: SICK Proximity Detection & Operator Guidance Systems protecting people and equipment Nicky Guenther, Technical Industry Manager SICK Solution Centre Mining 04/03/2013
Contents : Situation in the Industry : Background: : Terms & Terminology : Advanced Driver Assistance : Technologies : System Acceptance Measures : Fit for Purpose - Collision Scenarios : Examples: Best Practice - System Implementation : TPS Truck Protection System : TCW Tunnel Collision Warning System : EPS Excavator Protection System : WPS Wheel Loader Protection System : SICK Pty Ltd. : Confidential : Strategic Industry Mining 2
Current Situation - Facts : World s steel & coal production grows significantly (China, Steel: 500 Mio t in 2008 683 Mio t in 2011, coal: 3050 Mio t in 2011) : Continuing mining boom in resource rich countries in North & South America, Africa, Australia, Asia & Europe : In order to increase productivity, the number, physical size and speed of mining vehicles increases in open cut and underground mines. : This increases already existing hazards such as poor visibility and so far unresolved risks such as vehicle interaction which still too often result in the accidental collision of vehicles and the death of vehicle occupants or pedestrians. : 3 out of 4 fatalities in mine sites are vehicle related : Mining remains the second most dangerous occupation in America (according to the Bureau of statistics) : SICK Pty Ltd. : Confidential 3
Current Situation - Facts Queensland mine safety and health commissioner, Steward Bell (AUS): up to 50% of our mine sites already use or trial Collision Avoidance Technology Vs. Every week, almost without fail, we can see issues where vehicles collide with each other Recent Crash Reports Causes of Accidents Impaired Awareness: limited rear vision, blind spots, lack of light, glaring sunlight, missing alignment, lack radio communication/intervention/noise, other vehicles in proximity, loss of control, fatigue, working in the night shift Still unresolved: Accurate Interaction: Operator Vehicle or Vehicle - Vehicle : SICK Pty Ltd. : Confidential 4
The vision of autonomy : Combination of guidance systems with reliable proximity detection technology could deliver all the necessary functions leading to autonomy for the unmanned - more important increases safety, productivity and utilisation for the manned mine. Full autonomy can only be achieved by means of: - Proximity Detection - Interaction with other machines - GPS control and - Vehicle Control - Computerised Supervisory and Management System (SCADA) : SICK Pty Ltd. : Confidential
Terms and Terminology : Collision Avoidance actively interferes with (brakes or steers) the vehicle in order to avoid a collision. There is no off the shelf collision avoidance system available from any provider (at least in mining), which unfortunately does not stop companies to use the term collision avoidance even for GPS or RF traffic information systems. : Collision Awareness provides a warning to the operator which is aimed at a reaction. The operator is in the loop and has to (re)act himself. : Proximity Detection (PDS) sensing and ranging of surrounding (hazardous) obstacles in (critical) proximity. This can only be done by LIDAR (laser scanners), RADAR, Utrasonics, Stereo Vision Cameras. : Traffic Awareness Information System delivers information about presence of other vehicles in a certain range. Due to GPS inaccuracy can t distinguish between normal and critical driving situation. Requires GPS and radio coverage. : SICK Pty Ltd. : Confidential : Guenther (2011-11-14) 6
Necessities for operator in the loop Solutions available on the Market Proximity Detection or Environmental Perception : Passive Collision Warning Passive Operator Interaction (Mirror, Camera) : Active Collision Warning - Proximity Detection (RADAR, LIDAR, Ultrasound, Stereo Vision Camera, GPS) Necessity: sophisticated advanced warning strategy Operator Acceptance : SICK Pty Ltd. : Confidential : Nicky Guenther, 06.02.2011 7
