Training and Simulators

AUSTRALIAN JOURNAL OF MINING – NOVEMBER 2012

AJM spoke recently to ThoroughTec’s senior management about a range of topical issues affecting the South African simulation training provider.

Q: When did ThoroughTec release its first simulator in any industry? And for mining?
A: ThoroughTec Simulation executive director, Dr John Waltham: ThoroughTec was established as a company in 1997 and almost immediately began the development of haul truck simulators for the South African mining industry. Prior to this, however, the directors and senior developers at ThoroughTec had been instrumental in paving the way for the use of cost effective training simulation at both the operator and tactical levels in the South African Army through their previous company. The migration of technologies developed for the military ground-based simulators into mining was a natural progression and one that was actively stimulated by the mines themselves.

“It is difficult to argue that simulation is likely to become less relevant.”

Q: Are simulators able to be upgraded as technology develops? Are they in danger of becoming obsolete?
A: ThoroughTec software manager, Richard Belengere: There are two ways to look at this. Even if the installed simulator is never upgraded from the day it was delivered, it still remains as functional and as relevant as it was on day one. In the bigger picture, computer-based simulation technology is advancing at a pace that far outstrips advancements in actual vehicle tech, so it is difficult to argue that simulation is likely to become less relevant. Also, the CYBERMINE modular system allows new developments to be deployed to simulators already in the field, eliminating the need for a new simulator base unit. ThoroughTec’s fourth generation CYBERMINE product allows for both surface and underground cabs to be installed on the same simulator base unit. This obviates the need for further capital investment when, for example, an open-pit mine starts with an underground expansion or vice versa.

Q: ThoroughTec ‘makes simulators for a range of industries. Are the basics of the machines designed for mining, aviation and defence the same?
A: ThoroughTec software developer, Richard McKenzie: The same military engineering, design and quality control systems are put in place for all of ThoroughTec’s simulators. ThoroughTec builds two different classes of CYBERWAR military simulators: tactical and operator training simulators. The tactical simulators have a very different purpose to current mining simulators, which are designed to train a single operator, and therefore are quite different in structure. While tactical simulators do teach the essentials of vehicle operation, the real goal is interaction with other simulated and artificially intelligent vehicles in a battle scenario, training and scoring the tactics involved in battle. This is done by networking the vehicles so that they interact with each other in open warfare on a virtual battleground of up to 1,500km2 ThoroughTec also manufactures military operator training simulators. The CYBERWAR driving simulators, such as the Patria Armoured Modular Vehicle (AMV) Training Simulator System that ThoroughTec is currently producing for the Swedish and Croatian Armies, are virtually identical in layout and structure to CYBERMINE mining equipment simulators. Both are designed to teach trainees how to operate the equipment, both incorporate scoring checks, both teach how to react to certain faults and conditions, and both record the trainee’s reaction to all of these situations. The aim is to train the student in the operation of the equipment and to evaluate his performance. Because they play such similar roles, they use virtually identical core software.

Q: What are the milestone advances in simulator technology?
A: Dr Waltham: The invention of the computer was the single largest advance in simulator technology. While simulators did exist before that, they were crude mechanical constructions that didn’t deliver a truly realistic experience. Since the invention of the computer there have been very few ‘milestones’ in terms of simulator technology, but rather a continuous progression of incremental advances that have brought us to the present levels of fidelity and training effectiveness.

Q: Any examples of Thorough Tee supplying simulators for use at a greenfield site to train an unskilled workforce?
A: Rio Tinto’s Simandou mine in Guinea, West Africa, is using ThoroughTec CYBERMINE simulators to cope with the challenge of recruiting operators from an area so remote that most were unfamiliar with cars, never mind driving them. As a result they were experiencing high incidences of light vehicle accidents on site, in addition to the need to train operators for heavy equipment.

Q: How are simulators used to train/upskill skilled technicians?
A: Even experienced operators need to learn new skills when new technology is released, or brush up on their existing skills and eliminate bad habits that have crept in over the years . As an example, Sandvik, one of ThoroughTec’s longstanding clients, was experiencing excessive breakdowns of their machines at a mine site and could not identify any mechanical fault. Sandvik suggested that the mine operators brush up their skills on Sandvik’s CYBERMINE4 simulator system. They soon discovered that many operators were scoring high on the fault: ‘Used the accelerator and brake pedal simultaneously. This was due to the operators resting their foot on the brake pedal instead of the foot rest, causing an increase in wear and tear. Upon completion of the simulator training course the problem disappeared and the mine site enjoyed a considerable reduction in maintenance costs.

Q: Where does the future lie for simulators, in terms of new technology and new uses?
A: Dr Waltham: Simulation must respond to the changing demands of the operational mine environment. As more complicated vehicle subsystems are introduced, so these subsystems must be accurately replicated by the simulator providers. On a broader level, mining vehicles don’t operate in isolation, but in integration with other vehicles and systems to produce an end result, which is a safe and productive environment. To replicate this and enhance training, simulator systems are moving from operator training to a more tactical level of training. In the more tactical level of training, simulators look at not only the way a haul truck interacts with a shovel, but also how many trucks interact with each other and with many shovels. This can help optimise the mine’s performance based on a tactical command and control environment that you can tweak in the simulated environment to play out the results of different scenarios. If a shovel can load 10% more ore, how does that affect the whole production cycle, for example. The effectiveness of simulation increases as the fidelity and behavioural realism increases. Visual feedback to the trainee is one way to do this. The introduction of stereoscopic or 3D technology is another way to harness current and immediate future technology. The challenge here is to get the technology to synchronise well across three or four display screens, as opposed to the very simple use of a single display screen.

Q: Curtin University’s School of Mines recently commented that ThoroughTec’s price was a significant factor in winning a contract to supply CYBERMINE4 simulators. With the mining bubble deflating, is competition rising, causing you to trim your prices?
A: ThoroughTec’s strategic planning executive, Greg Lew: Curtin University, and many of our other clients, chose us not only on price, but on the overall value that CYBERMINE simulators represent. CYBERMINE units are able to run both surface and underground cabs on the same base, saving the customer the expense of buying two base units. We also try to save our customers money on research and development. We don’t pass on the development costs of new machinery, believing that it is beneficial for us to have that piece of equipment on our books for future business. Our cost of ownership is also reduced by our very low incidences of breakdowns, as well as our lack of routine software updates that are charged for. Instead, we build our simulators complete the first time. Furthermore, we try to give academic institutions the very best deal we can, because we believe that furthering mining education is of benefit to the mining industry as a whole.