Loading
Rockwell Automation Home
  • Industries
    • Industries Chevron RightChevron Right
      • Automotive & Tire
      • Cement
      • Chemical
      • Entertainment
      • Fibers & Textiles
      • Food & Beverage
      • Household & Personal Care
      • Infrastructure
      • Life Sciences
      • Marine
      • Metals
      • Mining
      • Oil & Gas
      • Power Generation
      • Print & Publishing
      • Pulp & Paper
      • Semiconductor
      • Water Wastewater
      • View All
    Industries
    Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
  • Capabilities
    • Capabilities Chevron RightChevron Right
      • The Connected Enterprise®
      • Consulting & Integration Services
      • Cybersecurity
      • Digital Transformation
      • Industrial Analytics
      • Industrial Automation & Control
      • Industrial Maintenance & Support
      • Industrial Networks
      • Lifecycle Services
      • Machine & Equipment Builders
      • MES Solutions
      • Process Solutions
      • Safety Solutions
      • View All
    Capabilities
    Blogs DistributorDistributor How to Buy EventEvent Events
  • Products
    • Hardware Chevron RightChevron Right
    • Software Chevron RightChevron Right
      • Circuit & Load Protection
      • Condition Monitoring
      • Connection Devices
      • Distributed Control Systems
      • Drives & Motors
      • Energy Monitoring
      • Human Machine Interface
      • Independent Cart Technology
      • Industrial Computers & Monitors
      • Input/Output Modules
      • Industrial Control Products
      • Lighting Control
      • Motion Control
      • Motor Control
      • Networks Security & Infrastructure
      • Packaged Solutions
      • Power Supplies
      • Programmable Controllers
      • Push Buttons & Signaling Devices
      • Relays & Timers
      • Safety Instrumented Systems
      • Safety Products
      • Sensors & Switches
      • Signal Interface
      • View All Hardware Products
    • DesignSuite
      • Dynamic Digital Twin Software
      • Studio 5000 Design Software
    • OperationSuite
      • FactoryTalk Edge Gateway
      • FactoryTalk Batch
      • FactoryTalk Historian
      • FactoryTalk View - HMI Software
      • FactoryTalk Metrics
    • MaintenanceSuite
      • FactoryTalk Analytics for Devices
      • FactoryTalk AssetCentre
      • FactoryTalk Emonitor
      • FactoryTalk Network Manager
      • FactoryTalk TeamONE
      • Fiix CMMS
    • InnovationSuite
      • Augmented Reality
      • FactoryTalk Analytics
      • MES
      • ThingWorx IIoT Platform
    Products
    Find Products by Our Brands: Allen-Bradley FactoryTalk
  • Support
    • Product Support Chevron RightChevron Right
    • Documentation Chevron RightChevron Right
    • Knowledgebase Chevron RightChevron Right
    • Training Chevron RightChevron Right
    • Downloads
      • 2D & 3D Drawings
      • Activations
      • Add-on Profiles
      • Application Code Libraries
      • Compatibility & Downloads
      • Drivers & Firmware
      • Electronic Datasheets
      • EPLAN Macros
      • Sample Code Library
      • Software Patches
      • View All
    • Selection & Configuration
      • Control Systems Configuration Tools
      • Procurement Specifications
      • ProposalWorks Proposal Builder
      • Global Short-circuit Current Ratings Tool
      • Integrated Architecture Builder
      • View All
    • Compatibility & Migration
      • Migration & Modernization
      • Lifecycle Status
      • Product Replacement Lookup
      • View All
      • Technical Documentation Center
