … · the 'state of the art' in...

The South African Institute of Mining and Metallurgy RISE OF THE MACHINES-THE 'STATE OF THE ART' IN MINING MECHANISATION, AUTOMATION, HYDRAULIC TRANSPORTATION AND COMMUNICATIONS Casper Swart

MODERN TRENDS IN DRILL NAVIGATION AND SYSTEM INTEGRATION.

CASE STUDIES FROM BOLIDEN AND KEMI UNDERGROUND MINES

Mr Casper Swart Atlas Copco Rock Drills AB, Sweden

Navigation of drill rigs, both in mining and tunnelling applications is a time consuming and tedious task. Precise navigation is necessary when correctly placement of the drift is required and production round logs needs to be analysed.

Atlas Copco has developed an option to the drill rigs with the RCS control system to facilitate orientation and navigation. This option helps the driller to locate the rig position and to navigate the rig. Depending on the equipment (theodolites, laser beams, total station) used by the mine there are several alternatives for the final step in navigation.

Navigation and mine map orientation is just one step in the complete integration . of the underground machines into the mine computer/administrative network. One important cornerstone is effective and automatic communication with underground vehicles. By using existing commercial equipment, underground communication is quite feasible. The Atlas Copco underground vehicles can be equipped with the Rig Remote Access option and integrated into LAN networks in the mines.

These two options are in Boliden mines in Sweden (Mine Map Navigation) and in the Outokumpu's Kemi Mine in Northern Finland (Rig Remote Access).

Mine design is transferred into the drill rig and displayed to the operator when he deploys the rig. After defining the ore volume to be drilled, a drill plan is generated on the drill rig. Every drill plan is thereby adapted to the actual conditions in the drift and correctly identified and navigated. Drill rigs are connected into the Ethernet WLAN communication network covering the whole new underground mine in Kemi. Drill plans, tunnel and laser definitions as well as round logs are automatically exchanged between the planning department and the drill rig. The drill rigs are also logically integrated into the information systems in Outokumpu's administrative organization.

These are some of the building block for automation integrated into the products from Atlas Copco Rock Drills AB.


1. Introduction

1.1 Atlas Copco Rock Drills AB

Based in Orebro, Sweden, Atlas Copco Rock Drills AB has, since 1998, introduced a number of new computerized products for underground excavation. The first product was a drill rig, introduced in 1998, the Rocket Boomer L2C.

Fig 1. Rocket Boomer L2C

The L2C was rapidly followed by Rocket Boomer L3C, Simba LIM C, Boltec LIM C, Raise Borers and lately LHD products. These products are all based on the same automation platform; the computerized Rig Control System (RCS, Fig 2). Today, the RCS is available in all of Atlas Copco Rock Drills AB product families.

Fig 2. The automation platform: RCS (Rig Control System)

The RCS can be extended with a wide range of options. The most recent additions, for the Rocket Boomer family, are the Mine Map Navigation, Drill Plan Generator and the Rig Remote Access (RRA) options.

1.2. Products - ABC Regular and ABC Total

One basic cornerstone for the RCS options in the Rocket Boomer Gumbo) family is the ABC Regular. This automation option includes, what previous was called Contour Control:

11 Computer guided positioning of booms and feed according to pre-selected drill plan 11 Boom position feedback on operator's display


III Navigation to tunnel laser " Logging of drilled hole on PC-card. 11 Planning and evaluating tool Tunnel Manager

Fig 3. ABC Regular

ABC Regular Boom and teed moved by opemror'

ABC Regular can be extended to the next level of automation - the ABC Total: 11 Computer guided positioning of booms and feed according to pre-selected bolt plan. III Automatic round drilling from pre-selected drill plan. 11 Electronic parallel holding 11 Hole to hole move strategy III Boom collision control III Hole sequence programming.

ABC Total

AdditionaL /iatures: I·Me 5efI.~ pro9mmmLrl9 CcU/sLon contro~ of boo)1J5

Fig 4. ABC Total These ABC configurations are the basis for the two new options described in this paper.

2. Boliden Mines, Sweden

2.1 Background

Boliden operates mines in Garpenberg and in the Boliden Area (BAO) in northern Sweden.


Fig 5. Boliden Mines in Sweden

Starting 1999 with two drill rigs (Rocket Boomer L2C) in the Garpenberg mine, the Mine Map Navigation system has now been expanded and is in use also in the mines in Boliden Area.

The Boliden ore bodies form narrow winding layers embedded in the surrounding granite, which are hard to estimate without extensive exploratory drilling. To be able to follo~ the windings with the drifts, information such as production map, geologist's estimates, previous rounds, levels and accurate drill rig navigation are essential. A typical ore deposit is shown in fig 6.

Fig 6. Ore deposits with winding ore bodies

2.2 Mine Map Navigation

The system introduced in the Boliden mines links the planning department with the drill rig operator. Data prepared in Tunnel Manager in the planning department is transferred into the drill rig.


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,J~~t;~~~i'" BOlidenpl~n~ ! department -...