Technology Overview: Situational Awareness : The most important requirements on a sensor for longitudinal and lateral guidance on mobile equipment are described on the following tables : These tables were developed in collaboration with international mine managers and industry experts during a Mine Automation Summit in South Africa (IQPC 2nd Annual Mine Site Automation & Communication Africa 2012, 23-25 July, 2012, Sandton, South Africa) : SICK AG : confidential : Nicky Guenther, 06.02.2011 8
Technology Comparison - Attributes Relevant criteria Magnetic field (VLF) Antenna Laser scanner (LIDAR) Radar (77Ghz Doppler and monopulse) Traffic Monitoring Systems - GPS tracking Traffic Monitoring Systems WIFI/ RF Range 2..15m >150m >150m dependent on the radio in use dependent on the radio in and RFID tags used (active 100 150m, passive 5 7m) Distance accuracy m (sub meter only under ideal conditions) very high precision (20 mm) m (sub meter only under ideal conditions) sub meter only with high precision (base stations etc.) Meter Video Cameras >150m usually > 1m Angular resolution very limited directional perception 0.1 2 4 dependent on the GPS bearing quality very limited directional perception pixel usually 1...4 Field of perception (single unit) 360 up to 360 17...50 (single beam... multi beam) 360 360 up to 127 Update rate ms 10ms 70ms sec sec 40ms Deposits at sensor usually no issue active surface Dust, fog, rain and snow impairment Ambient light, sunlight impairment Requires Tags Requires line of sight Availability / Reliability No No Yes (PAD: personal alarm devices necessary) Limited perception around corners (in tunnels) possible (VLF) dirt & blockage detection standard. Mounting Precautions necessary impaired in dust, if no further processing e.g. multi echo, filtering and internal dust classification Independent of illumination, internal dazzle filters blockage recognition standard. mounting precautions necessary. scattering noises possible usually no issue usually no issue mounting & protection precautions necessary Impairment usually no issues Impairment No No No Yes standard No No Yes, every vehicle needs to be equipped with this technology Yes Yes GPS (requires "line of sight"), RF communication impaired High High High GPS very much dependent on the environment. Yes, every vehicle needs to be equipped WIFI 2 6GHZ, VHF/UHF com very limited (1 5m around corners) Increased availability through multi channel transmission vision impaired. No Yes High : SICK AG : confidential : Strategic Industry Mining 9
Technology Comparison - Applications Requirements for applications Collision avoidance speed range 0 60km/h Guidance: e.g. Road Departure Warning / Tunnel Collision Warning Detection of Infrastructure: merging / oncoming traffic, stockpiles, crusher, intersections etc. Aboveground Magnetic field (VLF) Antenna Low speed (dependent on vehicle) Laser Scanner (LIDAR) Yes Radar (77Ghz Doppler and mono pulse) high speed scenarios can still not be applied to mine sites (discrimination between road surface and obstacle reflections difficult), inoperablefor speeds greater 7 km/h No Yes artificial mine structures necessary for tracking No Yes limitations in detection of crossing traffic (due to detail, resolution and field of vision) Traffic Monitoring Systems - GPS tracking the functionalities are widely used in Traffic Awareness Systems it is not collision avoidance if high precision GPS and accurate map available, positional navigation possible If high precision GPS and accurate map available, positional match possible (Black spot function) Traffic Monitoring Systems WIFI/ RF Update rate and accuracy critical for CAS this is not collision avoidance (not used, due to Yes Yes Yes Yes Yes limited range) Underground Yes Yes Questionable (due to No Yes Yes tunnel reflections) Safety (IEC 61508) fail safe available fail safe available fail safe available, use of reference targets Increased reliability through multi channel transmission Increased reliability through multi channel transmission No No No Video Cameras used as complementary system Always dependent on other system components (safety PLC, watchdogs, observers, system diagnostics etc) for the measurement technology to ensure availability and fail to safe if necessary Beneficial technology Combinations with some systems most systems Combination with LIDAR Combination with LIDAR cameras are not used combination WIFI common already include combine already with or RADAR necessary in or RADAR necessary in in mine automation GPS and V2V GPS, V2V radio - order to detect the order to detect the tasks, but radio. LIDAR untagged environment untagged environment complementary item Combination with recommended for as a passive assist or radar and camera high speed scenarios for remote controls : SICK AG possible : confidential and guidance : Strategic Industry Mining 10 No No
