There are two mining modes:
- Material Design mode (legacy)
- GIS mode
In this mode, Terrain uses Material Design files, *.cat files sent to the machine from Terrain office software, to show material and mining status. The information about the materials in the design file is stored in two-dimensional (2D) material polygons.
Polygons have colors which represent materials. Text located within the polygon provides more information about the material, such as polygon ID and name. The polygons are 2D and are not associated with an elevation (level / bench).
Terrain detects the dig state of the machine while in the material polygon. If Digging, then this material appears in the bucket and in reports. The software accumulates dipper information until the operator selects Send Truck, at which stage the software sends the report to the office.
The operator relies on the office providing updated Material Design files for the working area, but can override the material while digging.
Large mines divide the site into small three-dimensional (3D) units of resource information. These small units of information are joined into a secondary unit to create a grade block. Surveyors, geotechnicians, and pit bosses refer to the site in terms of grade blocks. The grade blocks are used by the MineStar Geographic Information System (GIS) of the mine.
Grade blocks have many GIS parameters. The parameters include:
- Material (called the primary material)
- Block ID
- Block Name
- Floor elevation
- Names of alternative materials
The parameter Terrain uses is the elevation of the block floor.
The MineStar GIS maintains the ore body information for the mine site. The on-board software accesses GIS data by polling GIS every 5 minutes and receiving information about the material in the area the machine is working.
The grade block polygons from the GIS database are stored in JavaScript Object Notation files (JSON files) on-board for easy access to the data by the onboard software. The polygons should not overlap because blocks and stockpiles do not overlap.
The on-board software uses both the group number associated with the block, and the floor levels in the block, to assign a material to the bucket.
When a dig is triggered, Terrain associates the dig with the block where the machine is located. All the details associated with this block (material, ID, and others) are then gathered from the GIS by Terrain and added to the dipper and load reports.
When moving between benches, the on-board software automatically selects the appropriate grade block by choosing the block with the grade block floor elevation that most closely matches the current elevation of the machine. The software checks for flags in the block data that indicate whether the machine is allowed into the block, or not. If the block can be used, then the software notes the grade block group ID and automatically assigns this ID to the current material that is being moved by the machine.
Identifying GIS Mode on the Machine
Note: When in GIS mode, the machine ignores any Material Design files set as "Prime" or "Active", but still updates as-built surface files regularly.
When changing from Material Design mode to GIS mode, complete the following:
- Observe the reboot of the on-board software after the office sends a new mach_cfg.txt file with GIS enabled.
- On the top Status bar, select the loading method:
Load to Truck (Prime) - Default method
Load, Haul Dump (LHD) - Load from stockpile and dump to processor
Clean up and others (Aux) - Tasks on the run of mine (ROM) pad other than loading.
When in GIS mode, the machine ignores any Material Design files set as "Prime" or "Active", but still updates these files regularly.
- Select one of the following reminder icons:
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Prime mode (prime) - This machine is loading to truck. |
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LHD mode (load, haul, dump) - This machine is loading to processor/hopper. |
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Aux mode (auxiliary) - This machine is cleaning up, or doing other non-loading activities. |
Note: Keep the reminder icons up to date in the Status bar so that you know which loading tool operating mode you are in.
In GIS mode, the on-board software requests data for a 500 m x 500 m area around the machine. The on-board software polls the GIS database every 5 minutes and automatically updates the stored data. The software also checks the proximity of the machine to the edge of the area. When the machine is within 150 m of an edge of the area, the software requests an update.
The on-board software reads information from the GIS database and shows some of the information on the Ore Plan window and Digital windows.
The following applies:
- Processors are not assigned to groups and do not have an elevation.
- Blocks are assigned to groups. The on-board software reads the elevation of the block floor as the bench elevation.
- Sloping grade blocks are treated as flat blocks with the floor elevation used as the elevation of the whole block.
Use the Elevation/Stratum window on the display to find or change the elevation/stratum on which the machine is working when in GIS mode.
Elevation in an open pit metal-extraction operation refers to one or more of the following concepts:
- Bench
- Subbench
- Flitch
Stratum in an open cut coal mining operation refers to one or more of the following concepts:
- Seam
- Ply
- Pass
- Horizon
Use this window automatically or with operator input.
When the window is used without operator input software assigns the elevation/stratum automatically, the text reads "Auto is ON". The software automatically locates the nearest grade block and the floor level of this block becomes the elevation shown on the display. The software maps to the correct elevation.
