Applying Systems Engineering in Mine Automation - FINSE

Applying Systems Engineering in Mine Automation

Jarmo PuputtiSANDVIK TAMROCK

System EngineeringLoaders & Drills

[email protected]

Content

1. Introduction- Sandvik Tamrock- Underground Mining- AutoMine Ore Transportation System

2. Sandvik Tamrock Offering Development Process

3. AutoMine System Delivery Process

4. Summary

1. Introduction

Sandvik

Sandvik 2001

! Sales about SEK 44 billion

! 35,000 employees in 130 countries

! Products with high R&D and added value

! Global leader in selected niches

! Chairman of the Board: Percy Barnevik

! President and CEO:Clas Åke Hedström

Sandvik AB

Board of Directors

Group Executive Management

Group Staffs

Business Areas

Sandvik Tooling

Sandvik Coromant

Sandvik CTT

Sandvik Hard Materials

Sandvik Tamrock

VA- Eimco

Driltech Mission

Sandvik Materials Handling

Sandvik Mining and Construction Sandvik Specialty Steels

Sandvik Steel

Kanthal

Sandvik Process Systems

Sandvik International

Sandvik South East Asia

Sandvik Information Systems

Sandvik Service

Other Group Companies

Associated Companies

Separate Business Units Regional Companies Service Companies

Sandvik Tooling

Cemented-carbide and high-speed steel toolsfor the metalworking industry,

cemented-carbide blanks and components

Sandvik Coromant Sandvik CTTTrade marks: Dormer, Titex,Prototyp och Precision

Sandvik Hard Materials

Sandvik Mining and Construction

Machinery, equipment and tools for rock-excavation

Sandvik Tamrock

VA-Eimco

Driltech Mission

Sandvik MaterialsHandling

Sandvik Specialty SteelsStainless steels, special alloys, resistance

heating materials and steel belt and process systems

Sandvik Steel Kanthal Sandvik Process Systems

Sales and Earnings

Sales Earnings Number of2000 SEK M SEK M employees

Sandvik Tooling 15 507 3 135 13 075Sandvik Mining and Construction 10 184 1 073 6 898Sandvik Specialty Steels 14 209 980 9 305Seco Tools 3 785 740 4 059Other 65 -261 1 405Group total 43 750 5 667 34 742

Capital gain 660Financial net -523Earnings before taxes 5 804

by Business area

Sales and Earnings 1981-2000

Operating profit, *incl. Capital gain

0

10 000

20 000

30 000

40 000

50 000

81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 000

2 000

4 000

6 000

8 000

10 000

Sales, SEK M Earnings, SEK M

*

Sandvik Tamrock

- Equipment (drilling, loading and hauling, rock breakage)

- Service & tools

for mining and construction business in hard rock

1. Introduction

Underground Mining

Typical Massive Underground Block Cave Mine

Production Area Layoutof a Block Cave Mine

Underground Mine Production Process

Ore bodyProduction control- production monitoring

Sub-processes

Business planning

Drifting Prod

uctio

n

drillin

g Load

ing &

hauli

ng Crush

ing

Hoistin

g

Sub-processControl

1. Introduction

AutoMine Ore Transportation System

FEATURESFEATURESFEATURESFEATURES!System for automated ore

transportation!Operator can supervise &

monitor multiple machines from a control room

!Automated tramming & dumping

! Teleoperated LHD bucket loading

!Automated truck box loading

! Traffic control! Fleet & production area

supervision!Condition & production

monitoring & reporting!Remote diagnostics!Connectivity to external

onsite systems

Ore Transportation System

BENEFITSBENEFITSBENEFITSBENEFITS! Increased safety! Improved working

conditions!Higher fleet utilization """"

increased production capacity

!Optimized tramming speeds """" smooth equipment operation

!Reduced maintenance & lower operating costs

!Real time production supervision & control

! Integration with onsite systems """" improved control of mining process

DASH-BOARD MODULE

CHAIRMODULE

OPERATORDISPLAY

REARFRAME

MODULE

MIDDLEFRAME

MODULE

FRONTFRAME

MODULE

INFRAFREENAVIGATIONCOMPUTER

CABIN

FRAME

ONBOARD CONTROL SYSTEM

MASTERCHANNEL

REMOTECHANNEL

MONITORINGCHANNEL

ENGINE

STEERING

BRAKE

GEAR

BOOM

BUCKET

OPERATOR CONTROLS

CANOPEN BUS

J1939 CANOPEN SENSORS AND ACTUATORS

INFRAFREE® NAVIGATION PRINCIPLEPOSITION MEASUREMENT BASED ONDEAD RECKONING:• DIRECTION FROM GYRO & ARTICULATION ANGLE• DISTANCE FROM DRIVE LINE• ALWAYS SOME DRIFT IN DEAD RECKONING, DUE TO