Fundamentals: Modern Operator Assistant System e. g. SICK Collision Awareness System : SICK AG : confidential
Autonomous / Automated System : Collision Avoidance : SICK AG : confidential
Fundamentals: Sensor Technology for Proximity Detection & Driver Assistance: LD-MRS : Total Detection Range 0.25 m 200 m : Range on Target of 10% reflectivity 50 m : Horizontal Field of View 100 (+/-50 ) : Vertical Field of View 3.2 (4 planes) : Angular Resolution up to 0.125 : Scan Frequency 12.5 Hz (25 /50 Hz) : Internal object tracking & classification : 4 Scan Planes full parallel and simultaneously : 3 Echoes per Shot for Weather Robustness : Repetition Accuracy 10 cm 1σ : Distance Resolution 4 cm : Degree of Protection: IP69k : Operating temperature: -40 C to 70 C : SICK AG : confidential
Fundamentals: Sensor Technology for Proximity Detection Laser Scanner (LD-MRS object tracking) Object Tracking & Classification : SICK AG : confidential Nicky Guenther, nguenther@sick.com.au 14
Features of a PD sensor used in a Guidance System Example: Path Following : SICK AG : confidential Nicky Guenther, nguenther@sick.com.au 15
Features of a PD sensor used in a Guidance System Example: Path Following : SICK AG : confidential Nicky Guenther, nguenther@sick.com.au 16
Features of a PD sensor used in a Collision Avoidance System Example: Adaptive Cruise Control & Following : SICK AG : confidential Nicky Guenther, nguenther@sick.com.au 17
Operator in the Loop - Reaction Time : Established driver assistant system concepts based on local vehicle sensors have to provide the warning under the adherence of a reaction time. : Recognised studies define a suitable time window for imminent crash warnings with 700-1500ms before collision. SICK uses red and yellow warning zones + audible alarms for imminent crash warnings. : A window of more than 1500ms can therefore be used to provide driver information (called early advisory warning ) to address the potential hazard, catch operators attention and establish readiness to react. SICK uses the early advisory component only to inform (cp. Picture: green = obstacle monitoring zone, no audible warning). : Traffic Monitoring Systems (GPS based) provide only the advisory warning (no imminent crash warnings, which increases the nuisance alarm rate dramatically). : Audible operator warnings are aimed to a direct operator reaction. The established timing structure can therefore be augmented in adding an early time component to the imminent component to enhance the effectiveness of the system. : SICK AG : confidential : Nicky Guenther, 06.02.2011 18
Questions to be asked before deciding for a technology! : What are most critical vehicle interactions in my particular site? This information is usually result of a risk analysis. : What is involved in an installation (time and effort, service shift is usually the critical limit e.g. for a complete TPS)? : Warning strategy applicable (and understandable) to particular mine site (adjustable & dynamic warning zones)? : Does the entire fleet have to be equipped with the technology in order to be effective? Is successive installation possible? : Layout active warning strategy (audible and visual) operator s focus lies on tasks at hand; operator information management (What s comfort? What s necessary?) : Does it provide interfaces fleet management systems (application event protocol, event logging)? : Reliability and robustness? : Availability / Maintenance - system self-diagnostics available. Ease of fault identification. Suited for onsite service by customer himself who stocks spare parts? : False alarm & nuisance alarm rate. Is the warning strategy reasonable, annoying or a real help? : Are we prepared to take ownership of this new technology? : SICK AG : confidential : Guenther (2011-11-14) 19