If the site uses sloping blocks, then the following rules apply:
One sloping block + "Auto is ON" - The software locates the nearest grade block and the floor level of the block becomes the elevation shown on the display.
Two or more sloping blocks + "Auto is ON" - The operator must select the elevation/stratum manually for every load. Do not let the software select the elevation.
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| Illustration 1 | g06086330 |
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Elevation/Stratum window using operator input | |
The operator selects the name of the elevation / stratum under the machine. The text reads "Turn Auto ON" and the software uses the elevation selected by the operator.
The operator can switch between using the window in automatic mode or in manual mode as often as needed.
In Illustration 1 the window shows "38-S07_X1_B01" as the elevation on which the machine is working.
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| Illustration 2 | g06086385 |
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GIS Materials window | |
Use the GIS Materials window on the display to track buckets when using a loading recipe.
Illustration 2 shows two buckets of yellow, material name "BSDE" and block, or stockpile, name "FTN04_01_550_601". The material listed is the material in the bucket or the permanent override ("Hold"). If the operator overrides the material while the material is in the bucket, then the original and the override are listed, one after the other.
Use an Ore Plan window on the display to show the following:
- Material status (ore status) of stockpiles, such as the hatching showing "Mined Out"
- The material design from the GIS database.
Example:
In a stockpile, the "Mined Out" ore state covering almost all the stockpile indicates that the stockpile is empty. Anything other than "Mining in Progress" or "Mined Out" ore state indicates that the stockpile has been refilled.
When configured to send back material status as-built surface updates (snippets) to the office, the machine keeps the material status (ore status) up-to-date, even when in GIS mode.
The location of materials supplied by the GIS database, but not the materials from the Material Design that is "Prime", appears on the Ore Plan window.
The on-board software does not save changes in material status or ore status to the GIS database.
When working on a ROM pad, use the Send Truck toolbar button or menu as normal.
The on-board software creates the Truck List from the trucks.mwf file. There is no change in the way the Truck List functions when working in GIS mode compared to Material Design mode.
Observe the following hints when dumping material when in GIS mode:
- Do not move through one block and into another block or you may see unexpected results. Terrain starts a dig cycle when it begins moving forward while on unmined ore and ends the dig cycle when the machine stops driving over unmined ore. The block chosen by Terrain will be the one at the location of the exact midpoint between the start and end of the dig cycle. The software starts recording a dig when you enter the first block. The exception is when moving through a "Mined Out" block into a second block when the software starts recording at the edge of the second block.
- Do not drive loaded through one processor to get to another processor.
- When you load and dump within a stockpile, the automatic dump trigger does not work.
- The software prohibits dumping to the same stockpile as was dug from, as this is assumed by the software to be clean up operations, and not productive work.
- Use the Manual Dump button to guarantee an unusual dump is recorded.
- Imagine a circle around the hexagon representing the processor on the display. The circle is the area considered to be the processor. Take care when cleaning up near outside the edges of the hexagon or the software may record incorrect dumps to the processor.
The on-board software knows when the machine is digging and dumping and sends the information to the office software. There are variations on how this happens (dependent on machine type) and where this happens (depending on Material Design mode or GIS mode) and some exceptions.
For the software to detect the start of a dig, the bucket must first be empty of material. Detecting a dig triggers a DR3.
There are two methods by which the software detects a dig:
- Automatically
- Operator using the Manual Dig button
The software treats information from both methods the same.
The automatic trigger for the software to start recording a dig differs with machine type. When the operator digs where a grade block and stockpile overlap, the on-board software identifies the stockpile, not the grade block, as the dig destination.
The automatic trigger for the software to start recording a dig is forward movement over a polygon that has an ore status "Mining in Progress" or "Not Mined"(ore status is not "Mined Out"), and then reversing out of the polygon.
Driving forward onto a polygon and then continuing to move forward until over another polygon may cause the software to record unexpected data. Always complete a dig cycle by driving forward and then reversing out of the polygon.
The loader knows the direction of travel by one of the following:
- Automatically
- Operator uses Calibrate button to change direction on machine and on display
- Operator uses a reverse (physical) switch
When the wheels move over a part of the polygon, the software marks that area as "Mining in Progress" and then as "Mined Out".
When the machine moves forward into a polygon and then drives out of the polygon before reversing (cutting across a corner), the software may record unexpected data.
Reference: Refer to SEBU8822, "Digging Near an Edge" later in this section.
When the machine moves forward over a polygon, then loads a truck within the polygon, the software will not record the dump because the software considers the loader is cleaning up.
