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 - 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.

Three-dimensional imaging for a very large excavator

In this paper we describe the development of a three-dimensional (3D) imaging system for a 3500 tonne mining machine (dragline).Draglines are large walking cranes used for removing the dirt that covers a coal seam. Our group has been developing a dragline swing automation system since 1994. The system so far has been `blind' to its external environment. The work presented in this paper attempts to give the dragline an ability to sense its surroundings. A 3D digital terrain map (DTM) is created from data obtained from a two-dimensional laser scanner while the dragline swings. Experimental data from an operational dragline are presented.

Development of a 3500-tonne field robot

The mining industry is highly suitable for the application of robotics and automation technology, since the work is arduous, dangerous, and often repetitive. This paper presents a broad overview of the issues involved in the development of a physically large and complex field robotic system—a 3500-tonne mining machine (dragline). Draglines are “walking cranes” used in open-pit coal mining to remove the material covering a coal seam. The critical issues of robust load position sensing, modeling of the dynamics of the electrical drive system and the swinging load, control strategies, the operator interface, and automation system architecture are addressed. An important aspect of this system is that it must work cooperatively with a human operator, seamlessly passing control back and forth in order to achieve the main aim—increased productivity.

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.

Robust sensing for a 3,500 tonne field robot

The mining industry is highly suitable for the application of robotics and automation technology since the work is arduous, dangerous and often repetitive. This paper discusses a robust sensing system developed to find and trade the position of the hoist ropes of a dragline. Draglines are large `walking cranes' used in open-pit coal mining to remove the material covering the coal seam. The rope sensing system developed uses two time-of-flight laser scanners. The finding algorithm uses a novel data association and tracking strategy based on pairing rope data.

Modeling and control of a 3500 tonne mining robot

Draglines are extremely large machines that are widely used in open-cut coal mines for overburden stripping. Since 1994 we have been working toward the development of a computer control system capable of automatically driving a dragline for a large portion of its operating cycle. This has necessitated the development and experimental evaluation of sensor systems, machines models, closed-loop control controllers, and an operator interface. This paper describes our steps toward the goal through scale-model and full-scale field experimentation.

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.

Dragline 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 mines production requirements.

A dragline-forming mobile robot inspired by spiders.

Mobility of wheeled or legged machines can be significantly increased if they are able to move from a solid surface into a three-dimensional space. Although that may be achieved by addition of flying mechanisms, the payload fraction will be the limiting factor in such hybrid mobile machines for many applications. Inspired by spiders producing draglines to assist locomotion, the paper proposes an alternative mobile technology where a robot achieves locomotion from a solid surface into a free space. The technology resembles the dragline production pathway in spiders to a technically feasible degree and enables robots to move with thermoplastic spinning of draglines. As an implementation, a mobile robot has been prototyped with thermoplastic adhesives as source material of the draglines. Experimental results show that a dragline diameter range of 1.17-5.27 mm was achievable by the 185 g mobile robot in descending locomotion from the solid surface of a hanging structure with a power consumption of 4.8 W and an average speed of 5.13 cm min(-1). With an open-loop controller consisting of sequences of discrete events, the robot has demonstrated repeatable dragline formation with a relative deviation within -4% and a length close to the metre scale.

Reproductive interference between two sibling species of gift-giving spiders

We investigated the possibility of reproductive interference between two sibling spider species, Paratrechalea azul and Paratrechalea ornata, which occur syntopically and reproduce synchronously. Males of both species offer a nuptial gift composed of prey wrapped in silk to females. Through laboratory experiments, we evaluated possible asymmetries in the outcome of heterospecific encounters between males and females, and investigated whether chemical signalling could function as a premating barrier between the two species. Males of P. azul were unable to discriminate conspecific from heterospecific female draglines, which resulted in wasted time and energy in nuptial gift construction. Males of P. ornata incurred a higher cost for discrimination mistakes because most of them were attacked by heterospecific females; 95% lost the nuptial gift upon the attack and 33% were preyed upon. This pattern is probably a consequence of differences in body size between males and females of each species. Both species showed erroneous female choice, but only P. ornata females courted heterospecific males, which are considerably larger than conspecific males and may resemble high-quality mating partners. Males of P. ornata also made discrimination mistakes, but at a much lower frequency compared to P. azul males. The selective pressure for precise recognition of conspecific female signs is probably stronger on P. ornata males because misdirected courtship may increase their chances of encountering predatory heterospecific females. This study provides the first detailed evidence of reproductive interference between two reproductively isolated spider species, showing that the costs paid by individuals of different sexes and different species are highly asymmetric. (C) 2012 The Association for the Study of Animal Behaviour. Published by Elsevier Ltd. All rights reserved.