Opportunity area

In-Mine

By taking advantage of new technologies, operators can benefit from smarter, safer, more cost-efficient transport. Autonomous trucks can move materials quickly and reliably, aided by built-in sensors to avoid collisions. And with advances in sensors and analytics, operators can carry out preventive maintenance and improve the lifespan of their transport assets.

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Analytics to reduce fuel and tyre consumption

Fuel and tyre consumption are significant cost drivers for any mining operation. This solution can significantly decrease these costs and improve truck flow across the site. It works by gathering information about the environment, operator and equipment through drones and GPS. Using data analytics, the tool then calculates optimal fleet parameters such as maximum vehicle speed, load size and road surface conditions. It’s ideal for complex, multi-shaft operations, or for fleets of older trucks with decentralised dispatching.

7%

Decrease in fuel consumption

12%

Decrease in tyre consumption

14%

Increase in run of mine (RoM)

Trolley assist system for climbing routes

Designed to help fully loaded dump trucks move materials up slopes without straining their engines, this trolley-assist system allows vehicles to move faster while consuming less fuel. The system works by supplying electricity to the vehicle’s diesel engine from a nearby substation via overhead power lines. This frees up engine capacity so the vehicle can generate more pushing power and climb slopes faster. This improves truck speed, mine production capacity and truck maintenance costs at the same time. As an additional benefit, truck emissions and noise are reduced, resulting in better environmental performance.

20%

Potential increase in mine production capacity

80%

Potential increase in speed

95%

Lower diesel consumption

Electric fleets for cleaner air in deep mines

These fully electrified trucks bring ore from ultra-deep mines to the surface, reducing the need for often exorbitant ventilation costs. The trucks are powered by batteries connected to four electrical engines, instead of traditional fuel combustion engines. Traction is distributed to both truck axes simultaneously for reliable movement within the mine. An emergency traction system also ensures the vehicle can move even if an engine fails. As well as reducing ventilation requirements and costs, using fully electrified trucks means cleaner air as well as reduced noise and heat in the mine.

70%

Reduced truck energy consumption

Real-time equipment health monitoring

This solution provides real-time monitoring and assessment of transport equipment health to help prevent emergency breakdowns. Using sensors, software and a communication network, it tracks and reports on factors like oil and lubrication, vibration and acceleration and fuel consumption. The data is compiled in a central database, where operators can see at-a-glance indicators of equipment status, alongside instant breakdown notifications. This can lead to increased throughput and equipment availability as well as lower operational costs, thanks to an improved ability to perform preventive maintenance.

80%

Increase in equipment availability

25%

Reduction in workforce required

10%

More work orders completed per technician

Autonomous ore haulage trucks

Autonomous vehicles are an increasingly common feature of different mining environments. This sophisticated remote-controlled navigation, high-precision GPS and obstacle detection system allows for partial or full automation of haulage fleets at a rapid rate.Implementing this technology can reduce the number of security events, and help achieve significant productivity improvements by reducing unscheduled stops and maximising travel speeds where terrain permits.

15%

Productivity increase

Laser beam 3D mapping and obstacle detection

This LiDAR system helps vehicles to avoid colliding with obstacles inside mines with poor visibility. It uses rebounding laser beams to detect and notify operators about rocks and other obstacles that could damage vehicle wheels, or even cause a serious incident. The solution also provides a 3D map of the environment, which can be used to gain better visibility and control over the ceiling stability.

Anti collision system

The Collision Avoidance Systems (CAS) technology helps prevent vehicles from colliding with nearby objects or vehicles. The technology is installed on existing vehicles and incorporates proximity sensors, radio wave ID tags, radars and GPS. When the equipped vehicle is dangerously close to another object or vehicle, the technology detects and activates systems such as sound alarms, brakes and steering. CAS technology can also be applied to autonomous vehicles. The CAS system can also be linked to a Collision Warning System, which only sounds alarms to alert the driver to danger.

50%

Reduction in over-speed events

85%

Of operators confident that the system provides additional safety

$300k

Annual savings on tyres for an average-sized mine

Robotic dump trucks

Dump truck fleets can now drive autonomously, thanks to a solution that combines GNSS navigation, machine vision and physical sensor technology to move along a route and avoid collisions. As well as improving safety by reducing the need for workers to drive in hazardous environments, this solution increases the efficiency of fleet use, reduces operational expenditure and boosts productivity.

25%

Increase in productivity

30%

Reduction in operational expenditure

24/7

Dump truck operations

Digital twin to optimise crane navigation

Crane logistics are often complex to manage and can cause operational delays and other inefficiencies without the right strategy in place. This digital tool helps to optimise crane movements by identifying the root cause of crane allocation conflicts and modelling potential mitigation strategies. Using validated inputs based on production data, the solution can help to remove bottlenecks and provide a pathway to expansion. It is ideal for use in multi-suspension crane workshops.

25%

Increase in production

Smart lubricant monitoring

An “always on” smart lubricant monitoring service delivering actionable insights and recommendations to help understand and improve equipment health, increase uptime and reduce costs.

45%

of defects due to poor monitoring

61%

believe they could reduce maintenance costs

~6months

RoI

Fleet Management Platform

Tracking and managing fleets of heavy equipment is a complex task and the costs to the industry are significant. However, productivity can be boosted and significant savings made using technology.

This solution is a cloud-based digital service for off-highway vehicles and fleets. It uses existing machine data or wireless smart sensors, combined with AI and ML to deliver powerful actionable insights. This helps operators and site managers to improve fleet operations and maintenance and reduce costs.

5%

increase in machine productivity

10%

decrease in machine rental cost

30M

machines unconnected worldwide

Radar and video anti-collision system

Driving large trucks in open pit mines can risk collisions with other equipment as well as presenting significant safety hazards. This computer vision solution uses proximity sensors, RFID tags, radars, cameras and GPS to detect and activate systems such as sound alarms, brakes and steering when a vehicle is at risk of a collision.This is particularly useful because of the blind zones created by these large vehicles. The technology vastly reduces the probability of emergencies during manoeuvres in parking lots, dumps and places with a high volume of vehicles.

Fleet location and performance tracking

Designed to optimise fleet management, this compact wireless multi-grade magnetic sensor device tracks the location and performance of individual vehicles. Containing a GPS tracker plus movement, heat and humidity sensors, it can be installed within one minute with no engineering work required and can also withstand temperatures from -40°C to +60°C. The vehicle’s movement and engine performance is tracked live and uploaded to the cloud through a wireless gateway device. Data from numerous vehicles is collated in a digital dashboard, allowing managers to track their entire fleet. The resulting insights help operators to minimise idling, reduce rental costs and increase productivity.

5%

Increase in machine productivity

10%

Decrease in machine rental cost

Our team has decades of collective experience, spanning all areas of industrial operations.

Dr Nick Mayhew

Chief Commercial Officer

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