Applying active RFID in mining

By Clive Wilmans, Managing Director: Core System Integration

Keywords: [active RFID, blind area,

last mile, mining]

An active RFID tag is an

electronic device that continually

transmits information on a pre-

set RF signal over a certain

range. The tag comprises

a microprocessor,

transmitter, battery, antenna

and firmware.

Abstract This paper introduces active RFID technology: its principles of operation and capabilities. Readers of this

paper can gain a proper understanding of the technology so that they can make informed decisions on its

application in their sphere of influence.

Like all new technologies when first introduced, RFID has been associated with successful applications

and with less successful projects. In some cases suppliers have overpromised and under-delivered for a

variety of reasons.

Introduction Active RFID technology is well suited to the mining industry, both on surface and underground. The

technology has been extensively tested, and has proved to be:

• Effective in its operation

• Efficient in achieving the required results

• Reliable in operation

• Robust enough to withstand harsh and aggressive environments

• Very affordable to deploy with a virtually zero cost of ownership

Potential applications for active RFID cover a wide spectrum as one can tag any asset in this way: Typical

applications include:

• Personnel safety

• Equipment inventory

• Monitoring and control of vehicles

Active RFID provides a platform for the active and dynamic

generation of real-time data, which can provide management

information to inform operations. This eliminates the need for

making operational assumptions when:

• Making production for casts

• Trying to determine the approximate position of missing personnel

• Investigating the disappearance of critical equipment

• Trying to analyze the events leading to an accident

The technology provides mine management with real-world solutions by adding the proverbial “last mile”

link to many daily operational problems. To paraphrase Albert Einstein, “One cannot use yesterday’s

solutions to solve today’s problems, or tomorrow’s.”

Safety & productivity The requirements and high demands imposed on mine management by the stakeholders include safety

and productivity.

Safety, a white hot topic and the flavour of the day, relates directly to injury to and fatalities of people,

and damage to property. South Africa’s poor track record in this regard has forced government to re-

address the issue and we could soon see new laws tabled, which will negatively influence any player who

does not comply.

Productivity directly influences production, which influences profits. It is related to the effective

management and utilization of all the assets (people, plant and equipment).

Do you know what your exact production figures (ore through the tips) were for the past eight hours? Do

you know the status of all your employees? Do you know where all your equipment is? Do you know

why a locomotive or vehicle is stationary in a haulage for two hours?

Technologies exist to provide answers to these questions and active RFID is being increasingly applied in

these areas.

“You cannot address the

challenges of tomorrow with

yesterday's solutions”

Albert Einstein

RFID – The technology A comprehensive active RFID solution consists of the following elements:

• Active RFID tags

• Active RFID readers

• A communication network infrastructure to relay the data to a central point.

• Software to process the data and convert it to management information.

Active RFID tags and readers can be used very effectively on a standalone basis, and provide the desired

results, however with the implementation of the communication infrastructure and software, users can

optimize the technology.

Active RFID tag

An active RFID tag is an electronic device that continually transmits information on a pre-set RF signal

over a certain range. An active RFID tag comprises:

• A micro-processor, which controls the operation of the tag

• A transmitter, which converts the tag’s ID to an RF signal

• A battery, normally about 2,2 volt

• An antenna, which provides effective propagation of the RF signal transmitted by the tag

• Middleware

Each Active RFID tag has a unique ID and its own power source. There are different tags for different

applications and the range is type and application specific. A tag emits only about 50 microwatt during

transmission, and is thus IS (Intrinsically Safe).

Active RFID reader

An active RFID reader constantly senses and detects RF signals from Active RFID tags, and it can detect

approximately 1000 tags with one read passing at 200 km/hr. An active RFID reader comprises:

• An antenna, which receives the propagated RF signal from the RFID Active tag.

• A micro-controller

• An RF module, which is a receiver and a demodulator

• An external power source, 12VDc

• Middleware

So you may ask, what is all the hype about? The core of active RFID technology is that it provides remote

identification.

Imagine being able to receive an hourly, or live update of the status of all your employees, the position of

all your equipment, and the location and movement of all your vehicles and locos.

Would it make your life easier? Would it improve your operation?

Active RFID technology can do exactly that, as it provides an automated remote identification system

through the active and dynamic supply of accurate location and movement information - it’s like being in

total control.

Surface mining solution Surface mining poses a serious challenge to both man and machine. In Figure 1 we see a 280 tonne truck,

about 8m H X 8m W X 12m L, and a shovel, which can typically be 15m H X 15m W X 20m L, with a

40m loading boom in front, and a bucket with an approximate 70 tonne capacity.

Figure 1. 280t truck and 70t shovel

Have you ever thought of the visibility challenges a truck driver and a shovel operator have to cope with?

This has resulted in many accidents in the past between a swinging shovel bucket and a truck, some

resulting in unfortunate fatalities and serious injury, and always with serious damage to both the truck and

the shovel.

The truck blind area diagram gives a clear indication of the visibility of a truck driver, at ground level

(Figure 2) and at 1,5 m level (Figure 3), which is the shoulder height of an average man. The dark areas

are the “blind” areas.

Figure 2. Truck blind area diagram – Ground level.

Figure 3. Truck blind area diagram – 1,5m.