      • Technical Specifications
      • Product Certifications
      • Product Drawings
      • Release Notes
      • Literature Library
    • Support Center
      • Support Options
      • Search for Answers
      • Chat Online
      • Call Us
      • View All
    • Online Forum
      • My Inbox
      • My Favorites
      • My Subscriptions
      • View All
    • My TechConnect
      • Chat History
      • Service Ticket History
      • Manage Your Favorite Answers
      • Field Service Request
      • View All
      • E-Learning Courses
      • Training Workstations
      • Training Calendar
      • Training Centre
      • Training Instructors
      • View All
    Support
    Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
  • Company
    • Events Chevron RightChevron Right
    • News Chevron RightChevron Right
    • Careers Chevron RightChevron Right
    • PartnerNetwork Chevron RightChevron Right
    • About Us Chevron RightChevron Right
    • Featured Events
      • Automation Fair
      • Process Solutions User Group
      • Smart Machine Workshops
      • VirtualConnect: Smart Manufacturing
      • View All
    • Webinars
      • Live
      • On-Demand
      • View All
      • Blogs
      • Case Studies
      • Automation Today
      • Podcasts
      • Press Releases
      • Media Contacts
      • View All
      • View Jobs
      • Teams & People
      • Hackathon
      • Employee Video Spotlight
      • Authorized Distributors
      • Encompass Product Partners
      • Licensed Developers
      • OEM Partners
      • Strategic Alliance Partners
      • System Integrator Partners
      • PartnerNetwork Portal
      • View All
      • Our Brands
      • Our Community
      • Our History
      • Integrity & Sustainability
      • Investor Relations
      • Customer Demo Centre
      • View All
    Company
    ProductivityProductivity Investor Relations
  • Sales
  • Sales
  • View All Industries
  • View All
  • View All
  • View All
  • View All
  • Automotive & Tire
  • Cement
  • Chemical
  • Entertainment
  • Fibers & Textiles
  • Food & Beverage
  • Household & Personal Care
  • Infrastructure
  • Life Sciences
  • Marine
  • Metals
  • Mining
  • Oil & Gas
  • Power Generation
  • Print & Publishing
  • Pulp & Paper
  • Semiconductor
  • Water Wastewater
  • View All
  • The Connected Enterprise®
  • Consulting & Integration Services
  • Cybersecurity
  • Digital Transformation
  • Industrial Analytics
  • Industrial Automation & Control
  • Industrial Maintenance & Support
  • Industrial Networks
  • Lifecycle Services
  • Machine & Equipment Builders
  • MES Solutions
  • Process Solutions
  • Safety Solutions
  • View All
  • Circuit & Load Protection
  • Condition Monitoring
  • Connection Devices
  • Distributed Control Systems
  • Drives & Motors
  • Energy Monitoring
  • Human Machine Interface
  • Industrial Computers & Monitors
  • Input/Output Modules
  • Industrial Control Products
  • Lighting Control
  • Motion Control
  • Motor Control
  • Networks Security & Infrastructure
  • Packaged Solutions
  • Power Supplies
  • Programmable Controllers
  • Push Buttons & Signaling Devices
  • Relays & Timers
  • Safety Instrumented Systems
  • Safety Products
  • Sensors & Switches
  • Signal Interface
  • View All Hardware Products
  • View All
  • View All
  • Technical Documentation Center
  • Technical Specifications
  • Product Certifications
  • Product Drawings
  • Release Notes
  • Literature Library
  • View All
  • Training Workstations
  • Training Centre
  • Training Instructors
  • View All