MINESIC Protection Systems advanced driver assist The Solution for mobile Equipment! : SICK AG : confidential
MINESIC TPS Introduction: Truck Protection System : SICK AG : confidential
MINESIC TPS Introduction: Truck Protection System : SICK AG : confidential
MINESIC TPS Truck Protection System integrated in CAT 789C Operator Display visual and audible Alarm Road Departure Warning Sensor Front End Anti Collision Sensor : SICK AG : confidential
MINESIC TPS Truck Protection System integrated in CAT 789C Rear Sensor Control Cabinet Rear End Anti Collision and Tire Protection : SICK AG : confidential
MINESIC TPS Truck Protection System warning strategy Radial distance measuring systems e.g. GPS or RF based cause false alarms in this scenarios. TPS only warns for obstacles located in driving path. : SICK AG : confidential
MINESIC TPS System Options: Fit for Purpose : Intelligent Front End Collision Warning Adaptive from stand still to high speed : Reverse Assist for approach to stockpile, crusher, steep slope for unloading, vehicles, objects like rocks Protects Tires. : Road Departure Warning (RDW) Fatigue Management, Discriminates between intentional avoidance of e.g. pottholes and a driver deviating of from his lane : Black Spot Warning Geo fencing of power lines, workshop, etc : SICK AG : confidential : Underground Tunnel Collision Warning (TCW) guidance alongside the tunnel wall, maneuvering assist
MINESIC Excavator Protection System (EPS) Introduction : SICK AG : confidential : Strategic Industry Mining 27
MINESIC EPS Target Applications Applications Where? Hydraulic shovels and excavators Rope shovels Drag lines : SICK Pty Ltd. : Confidential : Strategic Industry Mining 28
Excavator Protection System (MINESIC EPS) : SICK Pty Ltd. : Confidential : Guenther (2011-11-14) 29
Excavator Protection System (MINESIC EPS) : SICK Pty Ltd. : Confidential : Guenther (2011-11-14) 30
MINESIC Wheel Loader Protection System (WPS) : SICK AG : confidential : Strategic Industry Mining 31
MINESIC WPS Wheel Loader Protection System : SICK AG : confidential : Guenther (2011-11-14) 32
MINESIC WPS Target Applications Applications Where? Wheel loader in surface mines Wheel dozer in surface mines : SICK Pty Ltd. : Confidential : Strategic Industry Mining 33
Video Demonstration: MINESIC WPS Wheel Loader Protection System : SICK Pty Ltd. : Confidential : Guenther (2011-11-14) 34
MINESIC TPS TCW Introduction: General Why Tunnel Collision Warning Systems? - Driving in confined spaces can lead to critical situation and requires cautious maneuvering - Guidance through the tunnel necessary - Protection of infrastructure and equipment - Accidents cause extremely high cost due to repair and downtime related production loss MINESIC100 TCW (TCW = Tunnel Collision Warning) : SICK AG : confidential : Strategic Industry Mining 35
MINESIC TPS TCW Target Applications Applications Where? Mining vehicles in underground mines Haul trucks in underground mines Load Haul Dumps in underground mines : SICK AG : confidential : Strategic Industry Mining 36
MINESIC TPS TCW System Features Features Front and Rear-End tunnel collision warning Warns the operator audibly and visually when the driver comes to close to the tunnel wall Analyzing of turns and intersections Warns when dangerously cutting or overshooting the turn : SICK AG : confidential : Strategic Industry Mining 37
MINESIC TPS TCW System Features Features Front and Rear-End tunnel collision warning Road Departure Warning Warns of unintentional veering towards the tunnel wall : SICK AG : confidential : Strategic Industry Mining 38
MINESIC TPS TCW System Features Features Front and Rear-End tunnel collision warning Road Departure Warning Active assistance for maneuvering in confined spaces - displays the tunnel wall outline Distance profile is overlayed in relation to the front and rear end of the vehicle showing the space available : SICK AG : confidential : Strategic Industry Mining 39