Excavator / Hydraulic Front Shovel (DA) - Not Released v5.3
The automatic trigger happens when signals from the inclination sensors (bucket angle) and dig sensors (hydraulic pressure sensors) determine the bucket is being loaded.
The installer can set and change the automatic trigger points for the dig sensor.
Reference: Refer to the "MCU Help file"Dig Sensors for Stick and Dipper - after v 5.1 .
The start and end of the dig occur without the machine driving forward or reversing. Start and end are based purely on bucket angle and pressure.
Front Shovel (SA) - Not Released v5.3
The automatic trigger is the position signal for when the point sheave is over a polygon. The on-board software automatically uses the position of the sheave point over the polygon to know that the shovel is digging and to decide what the material is in the bucket.
Cat ERS 7495 (DA and Position Sensor) not Released v5.3
Non-applicable.
The automatic trigger comes from the on-board software using a combination of Beta Angle, Filtered Hoist Rope Tension, and Swing Speed.
Surface miner and Terrain Leveler (SA)
Non-applicable.
These machines dig, and then either dump to ground or to truck and are not used for stockpiles, processors, or blocks.
Track-type Tractor (SA, with/without Blade Control)
Non-applicable.
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| Illustration 3 | g06088138 |
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Digging in GIS mode (1) DipperReport contains green material (2) Software reports unknown material and opens Material Selection dialog (3) DipperReport contains blue material | |
When a dig occurs in GIS mode across a grade block or stockpile boundary:
- The recorded dig starts when the machine moves forward within the block and finishes when the machine reverses.
- The software identifies a point half way along the dig as the material in the bucket.
- The software also records the start and end of the dig so the office staff can process data further, if required.
Digging in "Unknown" or "Mined Out" Material
"Unknown" material is material from an area outside a stockpile, processor, or grade block. "Mined Out" material is the ore status of material in a stockpile or grade block that has been removed down to the bench elevation.
In all machine types, the software automatically triggers the dig whether the machine is over a grade block, stockpile, processor, or outside one. What the operator sees on the display, on the surface or in the bucket, changes dependent on the surface.
For Wheel Loaders working in GIS mode:
- If the surface is a stockpile or a block, then the color in the bucket is the color of the primary material in the block.
- If the surface is in a Material Design file, then the color in the bucket is the color of the material in that polygon on the design.
- If the surface is "Mining in Progress", indicating that some of the material has been removed, then the surface is a hatched charcoal gray.
- If the surface is "Mined Out", indicating that all the material has been removed, then the surface is solid charcoal gray.
- Buckets containing material from a "Mined Out" surface show as a pink color and are classified as "unknown".
Any bucket that, for whatever reason, contains "unknown" material can only be dumped into a stockpile or block that is already "Mined Out" (cross-hatched dark gray) or onto a surface that is not a stockpile, processor, or block. The software opens the Material Selection dialog and sends a report to the office with "unknown" or the override name as the material name.
Allow the operator to select a material name by enabling the "Unknown Material Time" setting in the MCU, or by supplying Material Modifiers (toolbar buttons).
GoTo: Operator Interaction > Material Identification
The trigger for the software to start recording a dig may be initiated by the operator in one of two ways:
Manual dig button - Use for infrequent overrides when in GIS mode, or on excavators and hydraulic front shovels when in Material Design mode.
Manual physical dig switch - Use permanently, if required.
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Manual Dig - Records the load as a Dig state and the dig cycle as started |
Use this button:
- To give the operator more control over defining the start of a dig cycle when in GIS mode
- When, for some reason, the software has not detected the load (no color appears in the bucket).
One dig report is sent to the office at the end of each dig cycle. Also applies to excavators and hydraulic front shovels when in Material Design mode.
To give the operator full control over defining the start of a dig cycle, install a physical dig switch. The software will never automatically detect digging when there is a physical dig switch configured in the mach_cfg.txt file.
The dig report records the position of the trigger point (described above) and the time stamp of that position.
The software sends one dig report to the office at the end of each dig cycle. This report applies for Prime, Aux, or LHD modes.
The Cat ERS 7495 detects the dipper weight. There is no change to the way this detection works.
The on-board software knows when the Wheel Loader is dumping and sends the information to the office software. There are variations on how (dependent on machine type) and where (depending on Material Design mode or GIS mode) the dump occurs. There are also some exceptions.
For the software to detect the start of a dump, the bucket must first contain material. Detecting a dump triggers a DR3. At the end of loading a truck, selecting Send Truck triggers a DR3 and an LR3.
