Automated control of a dragline using machine vision

The research described in this paper is directed toward increasing productivity of draglines through automation. In particular, it focuses on the swing-to-dump, dump, and return-to-dig phases of the dragline operational cycle by developing a swing automation system. In typical operation the dragline boom can be in motion for up to 80% of the total cycle time. This provides considerable scope for improving cycle time through automated or partially automated boom motion control. This paper describes machine vision based sensor technology and control algorithms under development to solve the problem of continuous real time bucket location and control. Incorporation of this capability into existing dragline control systems will then enable true automation of dragline swing and dump operations.

Dragline automation: experimental evaluation through productivity trial

Since 1993 we have been working on the automation of dragline excavators, the largest earthmoving machines that exist. Recently we completed a large-scale experimental program where the automation system was used for production purposes over a two week period and moved over 200,000 tonnes of overburden. This is a landmark achievement in the history of automated excavation. In this paper we briefly describe the robotic system and how it works cooperatively with the machine operator. We then describe our methodology for gauging machine performance, analyze results from the production trial and comment on the effectiveness of the system that we have created. © Springer-Verlag Berlin Heidelberg 2006.

Dragline automation

This paper examines the feasibility of automation of dragline bucket excavators used to strip over-burden from open cut mines. In particular the automatic control of bucket carry angle and bucket trajectory are addressed. Open-loop dynamics of a 1:20 scale model dragline bucket are identified, through measurement of frequency response between carry angle and drag motor input voltage. A strategy for automatic control of carry angle is devised and implemented using bucket angle and rate feedback. System compensation and tuning are explained and closed loop frequency and time responses are measured.

Dragline automation - a decade of development : shared autonomy for improving mining equipment productivity

Draglines are massive machines commonly used in surface mining to strip overburden, revealing the targeted minerals for extraction. Automating some or all of the phases of operation of these machines offers the potential for significant productivity and maintenance benefits. The mining industry has a history of slow uptake of automation systems due to the challenges contained in the harsh, complex, three-dimensional (3D), dynamically changing mine operating environment. Robotics as a discipline is finally starting to gain acceptance as a technology with the potential to assist mining operations. This article examines the evolution of robotic technologies applied to draglines in the form of machine embedded intelligent systems. Results from this work include a production trial in which 250,000 tons of material was moved autonomously, experiments demonstrating steps towards full autonomy, and teleexcavation experiments in which a dragline in Australia was tasked by an operator in the United States.

Automatic in-bucket volume estimation for dragline operations

This paper presents a method for calculating the in-bucket payload volume on a dragline for the purpose of estimating the material’s bulk density in real-time. Knowledge of the bulk density can provide instant feedback to mine planning and scheduling to improve blasting and in turn provide a more uniform bulk density across the excavation site. Furthermore costs and emissions in dragline operation, maintenance and downstream material processing can be reduced. The main challenge is to determine an accurate position and orientation of the bucket with the constraint of real-time performance. The proposed solution uses a range bearing and tilt sensor to locate and scan the bucket between the lift and dump stages of the dragline cycle. Various scanning strategies are investigated for their benefits in this real-time application. The bucket is segmented from the scene using cluster analysis while the pose of the bucket is calculated using the iterative closest point (ICP) algorithm. Payload points are segmented from the bucket by a fixed distance neighbour clustering method to preserve boundary points and exclude low density clusters introduced by overhead chains and the spreader bar. A height grid is then used to represent the payload from which the volume can be calculated by summing over the grid cells. We show volume calculated on a scaled system with an accuracy of greater than 95 per cent.

Real-time volume estimation of a dragline payload

This paper presents a method for measuring the in-bucket payload volume on a dragline excavator for the purpose of estimating the material's bulk density in real-time. Knowledge of the payload's bulk density can provide feedback to mine planning and scheduling to improve blasting and therefore provide a more uniform bulk density across the excavation site. This allows a single optimal bucket size to be used for maximum overburden removal per dig and in turn reduce costs and emissions in dragline operation and maintenance. The proposed solution uses a range bearing laser to locate and scan full buckets between the lift and dump stages of the dragline cycle. The bucket is segmented from the scene using cluster analysis, and the pose of the bucket is calculated using the Iterative Closest Point (ICP) algorithm. Payload points are identified using a known model and subsequently converted into a height grid for volume estimation. Results from both scaled and full scale implementations show that this method can achieve an accuracy of above 95%.

Development of a dragline in-bucket bulk density monitor

This paper details the implementation and trialling of a prototype in-bucket bulk density monitor on a production dragline. Bulk density information can provide feedback to mine planning and scheduling to improve blasting and consequently facilitating optimal bucket sizing. The bulk density measurement builds upon outcomes presented in the AMTC2009 paper titled ‘Automatic In-Bucket Volume Estimation for Dragline Operations’ and utilises payload information from a commercial dragline monitor. While the previous paper explains the algorithms and theoretical basis for the system design and scaled model testing this paper will focus on the full scale implementation and the challenges involved.

Dragline swing automation

Draglines are used extensively for overburden stripping in Australian open cut coal mines. This paper outlines the design of a computer control system to implement an automated swing cycle on a production dragline. Subsystems and sensors have been developed to satisfy the constraints imposed by the task, the harsh operating environment and the mine's production requirements.

Dragline modelling and control

Electric walking draglines are physically large and powerful machines used in the mining industry. However with the addition of suitable sensors and a controller a dragline can be considered as a numerically controlled machine or robot which can then perform parts of the operating cycle automatically. This paper presents an analysis of the electromechanical system necessary precursor to automatic control

Dragline swing automation

Draglines are very large machines that are used to remove overburden in open-cut coal mines. This paper outlines the design of a computer control system to implement an automated swing cycle on a production dragline. Subsystems and sensors have been developed to satisfy the constraints imposed by the task, the harsh operating environment and the mine's production requirements.

Case study: Dragline swing to dump automation

Dragline Swing to Dump Automation By Peter Corke, CSIRO Manufacturing Technology/CRC for Mining Technology and Equipment (CMTE) Peter Corke presented a case study of a project to automate the dragline swing to dump operation. The project is funded by ACARP, BHP Coal, Pacific Coal and the CMTE and is being carried out on a dragline at Pacific Coal's Meandu mine near Brisbane. Corke began by highlighting that the minerals industry makes extensive use of large, mechanised machines. However, unlike other industries, mining has not adopted automation and most machines are controlled by human operators on board the machine itself. Choosing an automation target The dragline automation was chosen because: ò draglines are one of the biggest capital assets in a mine; ò performance between operators vary significantly, so improved capital utilisation is possible; ò the dragline is often the bottleneck in production; ò a large part of the operation cycle is spent swinging from dig to dump; and ò it is technically feasible. There has been a history of drag line automation projects, none with great success.