Mine fleet management in the age of automation

An autonomous haul truck at a Rio Tinto mine in Australia. Photo: Ian Waldie/Bloomberg via Getty Images

Digitisation and automation are no longer futuristic concepts in the mining industry. Over the last decade or so, the proposition that mining could become automated, at least to some degree, with functions being conducted hands free and even remotely, has become a reality. 

By now, mining automation has turned into a multi-billion industry in its own right and operators around the world are investing in the development and roll-out of autonomous fleets. According to a 2023 report by GlobalData, the total population of tele-remote control and autonomous underground mining trucks and LHDs is estimated at 1,032, including both autonomous-ready equipment as well as those operating autonomously. Australia and Canada are leading the way, accounting for 41% and 17% of that fleet, followed by the US with 7%. 

“The adoption of automation obviously varies between mines and across the world,” explains Jyrki Salmi, research director and mining automation expert at Finland’s University of Oulu Faculty of Technology. “But in general, it is probably safe to say that the modern mining industry is already moving towards a smarter and more automated way of working.” 

It seems there are few subcategories of mining that are out of the reach of digitisation and automation. From operations to equipment and vehicle management, the so-called ‘touch free’ capabilities it brings are fast becoming the must-haves rather than the desirables.  

“Many modern mines have long since introduced automated machines such as trucks and drilling and bolting equipment that are remotely controlled, or even operated completely autonomously without an operator,” Salmi says. “Even the processes of rock extraction, that is, charging and blasting, have finally been automated and digitalised.” This reach, he suggests, even extends to rock transportation and logistics. 

As he says, vehicle fleets such as mine trucks, loading machines and drilling and bolting equipment can already operate completely autonomously, at least through most work phases, without human control, improving safety and increasing operational efficiency. 

At its last count, GlobalData estimated there were more than 100,000 vehicles in the global mining fleet, comprising over 86,000 trucks, 16,000 hydraulic excavators and shovels, 2,000 electric shovels and 19,000 dozers. Thus far the majority of vehicle automation has been seen in haul trucks, with much success arguably thanks to the labour-intensive nature of the function.

Haul trucks can often operate continuously, requiring several shift changes each day and a handful of drivers, with the obvious associated safety risks. But, says Salmi, there are other reasons haul truck automation has proved so successful: “Transportation routes and environments are generally much more predictable and stable compared with other working environments in a mine, which can be considerably more complex and variable often making their automation much more technically demanding.” 

It's the repetitive nature of these elements of transportation, clear road networks, signage, clearly defined and designated traffic rules and standardised regulations that prove advantageous to automation, simplifying the design and implementation of such systems.  

But, Salmi adds, these already obvious supporting characteristics should not deter the migration of automation to other parts of a mine’s vehicle fleet. “The development of software and algorithms will certainly also help to improve the automation of other functions, in addition to transportation,” he believes.

By enhancing viewing sensor technology such as cameras or light detection and ranging (LiDAR) systems, the ability to detect machines in their complex working environments can be improved, providing more accurate information. 

Artificial intelligence (AI) and machine vision can also bring intelligence to machine operations and autonomous decision-making, with powerful algorithms that help; for example, identifying obstacles and adapting to rapidly changing conditions. Added to this, real-time computing facilitates instant and remote analysis of sensor data, improving automation performance and reducing delays. 

“With the right software, intelligent data management systems can be created to improve the efficiency of mine operations and enable better control of processes,” Salmi continues, adding these packages, in particular the algorithms and now AI, further enable advanced mining process functions like autonomous vehicle movement, data collection from smart sensors and real-time data analysis. There is also cloud and edge computing, which has heralded new information and communication technology opportunities.

Together they make it “easier than ever to learn and adapt to the ever-changing mining environment,” Salmi says. These types of solutions and the evolution of the Internet of Things (IoT) – the ability of sensor-ladened devices to communicate via the Internet – provides scalability and flexibility to the increasingly popular smart mine.  

“Smart sensors and IoT technology are also bringing real-time big data from mining vehicles to mine maintenance monitoring systems,” he explains. “This data, properly analysed, will enable better machine fleet monitoring, predictive maintenance and safer usage.”  

Salmi adds that the data generated can then be used for continuous automated monitoring of the condition and performance of the equipment, further contributing to their efficient management. As a result of this increased autonomy, the efficiency of machines has been and can further be improved, allowing them to operate continuously, tirelessly and accurately without human intervention. “Remote control and management… in turn, also enables the centralised control and operation of large fleet volumes,” Salmi adds.