  • View All
  • Blogs
  • Automation Today
  • Podcasts
  • Media Contacts
  • View All
  • View Jobs
  • View All
  • Authorized Distributors
  • Encompass Product Partners
  • Licensed Developers
  • OEM Partners
  • System Integrator Partners
  • PartnerNetwork Portal
  • View All
  • Our Brands
  • Our History
  • Investor Relations
  • Customer Demo Centre
  • View All
  • iTRAK Intelligent Track Systems
  • MagneMover Lite Intelligent Conveyor System
  • QuickStick Intelligent Conveyor System
  • View All
  • Dynamic Digital Twin Software
  • Studio 5000 Design Software
  • FactoryTalk Edge Gateway
  • FactoryTalk Batch
  • FactoryTalk Historian
  • FactoryTalk View - HMI Software
  • FactoryTalk Metrics
  • FactoryTalk Analytics for Devices
  • FactoryTalk AssetCentre
  • FactoryTalk Emonitor
  • FactoryTalk Network Manager
  • FactoryTalk TeamONE
  • Fiix CMMS
  • Augmented Reality
  • FactoryTalk Analytics
  • MES
  • ThingWorx IIoT Platform
  • 2D & 3D Drawings
  • Activations
  • Add-on Profiles
  • Application Code Libraries
  • Compatibility & Downloads
  • Drivers & Firmware
  • Electronic Datasheets
  • EPLAN Macros
  • Sample Code Library
  • Software Patches
  • View All
  • Control Systems Configuration Tools
  • Procurement Specifications
  • ProposalWorks Proposal Builder
  • Global Short-circuit Current Ratings Tool
  • Integrated Architecture Builder
  • View All
  • Migration & Modernization
  • Lifecycle Status
  • Product Replacement Lookup
  • View All
  • Support Options
  • Search for Answers
  • Chat Online
  • Call Us
  • View All
  • My Inbox
  • My Favorites
  • My Subscriptions
  • View All
  • Chat History
  • Service Ticket History
  • Manage Your Favorite Answers
  • Field Service Request
  • View All
  • My Training
  • View All
  • [CCA101] AC/DC Motors and Drives Fundamentals
  • [CCA182] PowerFlex 750-Series Configuration & Startup
  • [CCA183] PowerFlex 750-Series Maintenance & Troubleshooting
  • [CCCL21] Studio 5000 Basic Ladder Logic Interpretation
  • [CCN130] Motion Control Fundamentals
  • [CCN145] Studio 5000 Logix Designer Kinetix 6000
  • [CCP143] Studio 5000 Project Development
  • [CCP146] Studio 5000 ControlLogix System Fundamentals
  • [CCP151] Studio 5000 Basic Ladder Logic Programming
  • [CCP152] Studio 5000 Function Block Programming
  • [CCP153] Studio 5000 Maintenance & Troubleshooting
  • [CCP154] Studio 5000 Structured Text
  • [CCP182] Industrial Ethernet Networks for OT Professionals
  • [CCP183] EtherNet/IP Configuration and Troubleshooting
  • [CCP298] Studio 5000 CompactLogix Fundamentals
  • [CCP299] Studio 5000 ControlLogix Fundamentals
  • [CCV204] FactoryTalk View ME & PanelView Plus Programming
  • [CCV207] FactoryTalk View SE Programming
  • [CCV209] FactoryTalk View ME & PanelView Plus
  • [EK-ICM201] Vibration Analysis – Level 1
  • FactoryTalk Asset Centre Design & Implementation
  • [FTVP] FactoryTalk VantagePoint Configuration & Reporting
  • [SAF-TUV1] Functional Safety for Machinery Engineer
  • [SAF-TUV2T] Functional Safety for Machinery Engineer Cert
  • [SI101] FactoryTalk View SE Configuration
  • [GBR8602] PUWER 98 Acquisition & the Safe Use of Machinery
  • [OEM100] OEM: Fundamentals & Troubleshooting
  • [PRS013] PlantPAx Process System Configuration
  • [RS-FTHSEC] FactoryTalk Historian SE Configuration
  • [SAF-TUV0T] Functional Safety for Machinery Technician Cert
  • [SI100] Logix5000 Project Development & Ladder Programming
  • [UK1003] SLC-500 Maintenance Part 1 with RSLogix500
  • [UK1203] SLC-500 Maintenance Part 2 with RSLogix500
