Imitating the Real World

MINING MAGAZINE – JANUARY 2011

South Africa’s ThoroughTec Simulation has 25 years of simulation experience, with a global presence in military, aerospace and mining applications. Clients that use the latter include BHP Billiton, Rio Tinto, De Beers, Atlas Copco, Anglo Platinum and Sandvik, with 500 simulators globally.

ThoroughTec says the military and aerospace industries had highly defined simulation standards, and the use of common architecture and codes enable the company to support mining simulation products more effectively.

The past two years have been busy for ThoroughTec, which has opened offices in Canada (Toronto) and Australia (Perth), while developing its fourth generation of CYBERMINE Simulators (launched in October).

The new Canadian office has reported several simulator orders, including units to Exxaro’s Grootegeluk coal mine and the Yukon Mine Training Association. The firm’s Perth office has reported increasing Australian interest in its simulation units.

“The software automatically identifies operational violations such as speeding, simultaneous brake and accelerator engagement, and incorrect gear selection.”

Examples of Australian users include the Mining Industry Skills Centre, which is using a ThoroughTec CYBERMINE surface simulator unit to train operators on a Komatsu 830E-AC haul-truck cab.

Sandvik Australia also has a CYBERMINE underground simulator, with plug-and-play cabs for its D420 and Solo 7 drill rigs, Toro 40D ADT and several LHDs. Sandvik says the simulator “encourages operators, new and experienced, to gain added experience in a true to life, non-destructive environment that could target certain areas if required.”

The company’s regional manager, Mark Gregson, notes that design and technology teams at ThoroughTec can engineer simulations specific to any machine. This is a component of the business, he says, that was one of ThoroughTec’s key strengths. “Anything can be simulated,” Mr Gregson claims.

A range of applications are supported by ThoroughTec’s technology for surface and underground operations, including drill and blast, rock reinforcement, and load and haul equipment. The company’s surface-mining simulators include units for trucks, locomotives, drill rigs, excavators, draglines and graders. Underground simulators include units for drill rigs, roof bolters, loaders, articulated dump trucks (ADTs) dozers, locomotives and scalers.

The new CYBERMINE design builds on the success of previous generations to give instructors and student operators “a significantly superior training experience”.

The CYBERMINE4 has the option of a full 360° panoramic display. ThoroughTec’s business development manager, Justin Collins, notes that “all four screens can be used when operating the equipment, providing increased awareness of surroundings and more accurate simulation”.

ThoroughTec says the instruments and controls are “either sourced from OEMs or are accurately replicated to function as they do in the real mining equipment. The operating subsystems such as engines, braking systems, hydraulics and drilling heads is mathematically modelled to the original manufacturer specifications so as to provide accurate, realistic feedback to the student.

Other simulated equipment and vehicles inter-operate with the student to test and enhance their skill levels. Accurate 3D surround-sound reproduction as composite visual effects such as reflections, dust, rain and shadows, complete the picture to ensure high-fidelity training experience.”

The new units retain the company’s “innovative and robust motion platforms” (with six and three degrees of freedom for surface and underground simulation, respectively). ThoroughTec claims “these high-performance, low-low maintenance platforms provide students with all the motion cues that one would expect when operating mining equipment.”

The interior of the CYBERMINE Simulator has received a significant facelift with improved ergonomics in a superior, classroom-like setting. The instructor station and reporting software have been upgraded for improved training and operator analysis.

Instructors can view their students’ performance and vehicle diagnostics on two high-definition, wide screen displays, allowing for a full ‘fly around’ view to run simultaneously.

“The software automatically identifies operational violations such as speeding, simultaneous brake and accelerator engagement, and incorrect gear selection, to which the instructor can then take corrective action with the student to eliminate these violations, and thus save the mine a fortune in unnecessary maintenance bills and prevent hazardous safety situations,” Mr. Collins explains.

All experiences on the simulator can be measured through printed reports to show progress. By training operators correctly, and instilling behaviour that reduces wear and tear on machinery, OEMs can ensure greater longevity of their vehicles, thus reducing maintenance cost for the customer.

Extract from Mining Magazine