OPTIFLEX – improved underground scaling system

OPTIFLEX Better visibility in scaling process

Mining project in collaboration with LKAB and Atlas Copco

Janis Beinerts | Umea Institute of design | janis.beinerts@gmail.com

2014/2015

Table of content Introduction About project LKAB Atlas Copco Field study Group research Group Ideation phase Manual scaling process Mechanical scaling process Problem analyses Design opportunity

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Method Design directions Design directions evaluation Concept 1 Concept 2 Concept 2 A Concept 2 B Technology research Final concept development Design language

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Result Position on the scaletec Side views vision modes Environment Optiflex Mounting system Flexibility Optiflex components Physical model making Physical model poster Presentation stand Presentation Summary / reflection

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About project

The first term project during Advanced Product Design is executed in collaboration with LKAB mining company and Atlas Copco.

The project is dealing with products and solutions for a special user group, in this case the personnel working at the LKAB mine in Kiruna, particularly the miners working in the underground iron ore mine. Focus is on new thinking and innovation, and exploring users’ emotional responses and their needs for products and solutions. The project searches for solutions how to make mining process more safe and jet more productive.

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LKAB

LKAB have existed since 1890 and main ore deposits are mined in underground mines several hundred meters down in the ground. Mining ore at great depths is a logistical problem. LKAB therefore is trying to mine the ore as efficiently as a large scale open-pit mine.

The mine in Kiruna is the world’s largest under- ground iron ore mine with a daily production of 76,000 tonnes of iron ore that is mined and brought up to the surface.

The new haulage level is located at 1365 meters.

LKAB obtain the ore in their underground mines by sub-level caving. This method uses gravitation to cause the ore to fall into development drifts from where it is transported to ground level on large trucks, trains and hoists. Sub-level caving is an efficient mining method for steeply dipping ore bodies that offers maximum take-out from the ore body with a high degree of safety.

Main stages: — Drift mining (preparation) — Production drilling — Production loading — Chute loading / Transport — Dumping / Crushing — Hoisting — Processing and transport above ground

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Atlas Copco

Atlas Copco is a world-leading provider of sustainable productivity solutions.

It serves customers in more than 180 countries with products and service focused on productivity, energy efficiency, safety and ergonomics.

They are also one of LKAB business partners. Atlas Copco biggest competitor is Sandvik.

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Field study

The study visit in Kiruna mine provided essential understanding of mining environment and scale. It was unique chance to see machinery in action and to get feedback from LKAB employees.

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Guided tour, with insights of mining process.

During field-study, we saw main procedures and areas, including deepest mining sector which is 1365 m deep.

Getting familiar with miners personal equipment, daily routine and working tasks.

Visitors center. Gained general information about Kiruna mine structure, mining type and future development perspective.

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Field study

LKAB maintenance workshop. Most of machinery is repaired and maintained on sight.

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Insights on remote controlled operations.

Safety zone and main underground control office. Information about general communication systems, data processing and emergency situation procedures.

Visited production drilling on sight. Explored the problems miners are facing regarding safety issues, mining environment and mining challenges.

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Field study

Lecture from Atlas Copco on mining trends, future challenges and possible design opportunities.

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User studies and interviews with current employees.

Lecture from LKAB about mining process, techniques and problems they are facing at the moment. Information about current place in iron ore industry and future goals.

Visited main control office above ground.

Deeper insights on mining control systems and remote operations.

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Group research

Information gained from study visit in LKAB was complemented with literature studies and was processed in visual way through different group work exercises.

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After each research stage, findings were presented for whole class, analyzed and selected the most important material for further processing.

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Group research

Step by step analyses. Each mining process is broken up in peaces and analyzed. Problem areas are marked out and transformed into potential design opportunities.

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Role play. To have a deeper understanding of user experience and possible emergency situations, a simulated problem situation had been made. Each team presented their own problem area.

Persona method. Combining insights from LKAB miners about their daily struggles and mining problems into a “Typical mining day� scenario.

Mining process analyzed in large scale.

Gives good overlook of how mining is been done chronologically and which mining processes take the most of the time.

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Group Ideation phase

First visualizations for some of the design opportunities.

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Grouping the problems and design solutions.

Ideation phase. Generated enormous amount of conceptual solutions for mining problems.

Best concepts are gradually filtered out through several stages. They are graded and selected the best ones.

