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Health, Production and Payload Management Solutions for Hydraulic Excavators

Features and Functionality

PULSETerraMetrixEX - Features and Functionality (2015) 2

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The PTM high �delity payload measurement system for hydraulic excavators and wheel loaders is achieving unrivalled accuracy in global payload monitoring.

The PTM platform supports productivity improvement by providing accurate payload feedback to the operator, directly engaging production, maintenance and training sta� in productivity improvement strategies. By practicing “smart loading” and optimizing truck loads, excavator productivity gains can be made and maintenance cost per ton of material moved reduced.

Advanced cycle time analysis supported by machine utilization statistics and operational KPIs enable training sta� to amplify excavator mining e�ciency. Supported by accurate real time machine positioning and mine plan compliance technology, the PTM has a proven track record of accuracy and productivity improvement with a rapid ROI.

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Smart LoadingImprove truck loading accuracy - reduce under loads and overloads and move more material for lower cost per ton.

Mine plan compliance Accurate machine positioning and Lidar bank scanning allows for accurate mining to plan.

Real time feedback Provide your operators with accurate real time payload information and engage them as an active element of the production cycle.

Health Monitoring Monitor the structural health of the excavator with con�gurable alarming coupled to a smart camera for targeted video recording of events and operator training intervention.

Training Simulator Deploy an accurate mechanical simulator for operator training in a controlled environment.

Digability AnalysisDigability analysis provides direct feedback on digging conditions and allows for optimized blasting practices.

Knowledge Base Utilize the knowledge base of our engineers and scientists and our in depth expertise in forensic structural analysis, fatigue failure and weld repair methods to reduce unscheduled maintenance.

Return on Investment (ROI) With an ROI of between 1 – 3 months, the PTM is gaining increasing industry recognition and worldwide application.

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Features and Functionality

ContentsOverviewProductivityPayload Measurement Optimum Truck Loading Structural Monitoring Camera System Reporting and Data Access System Integration Mine Plan Compliance Support, Training and Maintenance Feature Summary Related Products

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4PULSETerraMetrixEX - Features and Functionality (2015) 4

The PTM provides an advanced monitoring capability to the global open pit excavator mining �eet, including the following features.

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Operator InterfaceWith a concise ergonomically designed operator interface, the PTM enhances machine operator performance, supporting the vital role machine operators �ll in real-world mine productivity improvement strategies.

Payload AccuracyThe PTM high �delity payload measurement system supports dipper carryback compensation whilst maintaining accuracy in all operating conditions.

Payload Compliance The PTM enables machine operators to con�dently implement optimum �eet loading practices, including truck by truck targets, avoiding truck under/overloads and reducing truck �eet damage.

Machine Positioning and Mining to Plan Coupled with HPGPS and direct real time Lidar based measurement of bank cross sections, superior mine plan compliance can be achieved than by traditional “dipper teeth” tracking methods.

Digability Provides advanced digability formulations based on mechanical energy and dig time in the bank.

Event Alarms Operator training is directly coupled to con�gurable health alarm events through operator KPi reporting and ranking, allowing for rapid identi�cation of superior operator practices.

Smart CameraOur unique camera technology which couples video image with alarm events provides for rapid resolution, correction and enhancement of unproductive operator practices.

Dispatch Integration Supports any third party dispatch systems such as Wenco, Modular and Jigsaw.

DataCenter Web Based Portal All data stored in an SQL database and supported by a web based analysis API with feature rich reporting functionality.

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Features and FunctionalityOverview

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The PTM is a feature rich system capturing key performance indicators including:

• Payload statistics – average pass load, truck load, number of passes per truck.

• Cycle times and cycle component times (dig, swing, dump, return , waiting, delay, propel and shovel down time).

• Swing angles.

• Accurate shovel time usage and utilization tracking.

• Digability calculation and analysis.

• Cumulative fatigue damage and equivalent stress range calculations identifying operator practice or changing digging/blasting conditions.

• Accurate discard load identification and discard load tonnage.

• Operator logon capability and delay code functionality if not already provided by the truck fleet Dispatch system.

• HPGPS and machine positioning and mine plan compliance capability.

• Accurate bank and bench profiling using Lidar technology.

• Fully integrated with third party truck fleet dispatch systems (Wenco, Jigsaw, Modular) with bidirectionalcommunication of data.

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Features and FunctionalityProductivity

All data is reported into an SQL database allowing for real time current shift, historical machine/crew or cross fleet machine analysis. The system supports automatic reporting functionality or direct database access to allow mine personnel to formulate and implement custom dedicated Excel spreadsheet analyses.

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The PTM deploys accurate loadcell and inertial correction technology to achieve high �delity payload measurement. The high �delity of the measurement supports di�erential mass measurement, directly compensating for dipper carryback, a unique capability of the PTM .

The PTM payload system deploys accurate pre-calibrated loadcell technology to directly measure payload in the bucket. The system does not use hydraulic pressure or structural stain gauge measurement to approximate payload.

