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Over the last 100 years, construction equipment manufacturers have made continuous advancements in the capabilities and safety features of their machines ? today's heavy equipment is more robust, powerful and safe than ever before.

Manufacturers are now developing new machines with further improvements to lower operation and maintenance costs, and increase versatility and reliability. At the same time, they are applying advanced techniques to produce equipment with greater fuel efficiency and reduced emissions.

Equipment is advancing in the construction industry. Manufacturers are focussing on making their machines smarter through the use of proprietary technology systems that make operations more efficient.

• Machine-controlled bulldozers and hydraulic excavators perform heavy construction tasks with precision and efficiency (and without an operator).

• Using telematics, today's equipment can also communicate — instructs when a repair needs to be made, set limits on how deep an operator can dig, or alert the owner if someone tries to steal it.

• A drone circles above the construction site taking photos, and then darts in and out of the works to record measurements and identify potential hazards or quality issues.

• Not so long ago, this work-site scene was science fiction ? but unmanned machinery is currently on the market, and this type of drone is already being used in construction sites around the world.

• Taking things a step further, robots are building modular prefabricated components offsite for assembly at the construction site, reducing project time significantly.

• Digital data are being applied to things like equipment monitoring and GPS navigation in the construction industry, while 3D printing, advanced LED displays, and holographic 3D imagery are taking modelling to an entirely new level. And this data can then be downloaded to smartphones, computers and other internet-based devices for use worldwide.

New technologies are bringing remarkable advances in performance, productivity, efficiency, quality and safety.

Incorporating automated systems that offer greater productivity, purposing new technologies to aid in the discovery and accurate quantifying of deposits, and systems capable of real time analysis to increase efficiency and profitability, all stand to not only change but modernize the entire mining industry.

The adoption of centralised systems for operating, monitoring and controlling the mining or the processing activities from a remote location has been much sought after by mining companies over the last few years in the strive for maximum efficiency, improved safety, decreased variability and better identification of performance issues.

Automated and tele-operated drilling solutions can ensure mining personnel safety and improve efficiency during surface drilling operations. A tele-operated drilling solution comprises of an easily installable operator station on a range of mobile platforms connected to the drilling rig wireless network.

The technology allows the operator to carry out drilling from a remote location without entering hazardous areas. The real time video and data communication including all drilling controls and equipment status are displayed continuously on a graphical screen installed at the operator centre with the use of remote-controlled pan/tilt/zoom camera for drilling, rod-handling and tramming controls transmitting real-time images.

An automated drilling rig offers mining companies a mobile and rapid solution for hard rock excavation. While there are many variants of automated drill rigs in development, perhaps the most promising are battery operated drill rigs capable of drilling blast patterns more quickly and accurately than any human or human operated equipment. Battery operated drill rigs, unlike their diesel or gas counterparts, don't produce harmful exhaust fumes. Battery powered drill rigs also hold promise for lowering maintenance costs and if equipped with rapid chargers, or replaceable batteries, would contribute to the long-standing need of creating continuous mining operations.

 

In addition to being much more efficient at drilling blast patterns, automated drill rigs can be equipped with the latest advancements in cutters or preconditioning equipment – making cutting easier. These technologies include preconditioning the rock with water jets, thermal and explosive impulses, as well as other technologies being developed for weakening rock.

The application of robotic technology, although very limited in current mining operations around the world, has far reaching potential for the mining industry. Robotic devices powered by artificial intelligence can perform a range of tasks including drilling, blasting, loading, hauling, bolting mine roofs as well as ore sampling and rescuing trapped miners.

Internet of Things, an emerging network technology based on the convergence of wireless technologies, micro-electromechanical systems (MEMS) and the Internet, can potentially transform the mining industry by creating new ways of maintaining mine safety and productivity.

The technology involves connecting machines, fleet and people with unique identifiers based on radio frequency identification device (RFID) and sensor technologies while allowing them to automatically transfer and receive data over a network without requiring human-to-human or human-to-computer interaction. The IoT platform can not only improve traceability and visibility of the entire mining operation but also enable computers to observe, identify and understand different facets of mining operations without human intervention and to automate and improve the maintenance and operation of machines.

Research and development in the crane industry are being driven by the users of cranes to reduce the size, weight, and costs. Manufacturers are responding to those requests with innovation and thinking outside the box. Computerisation and the use of apps on the site are giving manufacturers instant information allowing them to adapt relatively quickly to a changing environment. There is already research being done on robotic cranes, particularly for the port sector.

For mobile cranes, some of the key advances in recent times include the ability to deliver higher load capacities over larger working areas through crane support technology. Advanced on-board computer systems allow the operator to monitor all aspects of the lifting process and allow the computer systems to be adjusted to fit specific lift requirements. New boom technology improves boom telescoping capabilities and with the introduction of carbon fibre technology, booms are now stronger and lighter.