  • View All
  • Automation Fair
  • Process Solutions User Group
  • Smart Machine Workshops
  • VirtualConnect: Smart Manufacturing
  • View All
  • Live
  • On-Demand
  • View All
  • Digital Transformation at Norbord
  • View All
  • Brighter, More Flexible Tower Light Now Available from Rockwell Automation
  • Delphi Award Received For Asset Management
  • Internal Bypass Expands Smart Motor Functionality
  • New IaaS Bundle Eases Industrial Networking
  • Rockwell Automation Names Sebastien Grau as Regional Sales Director for Middle East, Turkey and Sub Saharan Africa
  • Expanded Power Range for PowerFlex 6000 MV Drives
  • Studio 5000 Software Update Optimizes Productivity
  • FLEX 5000 I/O Modules Bring Greater Productivity and Flexibility to a Connected Enterprise
  • New Cable-Pull Switch Enhances Industrial Safety
  • Instant Industrial Device Analytics
  • Rockwell Automation to name Al Ghandi Electrical & Automation as Authorised Distributor in the UAE
  • Rockwell Automation to Broaden Connected Enterprise Consulting Expertise with Acquisition of Kalypso
  • Single-Control Multi-Well Pad Solution Cuts Costs
  • Advanced Light Curtain System Improves Flexibility and Safety
  • Automation University
  • Rockwell Automation to Showcase the ConnectedProduction Solutions and Premieres its ThinManager Software at ADIPEC 2018
  • Safe Torque Off Option Simplifies Machine Design
  • Machine Performance Analytics Bring OEM Expertise Into Producer’s Digital Environment
  • Software-Powered Connected Services
  • New Managing Director of Rockwell Automation for Sub-Saharan Africa announced
  • Rockwell Automation Simplifies Analytics for Industrial Productivity
  • New Managing Director of Rockwell Automation for Sub-Saharan Africa announced
  • Securely Deploy Cloud and Mobile Technologies with New Network Guidance
  • Rockwell Automation drive system selected for Sumitomo Rubber’s rubber mixers
  • PlantPAx DCS Roadmap
  • View All
  • Students & New Grads
  • View All
  • Hackathon Use Case for Manufacturing Optimization
  • Hackathon Use Case for Sustainability
  • Hackathon Use Case for Visual System Modernization
  • Hackathon Use Case for Dynamic Filtering
  • View All
  • 24toCode Event Recap - Winter 2019
  • 24toCode Event Recap // IT Internal Hackathon
  • Meet the 2019 IT Summer Interns
  • 24toCode Promo Video
  • Harbor View Plaza Ribbon Cutting
  • Check Your Blind Spots Mobile Tour at Rockwell Automation
  • Mechanic & Tool Apprenticeship at Rockwell Automation
  • Working at Rockwell Automation in Karlsruhe
  • Summer Internships at Rockwell Automation
  • The Intrapreneurial Skills Accelerator at Rockwell Automation
  • Makers Wanted
  • #LifeatROK w Katowicach
  • IT Summer Internship Program
  • #LifeatROK with Diogo
  • View All
  • Cisco
  • Endress+Hauser
  • FANUC
  • Microsoft
  • Panduit
  • View All
  • Our Focused Giving
  • STEM Education
  • Lifelong Learning
  • View All
  • Sustainability Report
  • Our Commitment to Diversity, Equity and Inclusion
  • Environmental, Health, & Safety
  • Ethics & Compliance
  • Global Supply Chain & Sourcing
  • Product Environmental Compliance
  • Quality Management Systems
  • Trust & Security
  • Workforce of Tomorrow
  • View All
Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
Blogs DistributorDistributor How to Buy EventEvent Events
Find Products by Our Brands:
Allen-Bradley FactoryTalk
Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
ProductivityProductivity Investor Relations
  • Literature LibraryLiterature Library
    Literature Library