The shovel blind area diagram gives a clear indication of the visibility of a shovel operator, again at

ground level (Figure 4), and at 1,5m level (Figure 5). Although this shovel tracks remain stationary, the

shovel rotates 360° in any direction with a potential shovel bucket radius of 40 meters.

Figure 4. Shovel blind area diagram – Ground level.

Figure 5. Shovel blind area diagram – 1,5m.

Active RFID technology provides a perfect platform for the “blind area” problem experienced in surface

mining. With the critical positioning of a combination of active RFID readers and tags on both the truck

and the shovel, one would have a continuous feed of remote tag information on people or vehicles which

can be displayed on an audio and visual interface, thus allowing the shovel operator or truck driver to

make a decision as to what action should be taken.

With the implementation of a communication network in the form of a Wireless Mesh Network (WMN)

the information can be relayed and viewed live on a GUI in a control room. The WMN will additionally

provide VoIP communication between drivers, operators, pedestrians, and the control room.

Underground mining solution In underground mining, rail-bound equipment (electric and diesel operated locomotives) and trackless

vehicles and equipment are used. In both instances active RFID technology can be used to:

• Enhance safety

• Improve productivity

The status quo in most mines today, has vehicles and personnel working and operating side-by-side,

seemingly in total harmony. However, everything and everybody seems to be covered in a cloud of dust.

This has traditionally resulted in numerous incidents and accidents, some tragically fatal, and others with

a huge loss of income due to downtime and fixing of infrastructure.

With the installation of active RFID technology, vehicles and personnel can be tagged, and vehicles

equipped with readers, thus immediately creating a safer environment for both man and vehicle/machine.

Each time a foreign tag is detected by a reader it can provide an audio-visual warning to the driver.

The next step would be the deploying of a backhaul communication network infrastructure, and access

points for wireless communication as well as wireless communication modules on the vehicles for the

relating of data to a central control room.

An open-ended network will allow for endless communication possibilities for the future mine with

primary communication on the WMN.

Criteria for selection of suppliers Which criteria should be used when contracting a supplier for the manufacture, supply, installation and

maintenance of active RFID technology solutions? Some points to consider are:

• Although each mining house has its own rules and regulations concerning the buying process, one

has to take cognisance of the fact that there is a global drive to improve transparency and to

encourage integrity of the equipment, the supplier and the end-user.

• Familiarise yourself with the physical design of the product, as well as with the architecture of the

solution. Question the robustness of the solution to be deployed in very corrosive and harsh

environments. Confirm that the solution architecture will provide optimum performance in

relation to the initial problems you experienced.

• Confirm in advance the ability of the solutions to interface with other technologies and

communication networks.

• Familiarize yourself with the SLA, and contact references if necessary.

Advantages of RFID technology The advantages of implementing active RFID technology solutions and systems are:

• The technology solutions and systems are very scalable and can easily be expanded to suit future

growth.

• The ease of implementation allows for quick plug-and-play deployment.

• Most of the mining solutions will be safety related, which will have an immediate impact on the

safety of personnel.

• Well designed systems and solutions will have an enormous impact on the increase of productivity

and production.

• The technology has a very low, virtually zero cost of ownership.

Advantages of communication networks The advantages of deploying a comprehensive communication network (preferably an open ended future-

proof network) are:

• Remote administration and control. Middle management would have the advantage of conducting

their administration from the underground environment, and underground / surface mining

activities can be monitored and controlled in real-time.

• The ability to have nomadic voice over IP (VoIP), as well as nomadic data access to the network.

• Real-time CCTV footage available of critical processes in the operation.

• Hands-on production management in real-time, with the added advantage to take pro-active

decisions.

Software Functional application software provides the key ability for the active RFID technology to interface with

the mining operation. The application software should be:

• Compatible with scada systems and/or SAP.

• Able to collect and archive raw data, and convert it to management information.

The software should also provide the ability to remotely access the management information, as well as

providing the active and dynamic upgrading thereof. The purpose of the management information being:

• To determine where you have been yesterday.

• To see where you are today.

• To make a decision where you want to be tomorrow.

The software should further allow for the real-time viewing on a GUI of:

• The status of the safety of all employees

• The position of your equipment

• The position and movement of all vehicles, for both surface and underground applications.

Conclusion I do trust that you have a better understanding of active RFID technology, how it interfaces with mining,

and how it could assist you with the implementation of “best practices” and “winning strategies”, and thus

allowing you to truly be mining industry leaders.

For more information contact Clive Wilmans, Core System Integration, +27 (0)11 792 3083,

clive@csisa.co.za, www.csisa.co.za

About the author

Clive is a 23 year veteran in industrial design and is currently an active RFID technology advisor to the

mining industry, also focussing on the interfacing and interoperability of active RFID with other

mining related technologies. He is CEO of a South African hardware system integrator and solutions

providing company operating internationally. He has been involved with the design, manufacture and

supply of real-world, cutting edge active RFID technology solutions for the past seven years. He

personally holds several registered patents.

Background: Technical, with multi-discipline experience as a draughtsman and Contracts Manager.

Research: Has spent the past seven years doing extensive active RFID (RF) research and testing in a

very challenging and demanding mining industry.

Specialization: Has developed unique and innovative safety and other active RFID solutions for the

mining industry.

Interest: Analyzing the status quo and trying to improve on it. The aim is always to make it easier and

to add value, and to satisfy the end-user