VR-based digital twin for remote monitoring of mining equipment:Architecture and a case study

Background Traditional methods for monitoring mining equipment rely primarily on visual inspections,which are time-consuming,inefficient,and hazardous.This article introduces a novel approach to monitoring mission-critical systems and services in the mining industry by integrating virtual reality(VR)and digital twin(DT)technologies.VR-based DTs enable remote equipment monitoring,advanced analysis of machine health,enhanced visualization,and improved decision making.Methods This article presents an architecture for VR-based DT development,including the developmental stages,activities,and stakeholders involved.A case study on the condition monitoring of a conveyor belt using real-time synthetic vibration sensor data was conducted using the proposed methodology.The study demonstrated the application of the methodology in remote monitoring and identified the need for further development for implementation in active mining operations.The article also discusses interdisciplinarity,choice of tools,computational resources,time and cost,human involvement,user acceptance,frequency of inspection,multiuser environment,potential risks,and applications beyond the mining industry.Results The findings of this study provide a foundation for future research in the domain of VR-based DTs for remote equipment monitoring and a novel application area for VR in mining.

Key technologies and equipment for a fully mechanized top-coal caving operation with a large mining height at ultra-thick coal seams

Thick and ultra-thick coal seams are main coal seams for high production rate and high efficiency in Chinese coal mines, which accounts for 44 % of the total minable coal reserve. A fully mechanized top-coal caving mining method is a main underground coal extraction method for ultra-thick coal seams. The coal extraction technologies for coal seams less than 14 m thick were extensively used in China. However, for coal seams with thickness greater than 14 m, there have been no reported cases in the world for underground mechanical extraction with safe performance, high efficiency and high coal recovery ratio. To deal with this case, China Coal Technology ＆ Engineering Group, Datong Coal Mine Group, and other 15 organizations in China launched a fundamental and big project to develop coal mining technologies and equipment for coal seams with thicknesses greater than 14 m. After the completion of the project, a coal extraction method was developed for top-coal caving with a large mining height, as well as a ground control theory for ultra-thick coal seams. In addition, the mining technology for top-coal caving with a large mining height, the ground support technology for roadway in coal seams with a large cross-section, and the prevention and control technology for gas and fire hazards were developed and applied. Furthermore, a hydraulic support with a mining height of 5.2 m, a shearer with high reliability, and auxiliary equipment were developed and manufactured. Practical implication on the technologies and equipment developed was successfully completed at the No. 8105 coal face in the Tashan coal mine, Datong, China. The major achievements of the project are summarized as follows： 1. A top-coal caving method for ultra-thick coal seams is proposed with a cutting height of 5 m and a top-coal caving height of 15 m. A structural mechanical model of overlying strata called cantilever beam-articulated rock beam is established. Based on the model, the load resistance of the hydraulic support with a large mining height for top-coal caving method is determined. With the analysis, the movement characteristics of the top coal and above strata are evaluated during top-coal caving operation at the coal face with a large mining height. Furthermore, there is successful development of comprehensive technologies for preventing and controlling spalling of the coal wall, and the top-coal caving technology with high efficiency and high recovery at the top-coal caving face with a large mining height. This means that the technologies developed have overcome the difficulties in strata control, top-coal caving with high efficiency and high coal recovery, and enabled to achieve a production rate of more than 10 Mtpa at a single top-coal caving face with a large mining height in ultra-thick coal seams; 2. A hydraulic support with 5.2 m supporting height and anti-rockburst capacity, a shearer with high reliability, a scraper conveyor with a large power at the back of face, and a large load and long distance headgate belt conveyor have been successfully developed for a top-coal caving face with large mining height. The study has developed the key technologies for improving the reliability of equipment at the coal face and has overcome the challenges in equipping the top-coal caving face with a large mining height in ultra-thick coal seams; 3. The deformation characteristics of a large cross-section roadway in ultra-thick coal seams are discovered. Based on the findings above, a series of bolt materials with a high yielding strength of 500-830 MPa and a high extension ratio, and cable bolt material with a 1 × 19 structure, large tonnage and high extension ratio are developed. In addition, in order to achieve a safe roadway and a fast face advance, installation equipment for high pre-tension bolt is developed to solve the problems with the support of roadway in coal seams for top-coal caving operation with a large mining height; 4. The characteristics of gas distribution and uneven emission at top-coal caving face with large mining height in ultra-thick coal seams are evaluated. With the application of the technologies of gas drainage in the roof, the difficulties in gas control for high intensive top-coal caving mining operations, known as ＂low gas content, high gas emission＂, are solved. In addition, large flow-rate underground mobile equipment for making nitrogen are developed to solve the problems with fire prevention and safe mining at a top-coal caving face with large mining height and production rate of more than 10 Mtpa. A case study to apply the developed technologies has been conducted at the No. 8105 face, the Tashan coal mine in Datong, China. The case study demonstrates that the three units of equipment, i.e., the support, shearer and scraper conveyor, are rationally equipped. Average equipment usage at the coal face is 92.1%. The coal recovery ratio at the coal face is up to 88.9 %. In 2011, the coal production at the No. 8105 face reached 10.849 Mtpa, exceeding the target of 10 Mtpa for a topcoal caving operation with large mining height performed by Chinese-made mining equipment. The technologies and equipment developed provide a way for extracting ultra-thick coal seams. Currently, the technologies and equipment are used in 13 mining areas in China including Datong, Pingshuo, Shendong and Xinjiang. With the exploitation of coal resources in Western China, there is great potential for the application of the technologies and equipment developed.