GYRO & WHEEL SLIP• DRIFT IN DEAD RECKONING IS CORRECTED

UTILIZING THE ENVIRONMENT MODEL AND WALL PROFILES

INFRAFREE® NAVIGATION SYSTEM

InfraFREE® Navigation

POSITIONSPEEDHEADING

GUIDANCE CONTROLLER

ONBOARD CONTROLSYSTEM

SPEED & STEERING

POSITION ESTIMATORWALLPROFILECORRELATION

SCANNINGLASER,

ENVIRONMENTMEASUREMENT

PRE-TAUGHTPATH &

SEGMENTS

PRE-TAUGHTENVIRONMENT

MODEL

DEAD RECKONING(LOCAL POSITION)

Communication

Video outAudio in/outData in/out

!DIGITAL REALTIME DATA LINK (1 Mbit/s per channel)

!SPREAD SPECTRUM TECHNOLOGY

!COLOR REALTIME VIDEO!HIGH SPEED DATA!VOICE / AUDIO FEEDBACK

WUCS

CONTROL STATION

BASE STATION

MOBILE TERMINAL

Fiber Optic

Radio

SAFETYSYSTEMSAFETYSYSTEM

ProductionProduction AreaAreaPLCPLCPLCPLC

PLCPLC

Safety PLC’sSafety PLC’s

MISSION CONTROL SYSTEM

MISSION CONTROL SYSTEM

CentralCentralCC

ontrolontrolRoomRoom

Mine planningMine planningExternalExternalsystemssystemsMaintenanceMaintenance

OPERATOR STATIONS

OPERATOR STATIONS

SCADASCADA

Wireless Communication

Wireless Communication OnboardOnboard

SystemsSystems

AUTOMINE SYSTEM OVERVIEW

NAVIGATIONNAVIGATION MONITORINGMONITORINGCAMERASCAMERAS

VIDEO

Ore Transportation System

2. Sandvik Tamrock Offering Development Process

Offering Development Process

OFFERING PLANBUSINESS STRATEGY

COLLECTING &SCREENING

BUSINESSPRE STUDY

DEVELOPMENT OF NEWPRODUCT, PRODUCTIONAND SERVICES(PROJECT)

TESTMARKETING

MARKETING &CONTINUOUS DEVELOPMENT

InternationalOffering Team

Business SectorSelection Group

Division SteeringGroups

TECHNOLOGY DEVELOPMENT

MARKET NEEDS AND IDEAS

Business Pre Study



BUSINESSPRE STUDY


TESTMARKETING




! Customer needs, definition of boundary conditions! Market analysis! Competitor analysis! Analysis of present offering! Definition of offering and business concept

(Offering = Product + Services; O=P+S)! Product specification, System requirements

Specification (SyRS)

! Conceptual design (modeling, industrial design)# alternative solutions# level of technology# risk analysis, dependability analysis

! Target costing! Project plan (timing, resources, cost)! Business Impact Analysis (BIA)

OUTCOMEPROJECT PROPOSAL

FOR BUSINESS CONCEPT

Offering Development Project



BUSINESSPRE STUDY


TESTMARKETING




DEVELOPMENT! Specified product definition! Purchasing and manufacturing analysis! Pre plan for marketing and services! Product modeling & analysis! Predictable Operating Cost -analysis (POC)! Dependability analysis! Test planDEVELOPMENT REVIEW

IMPLEMENTATION! Product structure! Prototype / product! Integration test, Factory acceptance test, Field test! Documentation! Marketing plan, Service planINTERMEDIARY DESIGN REVIEW! Factory process! Training plans (marketing, services, production)FINAL PROJECT REVIEW! Project reportEND OF THE PROJECTTRANSFER TO PRODUCT LINE

