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Optimising Loader Performance
Andrew Jessett
a.Jessett@mineware.com
Outcomes through Innovation
1. MineWare – an introduction
2. Some new technologies:
1. Loader based payload
2. Machine terrain mapping
3. Questions
MineWare
Office
Installations
MineWare provides monitoring system for:
Electric rope shovels
Hydraulic excavators (face shovels / back-hoes)
Draglines
AIMS:
Provide operators with real-
time in-truck payload
feedback to better control
loading process
Provide system to monitor
truck on-board weighing
systems
Work on electric and
hydraulic machines
Stay within CAT 10/10/20
rule
Technology 1: Loader Payload Management
Optimum
Truck
Payload
Reduce
Opportunity
Cost, avoid at-
face dumping
due to
overloads
Maximise
Circuit
Productivity
Reduce Truck
bunching/
queuing
Reduce Truck
and Road
Maintenance
Cost
(10/10/20)
Potential to
reduce # of
trucks
Reduced
spillage from
overloads
Argus Loader Based Payload Benefits
Increase average truck
payload, decrease variability
= more production +
less overloads
Why Loader Based Payload?
Truck systems not as accurate while loading
Truck payloads at point of load Vs second
gear reweigh
• Its real-time!
• Continued calibration of trucks is
difficult
• Some trucks have no weighing
system
• Most accurate truck weighing
occurs on ‘second gear reweigh’
Calculating Payload
Test Point
Test Point
Strain Gauge
Rope Shovel Hydraulic Shovel
Strain Gauge
Detecting the Truck
RFID Tag
RFID Tag
RFID Reader
RFID Reader
Argus Shovel Monitor
The approach: technology and simple feedback:
New Truck
Arrives
RFID
system
determines
Truck ID
Capacity of
truck
provided to
operator
Argus
payload
system
calculates
load for
each pass
Operator
provided
real-time
‘remaining
tonnes’ to
full load
Truck
loaded
correctly
and
dispatched
Visual Feedback
during loading
to operator
Example of Feedback
Real Time
Payload
Feedback per
load
Real Time
Operator KPI
Feedback
Results
Before Argus After Argus
AIM:
Provide a simple, effective,
low-cost system for real-
time monitoring of plan
compliance for loaders
Technology 2: Machine Terrain Mapping
BENEFITS:
Real-time feedback to operators on
compliance to excavation design =
better execution
Ability to engineers to easily monitor
excavation progress and forecast
Basic calculations of volumes
Visually represent data such as
production rates, operator technique
All done with existing sensors /
processors
How it works:
Uses real-time knowledge of track & teeth positions to generate a
real-time excavation map. This is then compared to design
Misfire Safety Marker
Colour Coded
Compliance to Plan
Indicators
Track Machine Position
Sequence per Plan
Strip Mine Example
Operator Screen
Example detection of non-compliance to plan
Similarly on a Back-
hoe
Better data replay abilities
Capability to calculate time to end of strip/design based on
historical rates
Sharing maps in real-time between machines (inc. dozers
and other mobile equipment)
Augment maps where other data sources available – i.e.
lydar, drones, scanners, etc. Export to planning packages
Look at estimating face shape (stability), stand-off distance
guidance, and incorporating excavation ‘technique’
guidance.
Technology 2: Future Work

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Optimising Loader Performance - Mineware

  • 1. Optimising Loader Performance Andrew Jessett a.Jessett@mineware.com
  • 2. Outcomes through Innovation 1. MineWare – an introduction 2. Some new technologies: 1. Loader based payload 2. Machine terrain mapping 3. Questions
  • 3. MineWare Office Installations MineWare provides monitoring system for: Electric rope shovels Hydraulic excavators (face shovels / back-hoes) Draglines
  • 4. AIMS: Provide operators with real- time in-truck payload feedback to better control loading process Provide system to monitor truck on-board weighing systems Work on electric and hydraulic machines Stay within CAT 10/10/20 rule Technology 1: Loader Payload Management
  • 5. Optimum Truck Payload Reduce Opportunity Cost, avoid at- face dumping due to overloads Maximise Circuit Productivity Reduce Truck bunching/ queuing Reduce Truck and Road Maintenance Cost (10/10/20) Potential to reduce # of trucks Reduced spillage from overloads Argus Loader Based Payload Benefits Increase average truck payload, decrease variability = more production + less overloads
  • 6. Why Loader Based Payload? Truck systems not as accurate while loading Truck payloads at point of load Vs second gear reweigh • Its real-time! • Continued calibration of trucks is difficult • Some trucks have no weighing system • Most accurate truck weighing occurs on ‘second gear reweigh’
  • 7. Calculating Payload Test Point Test Point Strain Gauge Rope Shovel Hydraulic Shovel Strain Gauge
  • 8. Detecting the Truck RFID Tag RFID Tag RFID Reader RFID Reader
  • 9. Argus Shovel Monitor The approach: technology and simple feedback: New Truck Arrives RFID system determines Truck ID Capacity of truck provided to operator Argus payload system calculates load for each pass Operator provided real-time ‘remaining tonnes’ to full load Truck loaded correctly and dispatched Visual Feedback during loading to operator
  • 10. Example of Feedback Real Time Payload Feedback per load Real Time Operator KPI Feedback
  • 12. AIM: Provide a simple, effective, low-cost system for real- time monitoring of plan compliance for loaders Technology 2: Machine Terrain Mapping BENEFITS: Real-time feedback to operators on compliance to excavation design = better execution Ability to engineers to easily monitor excavation progress and forecast Basic calculations of volumes Visually represent data such as production rates, operator technique All done with existing sensors / processors
  • 13. How it works: Uses real-time knowledge of track & teeth positions to generate a real-time excavation map. This is then compared to design Misfire Safety Marker Colour Coded Compliance to Plan Indicators Track Machine Position Sequence per Plan
  • 16. Example detection of non-compliance to plan
  • 17. Similarly on a Back- hoe
  • 18.
  • 19. Better data replay abilities Capability to calculate time to end of strip/design based on historical rates Sharing maps in real-time between machines (inc. dozers and other mobile equipment) Augment maps where other data sources available – i.e. lydar, drones, scanners, etc. Export to planning packages Look at estimating face shape (stability), stand-off distance guidance, and incorporating excavation ‘technique’ guidance. Technology 2: Future Work