Development of Mining Technology and Equipment for Seafloor Massive Sulfide Deposits

Seafloor massive sulfide（SMS） deposits which consist of Au, Ag, Cu, and other metal elements, have been a target of commercial mining in recent decades. The demand for established and reliable commercial mining system for SMS deposits is increasing within the marine mining industry. The current status and progress of mining technology and equipment for SMS deposits are introduced. First, the mining technology and other recent developments of SMS deposits are comprehensively explained and analyzed. The seafloor production tools manufactured by Nautilus Minerals and similar mining tools from Japan for SMS deposits are compared and discussed in turn. Second, SMS deposit mining technology research being conducted in China is described, and a new SMS deposits mining tool is designed according to the environmental requirement. Finally, some new trends of mining technology of SMS deposits are summarized and analyzed. All of these conclusions and results have reference value and guiding significance for the research of SMS deposit mining in China.

Mining truck scheduling with stochastic maintenance cost

Open pit mining operations utilize large scale and expensive equipment. For the mines implementing shovel and truck operation system, trucks constitute a large portion of these equipment and are used for hauling the mined materials. In order to have sustainable and viable operation, these equipment need to be utilized efficiently with minimum operating cost. Maintenance cost is a significant proportion of the overall operating costs. The maintenance cost of a truck changes non-linearly depending on the type, age and truck types. A new approach based on stochastic integer programming （SIP） techniques is used for annually scheduling a fixed fleet of mining trucks in a given operation, over the life of mine （multi-year time horizon） to minimize maintenance cost. The maintenance cost data in mining usually has uncertainty caused from the variability of the operational conditions at mines. To estimate the cost, usually historic data from different operations for new mines, and/or the historic data at the operating mines are used. However, maintenance cost varies depending on road conditions, age of equipment and many other local conditions at an operation. Traditional models aim to estimate the maintenance cost as a deterministic single value and financial evaluations are based on the estimated value. However, it does not provide a confidence on the estimate. The proposed model in this study assumes the truck maintenance cost is a stochastic parameter due to the significant level of uncertainty in the data and schedules the available fleet to meet the annual production targets. The scheduling has been performed by applying both the proposed stochastic and deterministic approaches. The approach provides a distribution for the maintenance cost of the optimized equipment schedule minimizing the cost.

The integrated monitoring system for running parameters of key mining equipment based on condition monitoring technology

An integrated monitoring system for running parameters of key mining equipmenton the basis of condition monitoring technology and modern communication networktechnology was developed.The system consists of a client computer with functions ofsignal acquisition and processing, and a host computer in the central control room.Thesignal acquisition module of the client computer can collect the running parameters fromvarious monitoring terminals in real-time.The DSP high-speed data processing system ofthe main control module can quickly achieve the numerical calculation for the collectedsignal.The signal modulation and signal demodulation are completed by the frequencyshift keying circuit and phase-locked loop frequency circuit, respectively.Finally, the signalis sent to the host computer for logic estimation and diagnostic analysis using the networkcommunication technology, which is helpful for technicians and managers to control therunning state of equipment.

