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2006 mine integration plan

Plan presented to a number of Mining companies.

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2006 mine integration plan

  1. 1. www.ict.csiro.au Elliot Duff Mining Robotics Project Autonomous Systems Laboratory CSIRO ICT Centre QCAT Brisbane Mine Integration Plan
  2. 2. www.ict.csiro.au Projects, Past Present and Future Sensor Networks for Coal Prep plants ACARP C11009 (03-04) Open Cut Automation ACARP C11054 Traffic Management Truck path planning ACARP C13041 (2004-05) Excavator Guidance Laser based measurement ACARP C14043 (2005-06) Dragline Swing Assist Algorithm Refinement ACARP C13040 (04-05) Digital Terrain Mapping Calibration and Integration ACARP C13034 (2004-05) Rope Shovel Automation Auto digging on scale model ACARP C12030 (2003-04) Trayscan Truck Load Volume Transcale ((2000-2004) Automated LHD's Commercial Prototype AMIRA/Caterpillar (99-03) Automated Explosive Loading Proof-of-Concept ORICA (2000-01) Shovel Dipper Volume Laser Scanning Feasibility BHP (1998) Automated Haulage GPS and INS guidance Komatsu & Caterpillar Dragline Swing Assist Feasibility demonstration ACARP C5003 (1996-98) Digital Terrain Mapping Proof-of Concept ACARP C10039 (2001-02) Dragline Swing Assist ACIRL Scale Model ACARP ME3 (1994-95) Dragline Swing Assist Production field trials ACARP C9028 (2001-02) Automated Explosive Loading Commercial Prototype ORICA (2005-) Rope Shovel Automation On production shovel ACARP proposal Shovel Force Feedback Based upon DTM and performance ACARP proposal Boom Monitoring Wireless sensor network ACARP Automated Dragline Integration of DSA with DTM ACARP proposal Wireless Sensor Network for Mine Environment ACARP proposal ELAP Prototype ORICA (2002) Automated Explosive Loading Feasibility Study - Vision and Laser Scanning ORICA (1998-99) Rope Shovel Automation Auto loading / face mapping ACARP C14058 (2005-06) Surface Mining Completed Commercialized Current Proposed HMC Automation Auto Tramming Alcoa (2005-06) Software development RTX & DDX Hardware development IMU & IMU
  3. 3. www.ict.csiro.au Dragline Swing Assist (DSA) • Since 1994 we have been automating a large part (80%) of a dragline’s cycle (swing, dump and return). • We have installed two systems on production machines • In 2003 we ran a two-week production trial on the BE1350 • This work has been supported by five ACARP projects Optimized swing path
  4. 4. www.ict.csiro.au Dragline Digital Terrain Maps (DTM)  We have installed a protype system on a BE1350 dragline at Boundary Hill (Callide)  It assists the operator in excavating to specific bench heights with increased precision and confidence.  It displays a high resolution image of spoil pile and the surrounding terrain.  DTM can also guides the operator in correct movement and positioning of the dragline tub.  This work has been supported by two ACARP projects
  5. 5. www.ict.csiro.au DTM Masterplan Overview Images include cross-section, plan view or 3D. Operator prompts include a tub positioning reference and critical dig lines The elevation image is shown. Plan package will also utilise colours and effects to highlight variations between the dig and actual plan
  6. 6. www.ict.csiro.au DTM – Direct Operator Benefits…  It visually prompts the operator where to dig and dump overburden as per the dig plan.  Masterplan clearly and immediately highlights variations between the actual dig and the planned excavation.  Greatly aids in reducing excessive rehandle.  It assists the operator in excavating to specific bench heights with increased precision and confidence.  It displays a high resolution image of spoil pile and the surrounding terrain.  DTM can also guides the operator in correct movement and positioning of the dragline tub.
  7. 7. www.ict.csiro.au Rope Shovel Automation (RSA)  Automation of these machines could lead to significant productivity improvements  In 2003/04 we demonstrated autonomous digging on a scale model (1/7 th) machine (this work was supported by ACARP)  We are now running a second ACARP project to further progress the system and autonomously dump into trucks (scale model)
  8. 8. www.ict.csiro.au Shovel Traffic Control A combination of sensors will: • Generate a DTM of the local environment • Enable the swing loader to locate each haul truck as it approaches • Provide communication from the swing loader to each haul truck Develop a system which schedules and directs haul truck drivers to an optimum loading position for a swing loader. Handover Zone Work Zone Incoming Trucks Outgoing Trucks Obstacle
  9. 9. www.ict.csiro.au Excavator Guidance and Measurement Laser scan of terrain and bucket location
  10. 10. www.ict.csiro.au Truck Volume Measurement (Trayscan) Trayscan is an automated system that measures the volume of material in the tray of haul-trucks using laser-scanning technology. This technology provides the ability to measure the volume in-situ, whilst the truck is moving. Commercialised through Transcale.  A 3D profile is generated, as the haul truck drives under scanning laser.  The in-situ volume is estimated from a comparison of empty and full trucks.
