Simulator Systems: Integral to Training in Earthmoving Equipment

QUARRY – MARCH 2010

In the 21st century, the expenses of training operators on large earthmoving equipment have made simulators the ideal training tool. ThoroughTec’s CYBERMINE simulators are an example of the training tools available to operators of earthmoving equipment.

The design team at ThoroughTec Simulation began manufacturing simulators for the South African National Defence Force over 20 years ago. Military simulators deployed by ThoroughTec into the international military community include tanks, armoured fighting vehicles, tactical level trainers and even fighter aircraft cockpit trainers. For several decades, military simulators have been an efficient, safe and cost-effective solution to training new and experienced crew members.

The application of simulator technologies to the training of operators of heavy earthmoving equipment began in the late 1990s when ThoroughTec designed and manufactured simulators for the mining and quarrying industries. Over the past decade, the need for improved training methods intensified because of the expense of large earthmoving equipment, OHS risks associated with mining and quarrying and the constant drive by mine and quarry owners to increase productivity. Now, in this day and age, simulators are an integral part of the training process at most mines and quarries globally, with site managers and engineers understanding the benefits and payback that simulator training can offer.

“The simulators offer a controlled environment which is highly conducive to the professional training, re-training and evaluation of student operators of heavy earth moving equipment.”

The heart of ThoroughTec’s CYBERMINE simulators is the cab, a realistic replica of the actual equipment, with fully functional simulated instruments and controls. The replicated cab is optionally mounted on a motion platform capable of imparting six degrees of freedom feedback and is surrounded by a wide field of view, a high resolution projected display system with surround sound audio. Control of all aspects of training and evaluation is exercised in real time from a feature rich instructor station. The entire system is housed in a well appointed, self-contained ISO standard container. The simulators offer a controlled environment which is highly conducive to the professional training, re-training and evaluation of student operators of heavy earthmoving equipment.

BENEFITS OF SIMULATION
Each CYBERMINE simulator provides training and facilitates objective evaluation in the following areas:
• Training and evaluating novices in the proficient operation of equipment.
• Providing a new recruit screening system.
• Providing effective refresher training for experienced operators.
• Turning learned theory into practice.
• Providing training in emergency situations not possible on the real equipment.
• Entrenching safety procedures.

Operators who have trained on CYBERMINE simulators are safer when operating heavy machinery because they have been subjected
to emergency situations like engine fires, brake failures and blow outs. Operators identify dangerous situations and react to emergency situations faster, resulting in safer operations. As simulators are available for training 24/7, operators can hone their skills in correct operational procedures such as driving, digging and offloading without removing productive machinery from operations for training purposes, which is costly in terms of production and can contribute to inevitable increase in wear and tear, as inexperienced operators learn how to operate these expensive
pieces of equipment. The benefits of better trained operators are transferred to a mine or quarry’s bottom line, as they increase the daily production quota (increased operator performance), lower accident rates and lower maintenance costs. Users of the CYBERMINE system report that the cost of the simulator is more than covered by improved operator performance and reduction of operational damage to equipment.

CYBERMINE SIMULATOR RANGE
CYBERMINE simulators that are directly applicable to quarrying operations include haul trucks, surface drill rigs, articulated dump trucks, excavators, shovels, bulldozers, graders, TLBs and loaders. In the case of the haul truck, the simulated cab is accurately produced to match the original manufacturer’s specifications. The student operates from a driver’s seat, surrounded by instruments and controls positioned at ergonomically correct locations. The driver’s interface is accurate down to steering and braking systems, lights, horn, indicators, pedals and gauges. The system is delivered standard with a realistic, virtual quarry/mine world in which to operate. This simulated 3D quarry/mine comes complete with artificially intelligent shovels, excavators, dozers and other support equipment, together with loading, hauling and dumping areas, as applicable to the machinery being simulated. All simulated vehicle behavioural dynamics are based on detailed mathematical models that use vehicle manufacturer specifications to provide accurate behavioural realism. As a result, full loading, hauling, reversing and dumping capability is included with each haul truck simulation. Exercises may be configured for various training options, including different loads, loading methods, soil types, weather conditions, night driving, sub-system failures and advanced emergency situations. All aspects of the driver’s loading, hauling and dumping operations are monitored and recorded on the instructor’s station, including adherence to safety procedures, response to emergency situations and failures, driving techniques and productivity. These performance reports, together with the instructor’s after action review capability, provide a complete training and evaluation system.

THOROUGHTEC IN AUSTRALIA
ThoroughTec set up an office in Australia last year to service the Australasian mining, quarrying and construction industries. To date, it has supplied haul truck simulators to the Mining Industry Skills Centre (MISC) in Queensland and several underground mining equipment simulators, including drill rigs, bolters, ADTs and boggers to Sandvik in Perth. “The response from training institutions like MISC and Sandvik’s training centre has been
great,” said Brad Rouse, ThoroughTec’s director of business development for Australasia. “The fact that these well known, respected institutions are using our simulators is a testament to the training benefits that they can offer. CYBERMINE simulators provide students with an enhanced learning environment where they can take theory learned in the classroom and put it to practice on the simulator, giving the student an opportunity to build muscle memory and a detailed understanding of the machine’s operational characteristics.”

For more information about simulators and their respective benefits, visit www.thoroughtec.com