    Access technical and commercial publications for hardware and software products, applications, services and solutions.

    PCDCProduct Compatibility and Download Center
    Compatibility & Downloads

    Find downloads including firmware, release notes, associated software, drivers, tools and utilities.

    KnowledgebaseKnowledgebase Support Center
    Knowledgebase

    Browse the database of questions and answers on a variety of products and technologies.

    Product ConfiguratorProduct Configurator
    Product Configurator

    Configure and select products rapidly.

    Software SubscriptionsSoftware Subscriptions
    Software Subscriptions

    One stop shopping for software and subscription services.

    2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
    Tools
    UserUser Sign In/Create an Account
  • User Account User
Tools
Literature LibraryLiterature Library
Literature Library
PCDCProduct Compatibility and Download Center
Compatibility & Downloads
KnowledgebaseKnowledgebase Support Center
Knowledgebase
Product ConfiguratorProduct Configurator
Product Configurator
Software SubscriptionsSoftware Subscriptions
Software Subscriptions
2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
Case Study
Recent ActivityRecent Activity

Taking Intelligence Underground

First-of-its-kind ore handling solution puts safety first at one of the world’s largest copper and gold mines

Share This:

LinkedInLinkedIn
TwitterTwitter
FacebookFacebook
PrintPrint
EmailEmail
Main Image

Challenge

  • Design an ore handling chute that helps enable safer, more efficient underground material transport

Solutions

  • Smart safety solution - Featuring CIP Safety communicating over EtherNet/IP – and a wireless network
  • Allen-Bradley Compact GuardLogix safety controllers
  • Allen-Bradley POINT Guard I/O modules
  • Allen-Bradley PanelView graphic terminals

Results

  • Operates only after transport truck is detected and identified under the chute
  • Includes fallen rock protection to help safeguard vehicles and personnel
  • Monitors ore bins to help maintain safe material levels
  • Enables fast fill rates with a maximum instantaneous flow rate of 10,000 tonnes per hour (tph)

Mining companies are digging deeper than ever. And to maximize output, what starts as a pit mine often extends underground.

“As mines get deeper, extraction of valuable ore becomes more costly,” said Derek Meloche, manager of business development, Variant Mining Technologies. “In addition, safeguarding personnel from underground hazards is a critical concern.”

Located in the Sudbury basin in Ontario, Canada, Variant Mining Technologies specializes in solutions for underground hard rock mining. The company works to solve one of the industry’s biggest challenges – moving material underground safely and efficiently.

Opportunity at Massive Mongolian Mine

Recently, a leading global mining company engaged Variant Mining to solve an ore transport challenge for a copper and gold mine in Mongolia. The mining company began open pit mining at the site in 2011 and recognized the value that lay deep underground.

“In fact, this site boasts one of the largest known copper and gold deposits in the world,” Meloche said. “Specifically, the company approached us to design an ore-pass loading system for underground operations slated to begin in a few years.” 

Upon completion, the underground mine is expected to produce 95,000 tonnes of ore per day, tripling the current production at the site.

Block Caving Challenges

Transporting ore underground presents significant challenges, depending on the excavation method used. Underground operations at the Mongolian mine will use the “block caving” method. In block caving, a large section of rock is undercut. The ore then collapses – or “caves” – gradually under its own weight.

The resulting rubble funnels through a series of vertical ore passes at various levels in the mine. A chute system is located at the bottom of each ore pass.  

“The chute is a device that allows ore to be transferred safely to the haulage vehicles,” Meloche explained. “It controls the flow so haulage equipment can be loaded quickly and safely.”

Trucks collect the material from a chute at the haulage level and transport it to conveyance systems, which bring the ore to the surface.   

If ore is not sufficiently controlled, loading material at the haulage level poses a significant safety risk to personnel. Potential hazards include chute failures, falling debris, uncontrolled run of muck and unexpected vehicle traffic.

Safety First

“Safety is the number one priority for this customer,” said Meloche. “They are focused on creating a productive mining environment that mitigates safety risk – and is an attractive place to work.”   

The project is well aligned with Variant’s niche in the marketplace. Traditionally, underground ore chute systems have been viewed as steel fabrications, with very limited control. However, Variant brings control technology to the forefront to help make equipment safer, more efficient and more reliable.

Mining Automation
Main Image
Capability
Mining Automation

Click here to learn more about smart, efficient Rockwell Automation solutions that help enhance mine safety.

Explore Our Capabilities

A Two-Fold Control Solution

Successful operation of the ore loading system depends on the coordinated control of the ore chutes and haulage vehicles. Variant is charged with supplying the ore chutes – and a safety control system that meets functional safety requirements. To achieve a functionally safe system, in this case a system that meets SIL 3 ratings, the design considered the process that encompasses the bin, chutes and trucks.