  11. 11. www.ict.csiro.au Load Haul Dump (LHD) Automation  Demonstrated full speed operation at NorthParkes Mine  System based upon reactive navigation requiring no guidance infrastructure  Navigation technology licensed to DAS (CEPL) with commercial system launched April 2003  Pre-production prototypes developed for a three type of LHD including electric machines Automated CSIRO loader tested at Northparkes mine Automated Tamrock electric LHD from Northparkes at QCAT
  12. 12. www.ict.csiro.au Automation of Explosive Charging (AOC)  We have developed a robotic charging unit to automatically charge blast holes in underground metal mines (ORICA)  A scanning laser is used to create a 3D map in order to locate a ring of blast holes  A vision system is used to guide a hose into the collar of each hole
  13. 13. www.ict.csiro.au Autonomous Hot Metal Carrier • 30 tonne vehicle for navigation sensor • moving molten aluminium • Demonstrate full automation within the next 6 months • The vehicle is based on a large fork-lift truck • Will use laser scanners as the primary
  14. 14. www.ict.csiro.au Who are we ? Team Complement • 7.5 Research staff • 4 Engineering support – 2 engineers – 2 technicans • 1 BDM (theme resource) • 1 Executive officer (theme resource) • 2 Postdocs • 4 Co-supervised PhD students • Visitors (current) – 1 IAESTE intern – 5 undergraduate students Disciplines/Skills • Electrical engineering • Mechanical engineering • Computer Science • Aerospace engineering • Physics & Applied maths
  15. 15. www.ict.csiro.au What we do? The intelligent connection of perception to action  Robot navigation  Relative & reactive navigation  Visual homing  Visual servoing  Multiple cameras with sensor fusion  Ranging and measurement  Laser imaging  3D imaging  Omni directional vision  Stereo vision  Agent based systems  Low-cost distributed sensor systems  Ad-hoc wireless networks  Real time computing  Distributed systems  Real time libraries  Embedded systems  High-performance control systems  Hydraulic  Electro mechanical
  16. 16. www.ict.csiro.au Team Project Activities  External focus  Mining Robots • Unique issues facing mining sector: • Dirty, dusty, wet and hot • Constantly changing environment (the aim of mining!)  Strategic Focus  Competent vision-based navigation and control, • tested on our platforms: ground, air, underwater  Wireless sensor and actuator networks • Robot interaction & Environmental monitoring Deliver prototypes of complex engineered systems for non- traditional robotics applications (field/outdoor robotics)
  17. 17. www.ict.csiro.au Autonomous Underwater Vehicles (AUV) Starbug: Sea trials in Moreton Bay
  18. 18. www.ict.csiro.au Autonomous Land Vehicle • Experimental platform for land based navigation • Based on a ride-on lawnmower • Equipped with vision, laser scanner and magnetic compass • All computing on-board
  19. 19. www.ict.csiro.au Autonomous Aerial Vehicles Mark II – Mantis (2003) Mark I (1999-2002) • Experimental platform for testing CSIRO autonomous flight control system • Equipped with stereo vision, low-cost inertial sensors, magnetic compass and standard GPS • All computing on-board • We have developed a vision-based velocity and height estimation system • Currently investigating asset management and search support opportunities.
  20. 20. www.ict.csiro.au Cable-Array Robot • A set of spatially distributed motors which actuate cables connected to an end effecter – Similar to a Stewart platform • By changing the length of the cables, the end effecter can be moved • Examples include: – SkyCam – used in football stadiums for giving an overhead view – NIST robot crane – Quay cranes Schematic view of a cable-array robot end effecter actuator cables
  21. 21. www.ict.csiro.au Robotics & Sensor Networks Old thinking New thinking Robot carries/controls small number of expensive sensors Sensors are everywhere, robot asks for information Scientists go into field to gather data Robot goes into field to “harvest” data from sensors Robot goes into field to gather data itself Monolithic complex robot Multiple cooperating ‘physical’ agents
  22. 22. www.ict.csiro.au ADC/DIO Power Solar Programmer/ Serial port Connectors/ Mounting holes AdHoc Radio Networks Fleck 1  Temperature  ADC  DIO  Serial
  23. 23. www.ict.csiro.au AdHoc Radio Networks Fleck2  temperature  motion  compass  GPS  DIO/ADC  SD/MMC  Video
  24. 24. www.ict.csiro.au EiMU • Three solid-state gyros • Two dual-axis accelerometers • Three Honeywell magnetometers • HC12 based micro-controller • RS232 and Canbus outputs • Small: 50x50x50mm • Lightweight: 65g • Complementary filters for fusion
  25. 25. www.ict.csiro.au Navigation Technology • Laser Sensing – Reactive Navigation – Opportunistic Localization • Visual Sensing – Optical Flow (speed) – Stereo (range / height)
  26. 26. www.ict.csiro.au Navigation Technology Odometry: vision vs groundtruth
  27. 27. www.ict.csiro.au DDX: Distributed Data eXchange Local store C P C C CP P Local store internet Log file • Real-time publish and subscribe model • Shared memory within machine • Time stamping • Event handling & synchronization • Multicast between machines CPU2CPU1

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Plan presented to a number of Mining companies.

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