Rocket Boomer L2C

Fig 7. Planning department linked to the drill rig

The production map and the reference points are exported via Tunnel Manager. Drill plan parameters are added and the prepared information is stored on disk. When the driller starts his shift the prepared data is loaded into the drill rig and used for navigation and drill plan generation. The Mine Map is hierarchically displayed to the operator, who chooses the current level, area and drift. The Mine Map is gradually zoomed up to the face of the drift.

Fig 8. Current drift with reference points

Actual navigation is made with a theodolite or total station and the reference points. Once navigated the drill rig position is visualized in the Mine Map and the planned volume is presented to the operator on the standard display.

The South African Institute of Mining and Metallurgy RISE OF THE MACHINES-THE 'STATE OF THE ART' IN MINING MECHANISATION, AUTOMATION, HYDRAULIC TRANSPORTATION AND COMMUNICATIONS Cas per Swart

Fig 9. Planned volume presented to the operator

The operator can adjust sides, roof, and bottom and can place the cut in an optimal position. Every adjustment is directly confirmed on the screen.

2.3 Drill Plan Generator

When the operator is satisfied with the volume to be drilled he generates the drill plan.

Fig 10. Generated drill plan ready to be drilled

A drill plan is generated based on the parameters from the planning department which include experience of rock mechanics and blasting techniques. Several sets of parameters can be used for different rock conditions for various areas of the mine to gain optimal fractioning and production.


2.4 Experiences

The experiences from the end user and Atlas Copco can be summarized as: Introduction has been easy and fast. It has been possible to keep the drifts according to the planned design. The quality of drillinglblasting has improved because of correct drill plans. Drilling capacity has increased due to the fact that the driller always has a correct drill plan to follow. Though the ore deposits are complicated, the drifts can now be well adapted to the planned ore boundaries. The system is setting demands on the planning department. Reference points must be available. Production map must be regularly updated. Utilization of drill rigs has been improved, calculated in tons/percussion hour. Less waste in the ore, though exact figures are not yet ready. An estimated 5% less waste gives a short payback of the project.

3. Outokumpu Kemi Mine, Finland 3.1 Background

In Northern Finland, Outokumpu's Kemi chrome mine and Tornio Ferro Chrome and Steel works form a modem and effective production unit. The Kemi Mine has been producing chromite ore in an open-pit mine since the late 1960s. Today the mine is transitioning from open-pit to underground mine in order to maintain a high level of production for many years to come. The open-pit is planned to be closed in 2008.

Fig 11. Kerni I\1inc (Outokumpu) and Orebro (Atlas Copeo)

The South African Institute of Mining and Metallurgy RISE OF THE MACHINES-THE 'STATE OF THE ART' IN MINING MECHANISATION, A UTOMATION, HYDRA ULIC TRANSPORTATION AND COMMUNICATIONS Casper Swart

Fig 12. Open-pit mine in Kemi

3.2 The Kemi mine network

The Kemi Mine has a communication and data network that covers the whole mine. It is an Ethemet based 1 gigabit network, based on commercial available equipment. The backbone of the network uses optical fib er, while the distribution nodes are WLAN base stations. By using WLAN the miners are close to a network connection at all locations.

Fig 13. Backbone network and WLAN base stations

The South African Institute of Mining and Metallurgy RISE OF THE MA CHINES -THE 'STATE OF THE ART' IN MINING MECHANISATION, AUTOMATION, HYDRAULIC TRANSPORTATION AND COMMUNICATIONS Casper Swart

Basic strategy for the data handling in the Kemi Mine is to collect data only once at the source that generates the data. An example is that the amount of drill meters is not typed in by any driller or foreman, but instead automatically reported from the drill rig itself. The data control strategy of Outokumpu can be summarized as follows:

A network to transmit data is needed The network shall have capacity to transmit all kinds of data with high speed

and throughput All data shall use the same network (instrumentation, phone, video, data etc.) WLAN is the solution for the mobile connections

Even though the computer/data systems in Kemi Mine are as diversified as in any other mine, the data control system turns everything into one integrated system. Behind the central system there are several different data collection and handling systems in use. They are:

Main frame solutions, stock control, payroll administration Rock mechanics data collection from data-logger Manual data collection Windows, NT4, W2K and XP based programs MS Office and Excel Mine planning, surveying and cad-programs etc.

This is all turned into one virtual system:

Virtual networks VLAN

Fig 14. One virtual system


As Fig 14 indicates also the drill rigs are an integrated part of the system. This is thanks to the RRA option for all three types of drill rigs in Kemi, the Rocket Boomer L2C, the Simba M6C and the Cabletec. The drill rigs and other locations as well, can be equipped with web cameras. A positioning system is an integral part of the WLAN network in the mine. The planning department always know where the drill rigs are deployed for the moment.

3.3 The Rig Remote Access

The Rig Remote Access (RRA) gives the mine the ability to connect the drill rigs to the internal network in the mine.

The RRA consists of a communication server onboard the drill rig and a network adapter. The server renders the user three functions; one is a web server answering to a standard web browser!; the second is a FTP server enabling transfer of data (files) to and from the drill rig and the third is a server process that enables data to be integrated into the user's administrative systems.