The control system is built on a Rockwell Automation® platform featuring Allen-Bradley® Compact GuardLogix® safety controllers, Allen-Bradley POINT Guard I/O™ modules, and HMI based on Allen-Bradley PanelView™ graphic terminals.

The system is designed with a GuardLogix controller and HMI in each chute and aboard each truck. For fail-safe communication, the integrated system uses the CIP Safety™ protocol running on an EtherNet/IP™ wireless network.

“We have a history of working with Rockwell Automation during our design process,” Meloche said. “We’re a relatively small company developing state-of-the-art solutions, so we rely on the core competence of our larger group of companies and supply chain to support the development our solutions.”

Enabling Smart Technology

To optimize the system, Variant incorporated several technologies that are not new in other industries but new to underground mining. For example, the vehicle detection system in the chute loading area detects a truck’s presence and position – while RFID technology determines the vehicle model and type.

“This technology – and CIP Safety over wireless – allow operators in the truck cabs to control the chutes in a safer manner,” Meloche said. “The chute will not operate unless a haulage truck is present and in the correct position. Jeeps or other vehicle types cannot trigger operation.”

The system also includes fallen object protection. A gate at the end of the chute contains any loose rocks from the previous load to help safeguard approaching vehicles and personnel.

“And our system monitors the ore bins associated with each chute to make sure they don’t run empty,” Meloche said. “We keep material in the bins at all times to serve as a buffer – so ore falling 150 feet doesn’t come out of the chute like a rocket.”

On the mechanical side, Variant designed the chute with a large, 5’ X 10’ (1525 mm X 3050 mm) opening to improve throughput and minimize the risk for hang-ups.

Exceeding Expectations

Variant’s initial contract includes five systems. The final mine plan will have as many as 30 chutes distributed underground – and up to 40 surface and underground haulage trucks for loading. 

“We tested the first system onsite here in Canada,” Meloche said. “We fully assembled the system and ran it for a month. The customer was very pleased with the results they saw at our facility.”

The initial system has shipped to Mongolia and is awaiting underground installation. 

In addition to enhancing operator safety, the ore handling system is designed to optimize mine throughput. When installed, each chute is expected to achieve a maximum instantaneous flow rate of 10,000 tonnes per hour (tph). Variant anticipates the system will enable significantly better traffic control and equipment utilization than other systems on the market.  

“Overall, mining companies are most concerned about safety – and productivity,” said Meloche. “Our safety-rated SIL 3 system is designed to improve both.”

This truck loading control system is currently patent pending.

Published 05 February 2020

Subscribe

Subscribe to Rockwell Automation and receive the latest news, thought leadership and information directly to your inbox.

Subscribe

Recommended For You

Loading
  • Technical Question
  • Chat Technical Support
  • Phone Support
  • Contact Sales
  • General Questions
  1. Chevron LeftChevron Left United Kingdom Chevron RightChevron Right
  2. Chevron LeftChevron Left Company Chevron RightChevron Right
  3. Chevron LeftChevron Left News Chevron RightChevron Right
  4. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
Discover
  • The Connected Enterprise®
  • Create Your Account
  • Case Studies
  • Events
Information for...
  • Distributors
  • OEM
  • System Integrators
  • Encompass Partners
  • Investors
  • Career Seekers
Contact Us
  • General Questions
  • Technical Questions
  • Local Sales & Service
  • Pricing & Availability
  • Report Ethical Concerns
  • Customer Experience Survey
Site Information
  • Legal
  • Privacy Policy
  • Cookie Preferences
  • Terms of Use
  • Trademarks
Change Country Site SelectionChange RockwellAutomation.com site selection to a different country, region or language Change Country
United Kingdom/English

Keep Updated With Us

Sign up to receive our latest headlines for free.

Stay Informed Now
Follow Us
BlogRockwell Automation's Blog
Copyright ©2021 Rockwell Automation, Inc.
United Kingdom