Supply Lines
December 2007
Mission Not Impossible
Virtual reality offers the high-tech training opportunities that can transform your workforce into a squad of experts.
by Tina Grady Barbaccia, Senior Editor
Caterpillar
Full-scale power train simulators
At Aggregates Manager press time,
Caterpillar
was underway with developing its next generation of mechanical drive
mining trucks and a new line of AC electric drive trucks. The company
announced it plans to upgrade all its mechanical drive mining trucks —
785C, 789C, 793C, and 797C — as well as offering two AC electric drive
truck models with more than 200 short tons of capacity.
Three full-scale
power train simulators have been designed and constructed, two for
mechanical drive, and one for AC electric drive. The two mechanical
drive simulators occupy 3,500 square feet of space and include the
engine, torque converter, driveshaft, transmission, and differential
positioned as if they are on a real truck. The AC electric drive
simulator, which is housed in 1,740 square feet of space, can include
the engine, alternator, power inverter, retarding grids, cooling system,
and wheel motors depending on the test.
Sandvik Mining and Construction
Realistic drilling experience
Sandvik Mining and Construction, in
collaboration with Throughtec, has developed the CyberMINE Simulation
Technology. The training simulator is a fully integrated component of
the DeBeers-Snap Lake Mine Training program and includes loaders,
trucks, bolters, and jumbos in its training.
During the virtual training, the operator performs all the drilling tasks that would be performed in an actual machine and experiences realistic drilling situations, including interaction with several rock characteristics such as hardness and drillability. The operator views the simulation on three high-resolution, widescreen displays from a replicated cab with all of the instruments and controls located in the same way as the actual machine. An external view also is able to engage in a full classroom setting.
The CyberMINE virtual training tool serves as the foundation for the company’s simulation training for the DP1500i (the “i” stands for intelligent) surface drilling tool — formerly known as Pantera. The company is selling the education, not a product unit, so training is brought from site to site and can be tailored based on employees’ experience, ground conditions, and other factors. “We understand the lack of skills and how important it is to get the holes drilled right,” Dan Allen, president of Sandvik, told Aggregates Manager in an exclusive interview. “Our answer to the low number of trained people in drilling is the high use of technology…If you can immerse yourself into an environment, learning is much more real.”
Vista
Heavy equipment simulators
The PC-based Excavator Personal Simulator and
Off-Highway Truck Personal Simulator from
Vista Training, Inc. is
PC-based training that enables equipment operator training without
equipment downtime and possible damage. The Off-Highway Truck Personal
Simulator puts the user at the controls of a modern, 85- to 100-ton
heavy hauler in English, French, or Spanish. The virtual site is modeled
after an actual aggregates operation.
There are six simulation lessons of increasing difficulty — from the first lesson, “Controls Familiarity,” to the final lesson, “Complete Haul Cycle,” which combines loading, driving, and dumping. The data from each lesson are tracked to allow benchmark comparisons. Two types of simulator controls are available: A basic steering wheel and shifter, plus separate retarder, or a complete, realistic replica of the actual haul truck controls.
The manufacturer’s Hydraulic Excavator Personal Simulator places the user at the controls of a modern, hydraulic excavator at a virtual construction site. The simulator is available in English and French (at Aggregates Manager press time, availability in Spanish was in the works) with a total of 12 simulation lessons. Like its off-highway truck sister training program, it also offers increasing levels of difficulty. The training begins with the basic operation of the boom and tracks and ends with trenching and truck loading with the use of “dynamic terrain modeling” technology. All data are tracked to allow benchmark comparisons.
Simulator controls come in a standard PC joystick or industrial USB joystick, and each can be secured to mounting brackets to create an “operator chair.”
Excal Visual
Points out key hazards
Front End Loader 101 from Excal Visual LLC serves is designed as a basic safety training program for front-end loader operators that show them how to conduct pre-shift safety inspections, practices to use the loader safely, and proper methods to perform routine maintenance. The 11-1/2 minute training also points out key operational hazards and safe trailering and towing practices. According to Excal, the training is ideal for new operator safety orientation and for refresher training for experienced operators.
Vivid
Mine-specific training
MSHATrainingOnline (Mine Safety and Health
Administration) online training from
Vivid Learning Systems offers mine-specific compliance training that
can be customized to meet specific company needs. The training also has
a testing component, which allows companies to track exactly where an
employee might have a weaker knowledge area. The virtual training course
library includes an MSHA eight-hour annual refresher, new miner
training, employment law, and general occupational safety.
Caterpillar
Automated underground loader
Caterpillar says MineGEM is the first loader
automation system that allows the operator to work from a safe, remote
work station far from the loader, on the surface or underground. MineGEM
is said to give unprecedented control to the machine without the
operator on board, so the operator is not exposed to the risks of the
underground environment. It can also improve productivity by eliminating
operator changeover time and rest breaks. The system automatically
avoids contact with walls, producing less damage to the machine than
teleremote operations, according to Caterpillar.
It comes with two levels of control — Co-pilot and Autopilot. Co-pilot allows for operator-assisted automatic steering of the machine. Autopilot enables the operator to load the bucket using integrated digital teleremotes, which the operator uses to send the loader “on a mission” during which it automatically trams, dumps, and returns to the draw point. When in this mode, several machines can be operated by one operator. A laser-radar range sensing system (LADAR) provides spatial information to the machine, with one unit looking to the front and one to the rear of the machine. Additionally, one camera each on the front and back provides real-time video to the remote operator, with audio feedback also available on the machine.
Mirarco
Advanced edge blending
The Mining Exploratorium Program from Mirarco uses what the company says is the world’s first collaborative, immersive Virtual Reality Laboratory (VRL) that is designed to help mineral exploration and mining companies find solution to their mineral exploitation cost-reduction challenges. The VRL enables multi-disciplinary teams to reduce the amount of time needed to understand complex datasets while improving overall quality of decision-making, according to Mirarco. The facility projects 3.9 million pixels on a 22-foot radius spherical screen. An advanced edge blending provides a three-dimensional stereographic image around the session participants, providing a virtual representation of complex data sets. This virtual reality program has applications including data visualization, exploration review and planning, mine planning and event simulation, acquisitions, investor risk, and investor relations.
Superior Industries
Patent-pending pulley
Superior Industries offers an interactive CD to
allow potential users to experience how the Chevron Wing Pulley (which
is patent pending) can deflect threatening material, extend the life of
conveyor belts, and reduce noise by nearly 50 decibels, according to the
company.
National Institute of Standards and Technology
Detects collisions
With software developed by the National Institute of Standards and Technology (NIST), aggregate equipment operators can now learn how to operate an excavator, dump truck, and other equipment through user-controlled VRML simulation. The program allows simulation operations to dig and dump with the excavator, dump with the dump truck, and detect a collision between the excavator body and objects, except the dump truck and dirt.