OUTCOMEPRODUCT OFFERING (O=P+S) WITH

MANUFACTURING AND SERVICE READINESS

Test Marketing



BUSINESSPRE STUDY


TESTMARKETING




! Product follow-up! Product fine tuning! Fine tuning of production process! Fine tuning of services! Marketing material! Service product marketing plan! Training

! Test marketing report# process readiness for market release# marketing readiness# product follow-up report

MARKET RELEASE REVIEW

MARKET RELEASE PROPOSAL

OFFERING DEVELOPMENT PROCESS REVIEW

OUTCOMEMARKET ACCEPTED OFFERING

WITH SUPPORT AND SERVICES

SW Development as a Part ofthe Product Development Process

TYPICAL FEATURES OF SW PROJECTS! Project falls behind the schedule! End product does not fit to the requirements! Development costs are higher than expected! Reliability defects in products! Documents are not up to date

$ NEED TO DEVELOP SW PROCESS AND RESPECTIVE GUIDELINES! Initiation of SOFIA-project spring 1997! First guidelines ready autumn 1998! All new projects according to new process! Experiences even better than expected! $ Continuous Process Improvement

# new methods, guidelines and tools (OOD, UML, SE)# co-development together with partners

SOFtware In Automation (SOFIA)! Development process was analyzed with case studies

% 80% of identified defects caused by an inadequate requirement analysis phase! Optimum process was described! Work was directed to generate guidelines for:

# System Requirement Specifications (SyRS)# System Design Process# Software Requirement Specification (SRS)# Project Management

! The following standards and references were chosen as basics for the work:% IEEE 1233 Guide for Developing of System Requirements Specification% IEEE 830 Recommended Practice for Software requirement Specifications% IEEE 1062 Recommended Practice for Software Acquisition% ISO 9000-3 Guidelines for the application of ISO 9001 to the development, supply

and maintenance of software% ISO 10006 Quality Management – Guidelines to quality in Project Management% “Code Complete”, McConnell, S., Microsoft Press

System test

Test marketing

Field test

Unit test

Coding

Software detaileddesign

Software requirementsspecification

Software Development ProcessCollection and screening

of developmentneeds and ideas

Prestudy decision

Project Decision

System requirementsspecification

System design

Software architecturedesign

Integration test

Project End, Transfer to Product Line

Maintenance

BUSINESS

PRE STUDY

Equipment (HW) Development

Process

OFFERING

DEVELOPMENT

PROJECT

TEST MARKETINGMarket Release


SyRS


SyRS

Capability (solution independent), condition (measurable), constrain (absolute limit)

System designSystem designLimitations and restrictions. Major system components. Interfaces between subsystems. Test plan support.

SoftwareRequirementsspecification

Functional (system behavior, trade-off, redundancy, human aspect), performance, HW and SW interfaces, user interface, restrictions, functional and performance verification.

HardwareRequirementsspecification Mechanic, hydraulic and

electric functions, their restrictions and interfaces.

HW-engineering•architecture design•detailed design•drawings•parts lists•manufacturing instructions

SW-engineering• SW architecture design• SW detailed design• coding• unit test (development platform)• integration test (runtime platform)

System development

System test(drill rig)

Field test(at customer)

