As Real As It Gets

INTERNATIONAL MINING – JUNE 2013

The market for simulator systems is still dominated by simulator specialists, who may supply simulators to mines directly, or be contracted to develop a simulator for a particular OEM. Gregory Lew, EVP and Director – Global Business Development at ThoroughTec told IM: “Simulators are developed according to industry demand, either specific demand when a customer requests a particular vehicle, or perceived demand when we predict future demand for a particular vehicle. Because of this policy, most current mining machines are simulated, although obviously the bigger OEM manufacturers are better represented.

At ThoroughTec we are continuously expanding our range, so as an OEM launches a new vehicle we look at potential customer demand before beginning development. OEMs do contract simulator specialists to develop simulators, such as when Sandvik contracted ThoroughTec to simulate a number of their underground products. It is more common, though, for simulator specialists to supply mines directly. In the case of CYBERMINE, we offer highly customised simulator solutions that cater for a particular mine’s needs such as their own operating procedures and mine worlds. In terms of input from the OEMs, all the information necessary for accurate simulation of mining vehicles is available in the public domain, if not directly from the OEMs.” In some cases the OEM will develop its own simulator solutions, but not usually in-house. Because simulation is not their core business it is usual that the OEM will outsource the simulator development. In these cases it is typically the development of cheaper, low fidelity, PC-based simulator systems with limited functionality.

“Underground simulation is now becoming more established globally.”

Underground Simulation
The surface equipment simulator market for mining machinery is still more mature than that for underground equipment in terms of the number of simulators sold, but in terms of levels of technology, those in the industry argue that surface simulation has not made significant technological advances in a number of years and actually lags behind underground simulation in this regard. Gregory Lew comments: “In global terms, the surface simulator market is more established, but in South Africa underground simulation is very well developed due to the local prevalence of underground mining.

ThoroughTec is a global leader in underground mining simulation, having been developing underground mining simulators for over a decade and having an extensive range of simulator cabs covering all vehicle classes and major OEMs, both hard rock and soft rock. Underground simulation is now becoming more established globally and ThoroughTec has CYBERMINE underground simulator systems, now in their fourth generation, operating in all major mining regions in the world.” Another difference is that the underground environment requires a 360 degree view and enclosed space to accurately simulate elements such as lighting, views and machines that often require sideways orientation or full walk around capacity.

Another challenge of underground mining simulation is the complexity of the mining machinery itself, which limits the number of simulator companies capable of producing accurate underground simulation systems. For example, a dual boom drill rig can have over 40 moving parts in the boom alone, when compared to a haul truck which has a total of just four, while articulated vehicles add yet another complication. The underground environment is also more difficult to accurately simulate, taking into account such factors as rock density and the resultant effect on drilling time, drill bit rotational speed and drill bit wear, not to mention the extra dimension of tunnels that need to be navigated. Factors such as water pressures, air pressures, feed pressures and rock fissures also need to be taken into account for authentic replication of the actual underground mining processes.

Mining software and Simulation Equipment
Simulation and general mine management and development software are considered by some as independent fields with little synergy across technologies and few cross functional benefits to the customer. Whereas equipment simulation is a first-person “human-in- the-loop” experience focused predominantly on increasing overall proficiencies of equipment operators, mine management software is focused on providing more of a “strategic” operational analysis and optimisation function. That said, the key simulator players have held discussions in the past with mine management software vendors with a view to reviewing potential synergies and are likely to continue to do so periodically to ensure maximum benefit to mining customers. Gregory Lew comments: “Should a customer perceive added benefits to his or her organisation through integration with third-part mine management software, ThoroughTec will most certainly work to optimise the delivered solutions.” number of new underground simulation products, which it believes will help to cement CYBERMINE’s leading position in the underground mining simulation industry. CYBERMINE users include Anglo-American, BHP Billiton, Rio Tinto, Gold Fields, Vale, Newmont, Goldcorp and Assmang.

The group told IM: “CYBERMINE has the world’s broadest range of underground mining simulator systems. This has been further expanded with the addition of new generation underground drill rig simulators capable of scaling, bolting and mesh handling functions, a shotcrete sprayer simulator and a range of underground soft rock equipment simulator systems.” Richard Bellengère, ThoroughTec Software Manager and specialist in underground simulation told: “We pride ourselves on our development pipeline, which allows us to timeously react to customer needs. Customer feedback from Australia indicated a need for drill rig simulator systems that could accurately replicate the ancillary tasks of scaling, bolting and mesh handling demanded of the actual vehicle. The Atlas-Copco Boomer 282 and the Sandvik DD420 dual boom drill rigs were identified as the highest priorities, although the technology can obviously be adapted for any drill rig simulator if requested. The 282 and the DD420 are two of our most popular simulator cabs, now in their fifth generations, and this optional extension of their functionality further increases their versatility and effectiveness in training programmes. Three of these fifth generation drill rig simulator systems have already been sold.”

Another innovation is CYBERMINE’s entry into the arena of underground soft rock mining. “The CYBERMINE range of simulators has been extremely successful in realising productivity gains and safety improvements in both the hard rock underground mining environment and in surface coal mining operations, so it was a rational progression for us to apply these proven training technologies and techniques to the underground soft rock environment”, continued Bellengère. This new simulation technology, which has already been purchased by BHP Billiton, comprises a Joy 12HM31-B continuous miner, a Joy shuttle car, a Fletcher HDDR roof bolter, Sandvik LS191 LHD and two utility vehicles. “The BHP Billiton project has been a significant challenge in terms of both complexity and scale, but the standout challenge was accurate modelling of the breakout of rock as the continuous miner, a hugely complex machine, cut away at the rock face.” Another addition to the CYBERMINE product range is a simulator system for the Normet Spraymec 1050 shotcrete sprayer, developed for Rio Tinto’s Oyu Tolgoi mine in Mongolia. ThoroughTec argues that ancillary vehicles such as the shotcrete sprayer are frequently ignored by simulator manufacturers due to their complexity, but are necessary for a complete training programme in order to ensure that a mine operates safely and productively.