Tower crane technology has advanced, with research being undertaken to automate a tower crane. Remote tower crane operation already exists, and the researchers believe by adding an on-board micro-computer, encoders, and sensors that can memorise benchmarks and paths of the hook, and send instructions to the motors then automation is possible.

New gantry cranes are modular, adaptable and intelligent. New technology has enabled cranes to be more compact and energy efficient, which will eventually render legacy systems obsolete. Modular technology gives users the ability to change existing features or add new ones depending on the business need. Additional features could include remote diagnostics, maintenance monitoring or automated positioning. New technology enables companies to be more agile and realise larger returns on investment.

Truck loader crane technology has changed dramatically since the development of the remote control and now with the development of flexible stabiliser setups and automatically-corresponding load chart calculation markets will benefit where there is a deeply embedded understanding of the technology and well-trained operators. There is a movement away from knuckle-boom to stiff boom cranes as the truck loader cranes seek greater operating radius and capacity.

Since the inception of earthmoving machinery, equipment manufacturers have been striving to make the process faster, quieter, easier and more fuel efficient. In the construction industry, the earthmoving sector is among the pioneers in adopting new technologies to reduce operation costs, improve productivity, and enhance automation and safety. Fleet tracking and management systems, automated machine guidance and control, proximity detection devices for accident warning, energy-monitoring systems, automatic transmissions, and EH controls are some examples of emerging products for earthmoving equipment.

Telematics systems are being used to increase machine uptime through remote monitoring of the machine's health and the way it is being used, such as detecting and reporting excessive idling. Such systems have become something of a standard offering from many suppliers and the bigger the machine, the more likely it is to have a telematics system. Telematics systems combine GPS technology, on-board diagnostics and monitoring sensors to track, log and report data via cellular networks on the performance and operation of the equipment. Data from telematics systems are typically accessed through a web portal and can provide data on a number of machine systems. Common data points include GPS location, fuel consumption, idle times and machine alerts.

Integrated fleet information management is among the growing solutions in the heavy construction and mining sectors. Many of the large equipment manufacturers and construction information technology companies provide integrated fleet management systems. These systems utilize a series of built-in sensors and onboard diagnostic systems to provide a wide range of data about the condition and output of the fleet. Most of these systems use a global navigation system (GPS/GLONASS) to locate the machine and employ an on-board diagnostics system for health monitoring and maintenance planning of the fleet.

Machine control technologies are becoming easier to operate and integrate across fleets every day. Excavators, backhoes, graders, dozers and compact excavators can all be outfitted with 2D and 3D machine control systems to assist in everything from mass excavation, grading to precisely sloped trenches. Machine control systems allow contractors to maintain tight tolerances which led to great material savings and the cost reduction cost of earthmoving operations. For example, in case of graders, 3D machine control systems are capable of grading complex surfaces such as super-elevated curves without the use of any pegs or string lines. Automated machine control manages the blade elevation for the operators and also gives steering indication.

Automatic process control systems of crushing and screening plants has been developed for increasing the crushing and screening processing efficiency of stone materials. Modern automatic process control systems incorporate various elements brought together in order to reach some goal using branched interlocking bonds.

The evolving modern concepts of "Internet of Things" and the increasing number of industrial devices, machines and units are equipped with modern automation systems developed with the use of modern industrial controllers. Industrial devices, machines and aggregates have a permanent connection to the global network with used wireless communication channels. Control is performed with used Human- Machine Interface (HMI) implementing in software on interactive touch panels (touchscreens).

One of the most important factors for good product quality & shape is the requirement of a "choke feed" condition. This requires material to fill the crushing cavity to the point where maximum power can be drawn but without flooding the crusher. In Advanced Crushing Technology, multi layered crushing takes place with the increased predominance of interparticle crushing contributing to the production of cubical material. If the cavity is underfed, coarser less cubical products can be expected, supporting the need for automation. Level sensors of various types ranging from simple contact probes to ultrasonic and lasers linked to some method of feed control are used for this purpose.

Belt conveyor weightometers can be positioned strategically across the plant to weigh and totalise tonnage at key locations, such as: plant feed belt, crusher product conveyor belt and in between equipment for mass balancing purpose and measuring of re-circulating load. The weightometer readings are used to calculate efficiencies such as operational efficiency, plant production efficiency, and recovery efficiency. The performance of weightometers is highly linked to the operational conditions, such as spillage of ore/concentrate on the weightometers and problems in conveyor operation.

Cameras are used as an operation tool to monitor problematic transfer points and or plant equipment in an effort to detect problems prior to equipment damage and subsequent damage

common locations are: conveyor head pulley, above jaw crusher cavities, transfer chutes, and screens or grizzlies.

Vibration sensors can be mounted on the crusher adjustment ring to continuously measure adjustment ring movement and provide an alarm signal when the crushing force design limit has been exceeded due to presence of uncrushable. Via the signal trending either the operator or the advance control system can infer the nature of the problem and subsequently execute the appropriate control action.