CUSTOMER

BUSINESS SECTORS

ENVIRONMENT• Physical• Standards• Market• Organizational• Political• Cultural

TECHNICAL EXPERTS

• TECHNOLOGYCENTER

• ENGINEERING• PARTNERS

RAW REQUIREMENTS

CUSTOMER FEEDBACK

CUSTOMER REPRESENTATION

CONSTRAINT / INFLUENCETECHNICALREPRESENTATION

TECHNICAL FEEDBACK

OKREJECTION SyRSdocument

CONSTRAINT / INFLUENCE

FIELD EXPERIENCE

REVIEW

MARKET AREAS

PRODUCT LINE MANAGER

•SERVICE•PRODUCTION•PURCHASE

System RequirementsSpecification

SyRS

SyRS Process

Maintenance

SOFTWARE PRODUCT

ChangeProposal

CHANGE CONTROL PROCESS

Continuous Product Improvement Process

Programcode

SyRSdocument

Systemdesigndocument

SRSdocument

Structureddesigndocument

Detaileddesigndocument

Unittestdocument

Integrationtestdocument

Systemtestdocument

Fieldtestdocument

UPDATES

TECHNICAL EXPERTS• Technology Center• Engineering• Partners

TECHNICAL EXPERTS• Technology Center• Engineering• Partners

FEEDBACK

CUSTOMER

Business Sector

Market Area

Product Line

REQUIREMENTS

• Service• Production• Supply

• Service• Production• Supply

EQUIPMENTSYSTEM

+

HARDWARE

3. AutoMine System Delivery Process

System Delivery Process

! AutoMine offering has created new business model (integrated systems instead of independent units)

! Systematic way of working needed system delivery projects; currently under development and piloting

! Process based on System Life Cycle model and Systems Engineeringbest practices

! SEPFOR™ (Systems Engineering Formalized) by Techmans CC. (Philip Rust) used as basement

! First project currently in Concept Exploration phase! Strong demand from customer to apply formalized process

System Life Cycle

RequirementsFormulation

Need & requirements

NeedIdentification

Requirementsdetermination

System acquisition

Conceptexploration

Definition &validation

Design &development

Constructionmanufacture

& commission

System utilisation

Operations &Support

Disposal & Restoration

AcquisitionOperational

use andsupport

Why our customers drive SE approach! Top-down specification and design! Bottom-up manufacturing, construction and commissioning! Design focus shifts:

# From concentrating exclusively on the mission of the system to ENTIRE LIFE CYCLE# From EQUIPMENT in isolation to ENTIRE SYSTEM

! Can be used as an effective strategy to reduce the risk associated with system development and manufacturing

! System utilisation# Ensure exploitation of full potential# Measure SYSTEM performance and validate against SYSTEM requirements

! Some benefits# Brings understanding and insight# Up-front consideration given to support and management of the system# Effective management of risks# All stakeholders should be happy!

Evaluation&

Selection

Example ProjectConcept Exploration; Major deliverables

Need & requirements System acquisition

NeedIdentification

Requirementsdetermination

Conceptexploration

Definition &validation

Design &development

Constructionmanufacture

& commission

Cost effectivenessmodel

Systemspecification

Concep. Design 1Conventional

Concep. Design 2Autonomous

UserRequirementsSpecification

FunctionalArchitecture

Typical Massive Underground Mine Production System

TransferPoint

Drawpoint

ExtractionTunnel

RimTunnel

HaulageTunnel

CrusherBins

TransferPoint

Ore Extraction

System

Ore Transportation

System

OreHoisting System

User Requirement Statement

Client value system: Total Value

Value-for-Money

Wt = 0,90

StrategicDesirability

Wt = 0,10

Wt = 0,70 Wt = 0,30 Wt = 0,40

SystemEffectiveness

Wt = 0,60

AcquisitionCost

Wt = 0,30

O&SCost

Wt = 0,70

Availability

Wt = 0,33

Capability

Wt = 0,34

Dependability

Wt = 0,33

Life CycleCost

ImageEnhancement

BusinessSpin-offs

Systems Engineering Work Breakdown Structure; Concept Exploration

WBS # Systems Engineering1.3.1.2 Functional Architecture1.3.1.4 Set of Importance Weights1.3.1.5 System/Segment/Product Requirements Formulation1.3.2.3 Operating System Concept Design Report1.3.2.4 System/Segments/Products RAM Attributes Report1.3.2.5 System Effectiveness and Unit Costs Report1.3.2.6 Product FMECAs Report1.3.3.1 Preliminary System Support Concept Report1.3.3.2 Life Cycle Cost of System Concepts Report1.3.5.1 Preliminary System Management Concept Report1.3.5.2 System Management Cost Estimates Report1.3.7.1 System Selection Model Report1.3.7.2 Alternative System Results Report1.3.7.3 System Effectiveness Sensitivity Report1.3.7.4 Cost Driver Studies Report1.3.7.5 System Trade-off Studies Report1.3.7.6 System Concept Selection Report1.3.8.1 Concept System Breakdown Structure1.3.8.2 System Specification (A-specification)1.3.8.3 Segment Specification: Ops. Management System1.3.8.4 System Concept Configuration Schematics & Drawings1.3.8.5 System Concept Data Records1.3.8.6 Test Reports1.3.8.7 PES specification