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Manual Scaling process

Rocks are removed by long metal spikes. It is a time-consuming and physically very hard process.

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Workers are often unprotected under unsecured rock surfaces. As there are great tension forces and seismic activities in rocks, scaling is considered to be unpredictable and extremely dangerous.

Even after applying safety net and rock-bolts rock surface needs to be checked regularly for any structural changes that might happen after blasts.

Metal spikes gives very good audio feedback on which rocks need to be removed. Hollow sounds indicated problem areas.

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mechanical Scaling process

Most of the scaling process today is done mechanically with a help of scaletec rigs operated on sight.

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The most important scaling components are boom and hydraulic hammer which compared to regular hydraulic hammers have higher working frequency and less force. This reduces chances of big rockfalls that could be caused by high vibrations.

For operators security purposes carbine is moved as far form action point as possible thanks to long boom. Also carbine is reinforced with safety bars to withstand heavy rockfalls.

Modern scaletec rigs are supported with water jets that clean up the surfaces for better structural analyses and reduces high dust levels.

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Problem analyses

Despite constant improvements, mechanical scaling is still quite slow and low productive.

Mostly due to poor vision for operator.

There are several factors that reduces operators visibility.

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View from operators perspective. View is blocked by cabins’ frame and windshield security bars. The long boom is right in front of operator which at certain position blocks view completely. And there is no extra data support, that could assist operator at aiming and decision making.

The action point is far away as boom often reaches over10 m. It is hard to see in detail in this distance, and so aiming is difficult and surface structure analyses are incomplete.

Light support from scaletec rig is insufficient and one directional. This often creates casted shadows by rocks and tool itself. Also environment is very dusty.

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Problem analyses

Due to low visibility operator or his coworkers often assist scaling process from outside of safety cabin, that means under unsecured rock surfaces.

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This creates potentially dangerous situations as there might be rockfalls. Also uneven ground support can cause workers to trip over something which is the most common occasion of injuries in Kiruna mine.

Miners use flashlights to lighten up the work area and give instructions to operator.

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design opportunity

Improve scaling productivity and safety by improving operators visibility and access to better data.

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Benefits User / operator

Improved visibility would provide safer environment for worker. By reducing need to walk on uneven and unsecured surfaces accident rate will be minimized or excluded completely. With constant protection, operators stress levels will be decreased. By providing better visibility and extra data, operators will have better control over work process and productivity will be increased.

Atlas Copco

In future automated and remotely controlled machines will be more demanded.

This improvement could be a technological bridge to more remotely controlled operation.

Atlas Copco could increase their sales by upgrading their machines with this new functionality.

LKAB New system will allow to achieve higher productivity which means more profitable mining. Also new type of operating system might make operators recruitment process more successful as needed skill level for operator could be decreased. It could allow company to gradually move towards global mining trend, which is, semi or full automation through remotely controlled operations.

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DESIGN DIRECTIONS

Generating a wide range of possible solutions backed up by todays technology’s possibilities.

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DESIGN DIRECTION evaluation

1. MOVING CABIN

operator Moves closer

2. PERSONAL ARMOR 3. SHELTER

1. EXTRA CAMERAS

operator Stays in cabin

2. EXTRA DATA 3. MORE LIGHTS

1. REMOTE CONTROL

OPERATOR IS NOT IN MINE

2. NEW SCALETEC 3. FULL AUTOMATION

Conceptual directions are created based on operators’ possible work position.

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Specific solutions for each conceptual direction are created. They are analyzed and evaluated.

Improved visibility

Most potentially successful solutions are selected for further development.

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CONCEPT 1 – A Moving CABIN / cabinless scaletec

This concept’s basic idea is to bring the operator closer to the action point while still keeping him protected from rockfalls. By moving cabin, miner would have high level of flexibility and chance to set his own view point according to situation.

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It would be easier for operator to evaluate surface structure and take better decisions.

This concept also introduces new type of cabin-less scaletec rig, that can be remotely operated from distance.

Downside of this approach is that in drifts there is usually limited amount of space, as a result movable cabin would have difficulties to exchange way with scaletec rig.

Other downside is the in fact that closer you get to action point the more dangerous it gets. So movable cabin would get damaged more often compared to existing solution.

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CONCEPT 2 – extra viewpoint from tools perspective

This concept offers operator an extra closeup view from tools perspective. This improves working visibility and provides needed extra light for scaling operations.