The PTM sets the gold standard in payload accuracy and �delity when compared with traditional hydraulic or hybrid systems (structural or strain gauge based methods), which lack the capability to perform accurate di�erential payload measurement and maintain �delity in all operating conditions.

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Features and FunctionalityPayload Measurement

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The PTM is fully integrated with third party dispatch systems (Wenco, Jigsaw, Modular).

Dispatch integration provides bi-directional communication of data between the PTM and the Mine Dispatch system, allowing for truck identi�cation and optimal real time target load display. As a result, operators can accurately achieve loading compliance objectives and implement strategic loading practices to ensure optimal truck loading and �eet productivity.

Truck loading control provides the following bene�ts:

• Reduced opportunity cost caused by truck under loads.

• Reduced truck and tray maintenance cost caused by overloads.

• Extended tire life.

Operator feedback is provided immediately after the dipper breaks the bank where the instantaneous dipper load is displayed in real time allowing for corrective actions.

Loading compliance data can be displayed in real time to the operator, Dispatch center, or a historical analysis performed of a speci�c machine, crew or �eet of machines.

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Features and FunctionalityOptimum Truck Loading

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The PTM system includes a health monitoring system with POE (power over ethernet) strain gauges nodes positioned on the revolving frame, boom and stick. Each node is capable of supporting high precision strain gauge measurement from eight locations. The strain gauge data data is applied to formulate structural KPIs which re�ect machine operating characteristics and to provide operator feedback/event alarming for extreme boom stress and swing impact events.

In addition, each stress measurement is processed to extract the equivalent stress range per cycle per ton of material moved and to continuously monitor the overall cumulative mechanical fatigue damage to the machine. This data is logged to an SQL database to provide an indication of operator in�uence on the structural health of the machine and provide inspection maps for maintenance sta�.

Digability

The structural measurements are combined with the boom and stick angle rates to calculate digability from mechanical digging energy. Because the PTM deploys a loadcell to measure the digging tooth force, traditional digability formulations can be complimented with dipper tooth force formulation data.

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Features and FunctionalityStructural Monitoring

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Most machines are already �tted with low level safety camera systems. The PTM can be integrated to these third party devices or supplied with a four camera PTZ system with data-streaming functionality as custom option.

PTM is fully integrated to the structural monitor and event alarming system, capturing and cataloging events on the SQL database with the operators screen embedded on the image for the event cycle. This allows for highly e�cient interrogation of machine events by the training sta� as well as playback to operators during corrective training interventions. Boom jacking, swing in the bank, extreme stress events and gross under or overload events are recorded.

Because only relevant video image is stored to the database, bandwidth overhead is kept at a minimum.

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SmartCam

Features and FunctionalityCamera System

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The PTM stores all data to an SQL database using TCP-IP streaming and data bu�ering between the shovel and server. The database can be directly accessed or analyzed using the PTM web based portal. This custom API provides:

• Real-time multiple machine dashboards for any machine on the network.

• Shift analysis report for each machine on completion of a shift.

• Historical data analysis of crews, machines or a �eet of machines.

• Historical analysis of operator health, payload and productivity KPIs, including loading compliance data.

• Live data viewing through the PTM Server utility.

• The PTM Dispatch software allows for Dispatch or Command center viewing of all machines on the network simultaneously on a single large screen display.

• Direct extraction of data from the database and direct access to the database using Microsoft Excelspreadsheet tools.

The PTM Server Utility allows for remote software and hardware �rmware updates to be automatically completed at shift change. All system parameters and the setup con�guration for each shovel can be interrogated directly. The SQL database is an open means through which third party systems can gather data and information from the PTM database. This allows other applications to build on PTM functionality or access to data for uploading into consolidated data warehouses.

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DataCenter

Features and FunctionalityReporting and Data Access

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Features and FunctionalitySystem Integration

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The PTM provides mine sta� with direct access to the PTM database. User access can be controlled and di�ering levels of accessibility set. The DataCenter web based portal contains:

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DocumentsAll supporting documentation including operating and maintenance manuals, electrical and mechanical schematics.

Mine PlanView of the overall mine plan including shovel positions.

Machine Status Real time dashboard displaying the operating status of each machine. Each thumbnail can be selected to obtain a real time report on the machine for the current shift.

Shift Report Complete analysis and shift report available at the end of each shift, summarizing all relevant production and compliance KPIs for the machine.

Historical DataPortal for detailed historical analysis on a crew/�eet or operator basis summarizing:

• Production Statistics - daily production, pass and truck load histograms.

• Shovel Utilization data.

• Health Data - equivalent stress range, swing and boom alarm events, pad grade alarm (pitch or roll > 10% grade).

• Cycle Analysis - swing/ return angles.

• Digability - dig time, normalized minimum entropy energy calculation.

• Fleet analysis comparing shovel performance.

• Operator Analysis - comparing and grading Operator KPIs. Including production, loading compliance and productivity KPIs.