There are two methods the software uses to detect a dump:
- Automatically
- By the operator using the Manual Dump button
The software treats information from both methods the same.
The software uses the angle of the Wheel Loader bucket to define the "dumping" state.
The following occurs:
- A dump inside the processor polygon is a dump into the processor.
- A drive through the processor polygon by a loaded machine is a dump to the processor. The loader does not have to reverse in a processor for the dump to count, the loader only has to enter the processor polygon.
- A dump outside the processor polygon is not a dump to the processor. The dump is recorded, but has no associated processor name.
- Either the software automatically detects the dump, or the operator triggers the dump, but not both.
- While the loader moves backward and forward inside one stockpile, the software does not automatically trigger a dump, which allows the loader to clean up the stockpile.
- If wanting to dump within the same stockpile, refer to Manual Dump below.
Multiple dumps outside a processor may hint at an incorrect location for the processor.
When dumping in an area that has "unknown" material type, such as an area with "Mined Out" status, or when the bucket contains "unknown" (pink) material, the software opens the Material Selection dialog so the operator can choose the type of material. If a permanent override ("Hold") is in place, the software applies the override automatically
Excavator / hydraulic Front Shovel (DA)
In an excavator or hydraulic front shovel using the high accuracy dipper positioning system, the automatic trigger is the combination of max and min angles, max and min distances, max and min times, and bucket angle sensors to determine the dump.
With Material Design mode, the software records the automatic trigger anywhere on the design.
With GIS mode, the dump is a dump to the processor only if the bucket is inside the processor polygon.
In a Cat ERS, the automatic trigger is a combination of dipper trip flags and swing.
With Material Design mode, the software records the automatic trigger anywhere on the design. For each dump trigger while in GIS mode and when there is no truck allocated to the machine, the software sends a DR, DR3 and LR3 message.
This trigger could be a dump to ground or a dump to processor. However, the dump is a dump to the processor only if the bucket is inside the processor polygon. If the machine has a truck allocated to it, then a dump to the location of the truck is considered to be a dipper load, initiates a DR and DR3.
Once the truck is loaded, use the Send Truck to initiate the LR3 and DR3.
To give the operator full control over defining the end of a dig cycle, install a physical dump switch or the new Manual Dump toolbar button. The software on the Wheel Loader detects a manual dump event irrespective of the Prime, Aux, or LHD mode selected by the operator and irrespective of being in Material Design mode or in GIS mode.
The following occurs:
- A manual dump inside the processor polygon is a dump into the processor.
- A manual dump outside the processor polygon is not a dump to the processor. The dump is recorded, but has no associated processor name.
- Either the software automatically detects the dump, or the operator triggers the dump, not both.
- A manual dump over a stockpile or block records the dump into the stockpile or block, even if the material is "unknown".
When using the Manual Dump button with an "unknown" material in the bucket, the software opens the Material Selection dialog so the operator can choose the type of material. If a permanent override ("Hold") is in place, then the override applies.
The software then sends one DigReport message to the office at the end of each dig cycle, plus an LR3 and DR3 message. If the bucket was empty, the software only sends a DigReport message stating the known facts of the cycle.
The trigger for the software to start recording a dump may be initiated by the operator in one of two ways:
Manual dump button - Use for infrequent overrides.
Manual physical dump switch - Use permanently, if required.
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Manual Dump - Records the load as dumped and the dig cycle as ended. |
To give the operator more control over defining the end of a dig cycle, use the new Manual Dump button.
Use this button every time you want to dig and dump within the same stockpile, or dig and dump to trucks within the same stockpile. The software will never automatically detect a dump within the same stockpile from which the material was dug.
Use this button when, for some reason, the software has not detected the load (no color appears in the bucket). A common example of this is when a loader digs material in an area of the stockpile that is considered "Mined Out" by the software, or when the loader loads a truck within the stockpile boundary.
To give the operator full control over defining the end of a dig cycle, install a physical dump switch. The software will not automatically detect dumping when there is a physical dump switch configured in the mach_cfg.txt file.
Once the truck is loaded, the operator uses the Send Truck menu item or toolbar button to set up a series of productivity-related records and messages.
At times the operator may select Send Truck before dumping the final load into the truck. The software will recognize that this bucket load should be in the truck.
The software sends the following messages:
- the LR3 has loadReason = 1 (operSendTruck)
- the DR3 has dipperReason = 2 (endOfLoad)
When a dump occurs where a grade block and stockpile overlap, the on-board software identifies the stockpile, not the grade block, as the dump destination.