Although the acquisition of machines and tools with digital and automation capabilities is often costly, the benefits are evident and over time help reduce costs through efficiency, greater productivity and even reduced labour expenditure on the operations side; and more effective maintenance strategies and extended lifecycles for the equipment itself.  

As part of mine operator’s procurement strategies, it’s as important to consider the software applications selected to manage the hardware. 

“Software purchases are always strategic decisions,” says Salmi, “which naturally have long-term effects on the company's operations.” He says the first step in the procurement process is to assess your requirements and understand exactly what the business needs and objectives are that are being sought. Then consider what the necessary software functionality is before comparing your options, giving thought to their features, usability, price and references. Another concern should be the integration and compatibility of the package with existing platforms.

Salmi then suggests enlisting input from the soon-to-be end-users of shortlisted options, taking advantage of test runs and demos and, if possible, seeking feedback from other users – in particular on the usability and functionality of the software – before a final decision is made. These are important points given often users will not be familiar with new packages. They also highlight the need to give thought to aftersales customer support and user training. “essential” considerations that Salmi says “cannot be overestimated”.

Digital skills are fast becoming a priority for the industry and profession, as the more traditional manual skills involved in mining make way for a new range of technical skills. “The skills associated with this technological leap… will certainly continue to be emphasised in the future,” says Salmi.  

The next generation – and those already incumbent – of the mining profession will increasingly require digital and software skills to control and operate automated equipment, to handle complex sensor technology and to read and analyse data produced by machines.  

This is in addition to the growing need to understand programming more generally, how information systems’ algorithms work and how to communicate with machines. “As a consequence, training needs will of course also change, and the new generation of miners will need to be multi-skilled and able to adapt quickly to rapid developments,” Salmi cautions. 

It seems the sector is going through a significant period of change, with technology leading the way. Automation – particularly that of mining vehicle fleets – looks to be the next frontier, but for it to be successful the right skills and buy-in from what has traditionally been a manual labour force is critical. 

“People can be resistant to change and to adopting new technologies,” Salmi concludes, so it’s important to lead effectively and communicate its benefits. “It is worth remembering, however, that very rarely does anyone want to go back to the old ways once new technologies have been adopted.”

For an industry that’s been around for thousands of years, the mining sector can hardly be accused of being slow to innovate. You barely need scratch the surface to find examples of where vehicle automation is happening, quite successfully.  

In August 2023, vehicle autonomy specialists ABD Solutions introduced a new addition to its Indigo Drive offering, the Mobile Supervisory System. Indigo Drive, it says, is a technology ecosystem that “enables a limitless number of mining vehicles to be quickly and cost-effectively automated”.  

The addition of the Mobile Supervisory System means automated vehicles can operate anywhere in the world, without the need for existing infrastructure. Comprising a compact and modular network of servers and operator stations, it gives managers the ability to oversee their fleet of automated vehicles in the most challenging environments. Fitted into various configurations, including vans or even mobile containers, it can be operated in the most remote and hostile environments.

ABD Solutions says the system boasts a user-friendly software interface that allows for route planning, the hardware to move the vehicles (such as drive-by-wire and driving robots), communication (radio, V2X, GPS/GNSS), obstacle detection (LiDAR, camera, radar) and vehicle health and diagnostics (OBD2, telemetry, sensors). It’s powered by 24-hour operational lithium-ion batteries that can be hot swapped or recharged by solar power or hydrogen generators. 

Throwing its hat firmly in the ring of vehicle automation is sensor, software and autonomous technologies specialist Hexagon. The Swedish conglomerate operates in numerous industry sectors, but its mining division is making big waves providing a holistic suite of automation products.  

At an event in Las Vegas last year, the company presented its new automation package. This included the Mission Manager, which provides oversight of a vehicles location, route, job list and how it’s collaborating with other vehicles; the World Perception solution, sensors tracking the vehicle, vehicles around it and other potential hazards including people; and onboard systems effectively doing the driving, including steering, braking, changing gear and even using the horn and lights. 

These are just two of the growing number of automation specialists supporting today’s increasingly automated mining industry. For more on mine and fleet management software, Mining Technology has produced a comprehensive rundown of suppliers. Visit our buyer's guide to find out more.