SOSPortal for reporting and logging maintenance tickets and resolution of those issues. SOS tickets can be viewed and entered with user privileges.

The PTM system is supplied with a standard precision dual GPS system for machine positioning (+-2.5 m) and absolute heading (+-.5 degrees). The mine plan is uploaded from the server to the shovel allowing for real time indication of excavator position and mine plan bank cross section. Gyro enhanced roll and pitch sensors assist the operator with ramp construction.

HPGPS can be added as an option or if HPGPS data is already available it can be integrated into PTM for high precision machine positioning allowing for accurate reconciliation of actual versus planned machine work location.

A Lidar based bank scanning head can be supplied to allow for accurate measurements of the pad height and grade, bank pro�le and undercut. The as mined toe and crest data lines are calculated and stored and directly integrated with mine plan packages for ease of work to plan reconciliation. Optimal machine position is indicated to assist the operator in achieving improved dipper �ll averages and overall production.

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Features and FunctionalityMine Plan Compliance

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An accurate scale model of the PTM system is available in our Vancouver o�ce to train operators, maintenance sta� and payload specialists on the functionality and technical aspects of the system.

Training courses are provided as part of the product together with 24/7 remote support.

The simulator is available as a mechanical training simulator for new operators. It contains all shovel actions and is optimized to accurately simulate the actual machine inertia and cycle times. The use of virtual reality goggles provides a realistic training environment where material can be “mined” in a controlled and supervised environment by the Mine training sta�.

Full site support agreements are available. Alternatively mine personnel can be trained to perform installation, site maintenance, calibration and IT support.

An evergreen hardware option is available as part of the annual software maintenance support.

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Features and FunctionalitySupport, Training and Maintenance

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Production• Time utilization tracking.

• High fidelity loadcell based payload algorithm which measures dipper load and bucket tooth force directly.

• Inertial correction maintaining payload fidelity in all operating environments.

• Differential payload measurement with carryback compensation.

• Discard load tracking and statistics.

• Dispatch Integration and loading compliance statistics.

• Material Digability calculations.

Machine Guidance• Standard precision GPS with HPGPS optional.

• Real time dipper position calculation.

• Real time Lidar bank scan and bank profiling against mine plan cross section (optional).

• Integrated mine plan and operator feedback.

• Compatible with common mine plan software suites.

• Bank cross section analysis including optimal machine positioning and toe and crest determination.

• Gyro compensated machine pitch and roll sensors.

• Truck detection sensor to discriminate discard loads.

Structural Monitoring• Stress/duty cycle and cumulative fatigue damage calculations for every cycle.

• Boom and Stick stress detection.

• Swing impact detection.

• Pad grade alarming.

• User configurable alarm settings.

• Forensic and FEA stress analysis and design modification service available.

Features and FunctionalityFeature Summary

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Reporting• Real time machine dashboards and operator interface view.

• Dispatch or command center software for simultaneous multiple machine display.

• Production and time usage reporting.

• Truck loading and compliance reporting.

• Crew, Machine and Fleet historical analysis and reporting.

• SQL database access for custom macro report building.

Truck Payload Management• Truck Payload and discard load tracking.

• Integrated with third party dispatch systems allowing for target loading of trucks.

• Custom truck target load definition to accommodate optimal loading of trucks with light trays.

• Differential payload measurement and carryback compensation.

Support• Modular hardware design for ease of maintenance and support.

• 24/7 support.

• Software maintenance available to ensure software version upgrades.

• Microsoft windows and Microsoft SQL architecture.

• Compatible with any brand/make of shovel.

• Fully documented installation procedures and manuals.

• Buffered TCPIP data transfer protocols with low bandwidth usage ensures no loss of data due to wireless network outages.

• Evergreen warranty on hardware available.

Features and FunctionalityFeature Summary

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Health, Payload and Productivity Management systemfor Walking Draglines.

Features and FunctionalityRelated Products

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Health, Payload and Productivity Management systemfor Rope Shovels. Loadcell technology with inertial correction.

Whole body vibration and road condition monitor – withcapability for strain gauge measurements. On boardGPS, 3G Ethernet connectivity.

Operator awareness tool – 900Mhz GPS enabled – transmits the location of the vehicle to the PTM system to identify vehicle proximity to the operator.

Lidar based bank scanning system integrated to mine plan. Allows for real time bank section versus mine plan bank section display. Includes high precision GPS and machine positioning.

The PTM supports a range of compatible products focused on supporting productivity enhancement in open pit mining operations.

For more information please visit www.pulseterrametrix.com

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BMT WBM Denver Suite 1208200 S. Akron StreetCentennialDenver Colorado CO 80112United StatesTel (+1) 303 792 9814Fax (+1) 303 792 9742Email [email protected]

BMT WBM Vancouver 401 - 611 Alexander StreetVancouverBritish Columbia V6A 1E1CanadaTel (+1) 604 683 5777Fax (+1) 604 608 3232Email [email protected]

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