This concept is an add on so improves existing scaletec rigs and is customizable.

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As cameras are aligned with tool head, operator would have easier and faster aiming process. Gained data from these cameras could be accessible for operator directly at cabin or could be transmitted elsewhere for remote control operations.

This concept raises different technical challenges. One of them is how to protect cameras from constant rockfalls and from situations when tool is pressed against rock surfaces.

Other challenge is the enormous vibrations that are created during active scaling process. These vibrations are so strong, that often damage scaletec rig itself. As well there are a lot of dust, water and mud that can lower the quality of vision.

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CONCEPT 2 A – Strong protection shield

One approach on how to avoid cameras from being damage is to protect them behind strong shield. This shield together with cameras and lights could be mounted between boom and hydraulic hammer at mounting plate.

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The mounting plate despite from other scaletec components is usually in constant dimensions, so shield could be applicable to many scaletec types without major customization needs.

Downside of this approach is the weight of scaled rocks, which can reach several tons. Shield would have to absorb enormous amount of force and possibly would brake quit often.

Also shields dimensions and added weight might interfere with scaletec boom maneuverability.

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CONCEPT 2 B – Flexible antennas

The other approach would be to avoid falling rocks when they fall instead of going against them with massive force. This could be done, if cameras are flexible enough to dodge when hit by something.

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Camera and lights are protected in hard rubber casing and placed behind the mounting plate. This is a safe and jet close enough position.

Cameras are positioned around main axis of the hydraulic hammer to get the best overview of the action point.

There are still some technical challenges regarding shaky footage, modular mounting system and hardware protection system.

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TECHNOLOGY research

Vandal proof cameras. Even with high water or dust levels on glass dome, footage quality drops relatively only a little.

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Water and dirt reflective coatings.

Ring lights are used to get very even illumination.

“Fish eye” footage contains all visual data from 180° angle. It can be transformed back to usual “plain” footage.

Todays modern transparent materials are very strong and flexible.

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TECHNOLOGY research

Optical camera stabilization system.

3D data generator uses regular video footage to create CAD geometry of objects.

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Flexible power source.

Digital stabilization softwares.

Layered information on top of video footage.

G3 axial camera stabilizers with accelerometers.

Laser-scanned mining drift.

Vibration absorbers for audio equipment.

Shock absorbing rubber pads.

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Final concept development

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Design language

Visual concept: camera is an add–on for existing scaletec rigs. So visually it is designed to blend into the environment and look as a part of machine.

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Analyses of Atlas Copco design semantics. It was important to understand what colors are used for which purposes. Also overall shape language was considered.

As camera will be placed close to hydraulic hammer, the semantics of this tool was analyses and implemented in the design of cameras body. Most interesting parts were : the hydraulic pin and tubes, and the circular cap.

At the same time, work was also focused on functionality aspect. How it will be fixed, how camera will be powered and replaced in case of damage.

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Position on the scaletec

Analyzing Atlas Copco latest scaletec rig “Scaletec MC�. For better exploration CAD model was created based on dimensions of this model.

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These analyses helped to evaluate the size of the machine and to estimate necessary dimensions and distances for vision unit.

The optimal attachment position is right behind the attachment plate of the hydraulic head as this area is almost never hit by falling rocks.

There are 2 cameras, one each side. This is not only for safety reasons, but also opens up many opportunities for dual vision.

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Side views

Cameras are aligned with the bottom corner bolt screw. Camera itself is tilted 45째 outwards so that optics are aligned with the hydraulic pin. This alignment is necessary for the next step - creation of dual vision.

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This particular camera model is made for Atlas Copco hydraulic hammer SB 302. For other models the length of camera can be changed to achieve perfect alignment.

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vision modes

This is a view from left and right camera’s perspective. It is very close view, and the extra light source makes it easy for the operator to analyze surface structures and to aim.

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As there are one camera each side of the tool, there are 2 vision modes that the operator can choose to work with.

The first one is the “Basic view” when both cameras work separately and produce separate footage. This is especially useful, in case one of the cameras is temporary out of order, for example, is pressed against rock surface and doesn’t focus in right direction.

The second mode is “Dual vision” when both views are merged into one. The hydraulic hammer is erased from view and is replaced by aiming point. This is done by special software and works the same way as human vision: our eyes are not bothered by nose in front as it is erased from the view through image processing done by brains.