Fig 15. Rocket Boomer L2C with the RRA option

Using available uncritical "office" networks on the work site restricts the functionality to remote access, not permitting remote control, but makes it easy to install into existing infrastructure.

Standard communication equipment is used to make the RRA easy to upgrade and adapt to nevv and more effective equipment "vvhen available. The system utilizes standard communication protocols such as ppp2 or TCPlIp3

.

Benefits with the RRA system:

I E.g. Internet Explorer 2 PPP Point-to-point protocol 3 ::::: Internet protocol

The South African Institute of Mining and Metallurgy RISE OF THE MACHINES-THE 'STATE OF THE ART' IN MINING MECHANISATION, AUTOMATION, HYDRAULIC TRANSPORTATION AND COMMUNICATIONS Cas per Swart

The administrative system can automatically be updated with the latest infonnation, without time-consuming manual.handling.

The drill rig operator always has access to the latest production planning. Since all log files automatically will be saved to the planning department,

there is no need to hand write work reports after each shift. Instead of forcing work orders to be written before each shift, orders can be

issued even during the shift and directed onto the specific drill rig. Fault diagnostics can be conducted remotely. Service planning can be based on actual needs.

3.4 Integrated functions

As the drill rigs are integrated into the network there are a number of functions that are available. First and most visible, you get access to the same menus as in the drill rig just using a standard web browser. This gives you the ability to check status of the ongoing work and be prepared for the next task for the drill rig.

Through the web interface, the maintenance personnel can access status and faultfinding menus. The service technician can diagnose problems on the drill rig and e.g. estimate if it's possible to wait with the repair or advise the driller to repair. The technician might also prepare himself for the repair and bring the appropriate spare parts with him, when he goes to the drill rig.

The RRA gives the on-site maintenance personnel the ability the get backup from local or central Atlas Copco service organization. Kemi Mine has set up a secured Internet access to the network and the drill rigs. Atlas Copco maintenance personnel in Finland can assist local technicians of the Kemi Mine to diagnose the drill rigs and advise the change of settings or repairs. On-line assistance from central Atlas Copco in Orebro is also possible. Via the RRA you can not change anything on the drill rig, just observe and prepare. Preparations include changing settings and updating software, all which must be activated locally on the drill rig.

Log files that have been saved, manually or automatically, on the drill rig can be retrieved via a FTP program.

The South African Institute of Mining and Metallurgy RISE OF THE MACHINES-THE 'STATE OF THE ART' IN MINING MECHANISATION, A UTOMATION, HYDRA ULIC TRANSPORTATION AND COMMUNICATIONS Casper Swart

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Fig16. Drill plan from mine Cad Fig 17. MWD log generated by Simba

3.5 RRA Server

To increase the benefits even further, Atlas Copco has developed an automated system for exchanging data with the drill rig. In this system, all drill rigs act as clients that communicate with a server application called RRA Server, which runs on a PC in the mine network. The RRA Server system keeps track of drill rigs in the computer network and the data they produce and consume. The drill rigs will be virtually available even when they are outside the network.

machine!oq .(fl.BQb.y}fll9.m~..Mg§

El 0 Simba LSC (off-line) . status: listening for connection ...

seria~ 8S9130750[) machine It)g

Fig 18. RRA Server menus

The RRA Server acts as a buffer that automatically exchanges data with the rigs as they become reachable through the network. Now the drill rig just has to pass an access point to be virtually on-line all the time.


Personnel at the planning department, working with the Manager4 and mine design programs, can prepare work orders (drill plal1s etc.), download them to the drill rig, get drill logs and statistic logs back, as if the drill rig always is on-line.

Fig 19. Atlas Copco drill rigs connected to a RRA Server

4. Conclusion

Using commercially available equipment to design communication facilities for the drill rigs and to set up a network covering an underground mine has been very successful. The hardware and software design efforts have been kept at a very low level. Upgrading with new and better components and adding new functionalities has been easy.

Using the WLAN standard, IEEE 802.llg has proven to be effective and to fulfil the requirements.

Designing the RRA function was fairly straightforward, once the decision was taken to adapt to commercially standards.

Integration of several different systems has been facilitated by the IREDES standard. Today drill plans can be generated directly in the system for mine planning and exported into the production drill rig in the IREDES format.

The remote maintenance has already proven to be useful. Updates and corrections have been easv and fast to carrY out. Co-operation between local technicians ~md Orebro-based R&D and service departments is in standard use, when needed.

The integration helps the mine management to set up a system with better mine process control

4 Tunnel Manager™, ORE Manager™ and ROe ManagerTM

The South African Institute of Mining and Metallurgy RISE OF THE MA CHINES -THE 'STATE OF THE ART' IN MINING MECHANISATION, AUTOMATION, HYDRAULIC TRANSPORTATION AND COMMUNICATIONS Casper Swart

The biggest challenge, that was not foreseen, has been to build connections between private networks over Internet passing through several firewalls. Setting up access paths with correct communication security takes a lot of time and are very sensitive to any change in the networks.

From the installation of the RRA communication in the Kemi Mine we have earned a lot of experience to handle network-to-network connections in a secure way, still maintaining a high level of service.

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