Statistical approach to determination of overhaul and maintenance cost of loading equipment in surface mining

The purpose of this research was to develop a new approach in determination of overhaul and maintenance cost of loading equipment in surface mining. Two statistical models including univariate exponential regression (UER) and multivariate linear regression (MLR) were used in this study. Loading equipment parameters such as bucket capacity, machine weight, engine power, boom length, digging depth, and dumping height were considered as variables. The results obtained by models and mean absolute error rate indicate that these models can be applied as the useful tool in determination of overhaul and maintenance cost of loading equipment. The results of this study can be used by the decision-makers for the specific surface mining operations.

Long-term economic sensitivity analysis of light duty underground mining vehicles by power source

LHD's are expensive vehicles; therefore, it is important to accurately define the financial consequences associated with the investment of purchasing the mining equipment. This study concentrates on longterm incremental and sensitivity analysis to determine whether it is feasible to incorporate current battery technology into these machines. When revenue was taken into account, decreasing the amount of haulage in battery operated equipment by 5% or 200 kg per h amounts to a $4.0 × 10~4 loss of profit per year. On average it was found that using battery operated equipment generated $9.5 × 10~4 more in income annually, reducing the payback period from seven to two years to pay back the additional $1.0 × 10~5 investment of buying battery powered equipment over cheaper diesel equipment. Due to the estimated 5% increase in capital, it was observed that electric vehicles must possess a lifetime that is a minimum of one year longer than that of diesel equipment.

CHINA'S RECENT DEVELOPMENT IN COAL MINING,PROCESSING AND UTILIZATION

This paper describes the state-of-the-art and Outlook of coal mining and clean coal technology in China. As the major mining method,underground mining accounts for 96% of the total production. Among the state own mines, the percentage of mechanized mining reached 71 %. A rapid development of high-productive and high-profitable mines,especially those with longwall sublevel caving method, is described. The issues of heavy duty equipment, roof bolting,mine safety are also addressed. The Chinese government is paying more and more attention on the environmental problems inducing from coal mining,processing and utilization. A basic framework of clean coal technology is being formed and a wide range of technology is included.

A Life Evaluation System and its Application to Mining Machinery Equipment

Based on analyzing the mining equipment life evaluation theoretical system, the equipment life evaluation target system of the mining machinery is put forward taking the economic life, security life, reliability life and technical life as the targets. Then, the structure and model of the mining equipment life evaluation system are established and prepared for the realization of the system theoretically. Taking hydraulic support as the research object, the life evaluation system of hydraulic support is established and practice shows that the life evaluation system is feasible.

Capacity-based performance measurements for loading equipment in open pit mines

The purpose of this study is to develop an integrated framework for capacity analysis to address the influence of systematic hazardous factors on the haulage fleet nominal capacity.The proposed model was made to capture unexpected risks for mining equipment based upon data-driven method considering different scenarios.Probabilistic risk assessment(PRA)was employed to quantify the loss of production capacity by focusing on severity of failure incidents and maintainability measurements.Discrete-event simulation was configured to characterize the nominal capacity for mining operation.Accordingly,the system capacity was analyzed through the comparison of nominal and actual capacity.A case study was completed to validate the research methodology.The past operation and maintenance field data were collected for shovel operation.The discrete-event simulation was developed to estimate the rate of shovel nominal capacity.Then,the effects of undesirable scenarios were assessed by developing the PRA approach.The research results provide significant insights into how to enhance the production capacity in mines.The analyst gets a well judgment for the crucial elements dealing with high risk levels.A holistic maintenance plan can be developed to mitigate and control the losses.

On the design and selection of vehicle coordination policies for underground mine production ramps

Traffic management in underground mines,especially on production ramps,is a difficult problem to optimize and control.Most operations use one of a few common policies;e.g.,the so-called ‘‘lock-out" and‘‘loaded-vehicle-priority" policies.The work presented in this paper uses discrete-event simulation to study the efficiency of multiple policies.Based on simulation results,an improvement to the common lock-out policy is proposed.This new policy utilizes the rules of the lock-out policy but integrates an option that allows a group of vehicles to be given temporary priority in a certain direction of travel.Quantitative results are provided and,based on these,a systematic technique for ramp design that aims to optimize the efficiency of underground mine ramp traffic flow is described.