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vision modes

Based on todays technology’s possibilities, cameras can create 3D CAD model of rock drifts surfaces. This is very useful data that could improve operators productivity.

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Operator can switch from normal dual vision to 3D CAD view, which is constantly updated as he works. This gives clearer picture of rock surface geometry, hidden cracks and possible threats.

As Kiruna mine 3D scans their mine, it is possible to combine data from existing situation and planned geometry. This way we can assist operator on which stones needs to be removed. This data can be color-coded and placed on top of live-stream footage.

Operator has access to this data from the monitor placed in his cabin. In future scaletec models it could be displayed through heads–up display.

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Environment

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Environment

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Environment

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Environment

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OPTIFLEX

Optiflex design is based on Atlas Copco design language. It it very simple and functional product. It has calm and minimalistic appearance which is designed to bled together with scaling tools and mining environment.

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All parts are modular and replaceable by new one if needed. Components are designed to withstand big rock impacts.

Optiflex is water and dust proof.

There are 2 major blocks: hard rubber protection body and hardware core.

Components will be explained in detail later in this document.

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Mounting system

Camera is mounted through adjustment profile that allows to fix camera in needed angle and forbids it from any rotation. This metal profile also protects wires from being damaged.

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Metal profile is customizable according to the tool head and boom.

Cameras are wired through transformer box, which is powered by scaletec rig.

Through this transformer unit video footage is transmitted froward through LKAB Wifi network.

The top of the body will wear of sooner than mounting part, as it is exposed more to falling rocks. For this reason there is a quick replacement feature, so operator can plug in a new camera unit on sight with a help of a screwdriver.

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Flexibility

The body of camera is made of metal spring casted into hard rubber shell.

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This two material combination ensures good vibration absorption and allows camera to be flexible enough.

When camera is hit by rocks it bends. In this way Optiflex only receives a small portion from total kinetic energy that rock has. With such approach, camera can be much lighter and can last much longer.

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LED lights

Stabilizer of camera

Protection plate

Signal back light

Back cap

optiflex components

Bolts

Impact-proof glass

Protection shell

Optical unit

All components are fixed together with one set of bolts and the whole hardware block is fixed in the protectWion rubber case with back cap.

Optiflex is made of simple and symmetrical parts so it would be cheap to produce it. As product is discountable, it is easy to replace any part in case it brakes.

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Physical model making

The body of prototype was made by hands out of hard poliuretan material. Later it was painted according to Atlas Copco colors.

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A functional web camera and LED lights were build into the model.

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FINAL model

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poster

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Janis Beinerts Latvia

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PRESENTATION stand

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PRESENTATION

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SUMMARY / reflection

In general, I am very satisfied with the end result. The project definitely was full of challenges and it was a very good experience to work with such topic and with such collaboration partners.

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Positive aspects about the project based on feedback sessions.

Improvable aspects about the project based on feedback sessions.

+ The choice of topic and chosen problem area. + Very deep and wide research phase.

The problem was analyzed in very detailed manner. + Lots of alternative solutions looked through in ideation phase. + From the all the alternative problem solutions, seemingly the best direction was chosen. + Realistic and simple design solution.

Implementable today. + Good analyses of Atlas Copco design language. + Final design blends well in scaling environment and has adequate visual expression. + Good problem solution, which involves both product and interaction design component. + Human centered design. + CAD model in great detail, which made it easy to make model visualization and animation. + Good time management in the projects end phase. + Given feedback was considered and implemented in development process. + High quality final prototype with a functional camera and LED light. Reasonable hours spent of building stage. + Great animation video. + Extremely convincing and pedagogic final presentation. With clear explanations why this is a serious problem and more importantly, how the new system can actually make great improvements with technology available today.

– Exceeded expected work hours.

– Too much time spent on the first phase of project (research and ideation). As a result there was a lack of time for more refinements stages of the final design.

– Lack of working prototypes and ideation sketch models.

– The final design could be slightly redefined. There could be more details on the final product. More advanced looking.

– Mounting system could be more developed.

– “Client - designer” communication could be more friendly.

– Components of camera could be mounted from the back rather front.

– As final prototype had working components and realistic look, the bending rubber body would give an even more persuasive feeling.

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Janis Beinerts janis.beinerts@gmail.com +371 29499248