MINESIC TPS TCW Ready to go! Sophisticated system Easy installation Simple interface : SICK AG : confidential : Strategic Industry Mining 40
Video Demonstration: MINESIC TCW Tunnel Collision Warning System : Operator Touch Panel with sophisticated display of only the necessary information. : laser scanner field of view (SICK sensor visualisation tool) : SICK AG : confidential Nicky Guenther, nguenther@sick.com.au 41
Summary: MINESIC CAS - High Performance Proximity and Collision Detection Systems : quick & easy install (service shift is the critical limit e.g. for a complete TPS) : active warning (audible and visual) operator s focus lies on tasks at hand : Detection and tracking of moving and stationary obstacles without the need for RFID tags : adjustable & dynamic warning zones - configurable to mine site operational requirements : suitable for all machines types and sizes : day and night operation day and night view on the display : fully functional in all weather conditions (rain, dust & fog) : highly available - system self diagnostics (simple fault identification), : low maintenance onsite service by customer : lowest false alarm & nuisance alarm rate due to advanced object tracking : GPS black spot feature: location can be mapped to raise operator s attention when entering hazardous areas : Optional event logging function as well as further integration in fleet management and other systems (standard application event protocol). : Full service package provided by SICK LifeTime Services : Sound system knowledge thanks to comprehensive user training : SICK AG : confidential : Guenther (2011-11-14) 42
MINESIC xps Summary Key messages cost reduction due to: : reduction of incidents : reduction of repair costs : reduction of downtime costs : reduction of insurance premiums long term : reduction in investigation costs : fines and pay outs : SICK AG : confidential : Strategic Industry Mining 43
: Thank you very much for your attention!
Necessity of a PD Sensor used in Collision Awareness/Avoidance Systems All-weather capability Reflective Vest Reference Targets LD MRS (HD) : SICK AG : confidential Nicky Guenther, nguenther@sick.com.au 45
Necessity of a PD Sensor used in Collision Awareness/Avoidance Systems All-weather capability 6m Layer 1 Layer 2 5m Layer 3 Layer 4 4m Reflector Vest 3m Distance signs 2m Chamber Length 6m : SICK AG : confidential Nicky Guenther, nguenther@sick.com.au 46
Necessity of a PD Sensor used in Collision Awareness/Avoidance Systems All-weather capability : SICK AG : confidential Nicky Guenther, nguenther@sick.com.au 47
Necessity of a PD Sensor used in Collision Awareness/Avoidance Systems All-weather capability : SICK AG : confidential Nicky Guenther, nguenther@sick.com.au 48
Detection Probability Chart - LD-MRS probability(x) = detections(x) measurements(x) probability (k) = detections in bin (k) measurements in bin (k) : SICK AG : confidential 49
Detection Probability Chart - LD-MRS Detection Probability Chart for a standard LD-MRS Laser scanner Pick-up Truck Dust Probe Objects: light vehicle / pick-up (different angles) dump truck (different angles) 0.3m 1m Rocks Pedestrian (reflective vest and without) measurements have been taken under various environmental conditions : SICK AG : confidential Nicky Guenther, nguenther@sick.com.au 50
Necessity of a PD Sensor used in Collision Awareness/Avoidance Systems All-weather capability : SICK AG : confidential
Sensor Technologies for Guidance Systems latest state of the art RADAR sensor Automotive adaptive cruise control (ACC) sensor (77GHz) Total Detection Range 0.25 m 200 m (close up 0.25 60m) Repetition Accuracy 1.5% @>1m (0.25m) Horizontal Field of View: 17 far field, 56 (close up) Angular Resolution up to 1 2 Scan Frequency 15 Hz Operating temperature: -10 C to 85 C A special feature of the device is the simultaneously measurement of great distances up to 200 m, relative velocity and the angle relation between 2 objects. : SICK AG : confidential
Sensor Technologies for Proximity Detection latest state of the art (ACC) RADAR sensor : SICK AG : confidential