Image analysis technology system may be used either as a standalone instrument, or as a component of an integrated advanced control system for estimating rock size distribution and other rock properties, usually online, most often on a conveyor belt. In case of primary crusher applications, located on the feed and discharge conveyors for in-pit crushers, the feed and discharge size distributions are used together to assess the relative hardness of the fragmented rock and to provide data for the monitoring of the crusher performance and crusher wear. It is also possible to integrate the data to identify the location of the ore on each truck as they feed to the primary crusher and correlate the run of mine (ROM) fragmentation information to the blasting parameters. In case of secondary applications, image analysis technology is used to measure the crusher feed ore size distribution. The measured size distribution can be used together with feed tonnage and recirculating load measurements to classify the ore hardness

3D grade control, as used for asphalt paving, is a technique that uses sophisticated positioning systems in conjunction with the grade and slope control of the machines to reproduce virtual designs. The virtual designs, three dimensional CAD drawings produced by engineering firms, contribute positioning data that is used to guide the grade and slope system rather than external references such as stakes, the existing grade or a string line.

As a paver and screed lays down the mat, the screed conforms to a controlled depth, width, and/or cross slope. On conventional 2D systems, the paver/screed works from the 'ground up,' referencing the existing grade using sonics, averaging skis, or string lines, adjusting the depth and/or slope when required. Typically, the material is placed at a consistent thickness over the base.

By contrast, 3D systems utilize a fixed, 'known position,' rather than the existing grade as the reference. Detailed, highly accurate site plans are drawn up in CAD software and loaded into the paver's grade control system. On-site UTS (universal-total-station) networks then provide highly accurate positioning and elevation data to the paver/screed, relative to the known position, using lasers to track mast-mounted targets on the machine. So, rather than using ground references, the system follows the virtual design, based on the known position, with the UTS network providing the reference, translating that to screed positioning and adjustment automatically.

Compared to traditional 2D grade control systems, 3D systems are capable of reproducing roadway grades and slopes within mere millimeters of the engineer's specified tolerances. 3D grade control is thus ideal for construction or rehabilitation applications where smoothness is paramount, or producing a particular elevation or correcting a road profile is critical, such as airport runways or complex road curves.

3D grade control systems allow the operator to produce the correct profile for a road without utilizing external, on-site grade references, which can be flawed. This means that the work will follow the design rather than a potentially flawed reference.

Several tangible benefits arise from using 3D paver control: it reduces the survey cost as grade control stakes are no longer necessary, and stringline stake-outs are eliminated. Absence of stringline means jobsite traffic can move about more freely. This can mean better productivity for the entire process. Also, stringlines are prone to damage or displacement once they are in place. 3D controls can mean decreased total time for project completion. 3D paving enables working to tolerances within thousandths of a foot. The precision minimizes material usage, providing further cost savings.

Technology advances in compaction equipment like Intelligent Compaction along with compactor add-ons offer significant advantages for achieving targeted pavement density. Compactor add-ons such as Global Positioning Satellite (GPS) systems, IR measurement of surface temperature, and continuous density tools provide equipment operators with critical data for enhanced efficiency. New technologies such as vibratory pneumatic and oscillatory rollers offer unique alternatives for applying vibration to maximize benefits. There are proven techniques to identify and adequately compact problem mixes.

Intelligent Compaction (IC) refers to a group of features integrated into a system that provides real-time measurement and control of the compaction process. The IC technology is sometimes also called “continuous compaction control.”  It measures and records the quality of compaction during the compaction process. It changes the compactor's force in real time to increase compaction where needed, while preventing over compaction. The technology uses a global positioning system to create a map that shows the quality of compaction across the entire surface of each lift. Common equipment on an Intelligent Compaction roller, depending on the system, may include:

• Accelerometers and a highly accurate GPS to track machine-ground interaction and the position of the roller

• Infrared temperature gauges to monitor the temperature at the ground surface

• A computer with a dedicated software program that processes compaction data and reports measurement values

• Display readouts and controls to give feedback to the roller operator and allow for adjustment of compaction operations

Accelerometers, an advanced dynamic evaluation device, positioned on or in roller drums measure the response of the underlying materials to the compaction forces being applied by the drum. The accelerometer readings are then analyzed by an onboard computer that takes the readings and evaluates the compaction levels and uniformity of the materials.

Global positioning system (GPS) technology establishes the roller drum locations and displays data on the operation and measurements of the rollers in real time. A color-coded display assists the roller operator in achieving the needed coverage over the full pavement area in both daytime and nighttime conditions.

The IC technology is available on both single-drum rollers for soil and aggregate base materials and double-drum rollers for asphalt pavement materials. Some manufacturers also provide an onboard printer for on-the-spot reporting or summaries of the compaction operations, as well as wireless capabilities to remotely monitor the roller operations. For asphalt paving, onboard surface temperature measuring devices are included to assist operators in determining the optimum time for compaction.