General Functional Architecture

System Function 1.1.2System Function 1.1.1 System Function 1.1.‘n’

System Function 1

System Function 1.2System Function 1.1 System Function 1.‘n’

System Function 1.1.2.2System Function 1.1.2.1 System Function 1.1.2.’n’

Technical Function 1.1.2.1.2

Technical Function 1.1.2.1.1

Technical Function 1.1.2.1.‘n’

Level 0

Level 1

Level 2

Level 4

Level 3

OTS Functional Architecture

1. Provide Sustained, CostEffective Ore Transportation

1.1.1 Prepare for Transporting - Operating 1.1.2 Load Ore 1.1.3 Haul Ore 1.1.6 Control Operating

1.1 Transport Ore 1.2 Support Transportation 1.3 Manage Operations

1.1.4 Clear Minor Spillage 1.1.5 Plan Operating

System Hierarchy Levels

! L7 - Enterprise System! L6 - User System! L5 - System Segment! L4 - Product/Unit! L3 - Module! L2 - Component! L1 - Material

Operating System Concept Design

Autonomous Operations Concept

OreTransportation

System(OTS)

SL 7

SL 6Ore

HoistingSystem(OHS)

OreExtractionSystem(OES)

SupportSystem

OperatingSystem

OperationsManagement

System

SL 5

Customer MineSite

1.1 1.2 1.3

1

MiningDevelopment

System(MDS)

OTS Conceptual Design



OperatingSystem

SL 5

SL 5.1

1.1

LoadingSystem

1.1.1

HaulingSystem

1.1.2

OperatingPlanningSystem

1.1.3

OperatingControlSystem

1.1.4

Operating Segment

OTS Conceptual Design



SL 5.1

SL 4

SL 4.1

LoadingSystem

OperatorStation(x41)

SystemOperator

(x123)

Semi-AutonomousLHD(x74)

ControlRoom

Control Panels

PLC

PLC S/W

Video Monitor

MCS Client PC2

MCS Client S/W

WUCS Mobile Terminal

InfraFREE Computer

Video Switch

Bucket Weighing System

Antenna (x4)

Standard LHD

1.1.1

1.1.1.2 1.1.1.3 1.1.1.41.1.1.1

LHDProduction Area

1.1.1.5

ChairDesk

Laser Scanner (x2)

Gyroscope

Other InfraFREE Sensors5

Video Camera (x4)

NOTES:1. 3 Operator Stations required to meet normal production demands (1 redundant)2. Includes: PC monitor, keyboard, mouse3. 4 System Operators per shift4. Minimum of 5 operating LHDs required to meet normal production demand5. Includes: odometer, articulation angle, boom position, bucket position

Extraction Tunnel Roadways

Transfer Points (x4)

Rim Tunnel Roadways

Operating Segment



SL 5.1

SL 4

SL 4.1

HaulingSystem

OperatorStation1

(x4)

SystemOperator1

(x12)

ControlRoom1

Control Panels

PLC

PLC S/W

Video Monitor

MCS Client PC

MCS Client S/W

1.1.2

1.1.1.2 1.1.1.31.1.1.1

AutonomousTruck(x72)

WUCS Mobile Terminal

InfraFREE Computer

Standard Truck

Antennas (x4)

1.1.2.1

Truck Haulage

1.1.2.2

ChairDesk

Video Switch

Laser Scanner (x2)

Gyroscope

Other InfraFREE Sensors3

Video Camera (x3)

NOTES:1. Shared with Loading System2. Minimum of 5 operating trucks required to meet production demand3. Includes: odometer, articulation angle, boom position, bucket position

Haulage Tunnel Roadways

Transfer Points (x4)

Operating Segment

4. Summary

Summary

! Trend in mining business towards wider and more integrated process systems

! Expanding use of modern IT technology! Tightening quality and productivity requirements! Partnering in development; multi site projects! Need to compress development times! "Offering Development and Delivery Processes have to be well

defined! Systems Engineering Approach fits well to existing ODP! Full potential of SE not exploited yet

Thank You

Questions & Comments Please