A Way To Safer Shovelling

AUSTRALIA’S MINING MONTHLY – JULY 2010

Simulators can prove to be a shovel operator saving.

It is not just the productivity improvements that come from having more efficient operators. There are a host of other, potentially machine saving benefits.

One of the big benefits of simulators is that they allow trainers to put their subjects through scenarios they would never consider conducting in real machines.

Take hydraulic failures, for example. No trainer is going to deliberately shut down the hydraulics on an operating shovel to see if the trainee knows what to do. But in a simulator that is quite feasible. This allows the trainee to practise the correct procedures for dealing with such a calamity so it becomes second nature.

“Each operator’s dig, swing, dump and return phases are individually monitored for each pass.”

Simulators have another advantage. All the processes are computer generated and therefore the entire training process is monitored and recorded. This helps the trainer monitor how the trainee is going.

For example, in shovel operations each operator’s dig, swing, dump and return phases are individually monitored for each pass. This constant monitoring gives the trainer an advantage when training operators by automatically flagging incorrect operating procedures. They can then rectify the procedures with the trainee and monitor the improvement to achieve larger shovel loads and quicker cycle times.

Thoroughtec Australasia director Brad Rouse said simulators should not be seen as a cost.
“The initial capital outlay of simulators is marginal when one considers the improvements simulator training is able to offer,” he said.

“Considering that some users are recovering the initial costs in as little as six months, the savings that are transferred to the min in the simulator’s lifespan are colossal. Many users of the Cybermine simulator system report that the cost of the simulators system is more than covered by improved operator performance and subsequent reduction of operational damage to equipment.”

South African-based Thoroughtec offers a range of simulator options for most pieces of mining equipment, from draglines through to underground development drills.

In the shovel sphere the simulated cab is placed on top of a six degree of freedom motion platform that imparts the rotation and acceleration effects expected with shovel operation.

Additionally, the three-dimensional surround sound high-contrast projected displays immerse the trainee in a high-fidelity virtual environment.
Adding to the reality is Thoroughtec’s advanced soil interaction models. These allow trainers to specify soil properties, requiring the operator to exercise correct digging techniques to obtain efficient bucket fill factors.

Anglo Platinum Mechanised Training Centre human resources development manager Corrie Smith said: “From what we’ve seen in the international industry, Cybermine simulators offer by far the greatest simulated realism, essential for the correct training of operators of complex pieces of mining equipment to optimise safe use and minimize cost per tonne extracted.”