TRANSPORT PROBLEMS 2016 Volume 11 Issue 4

PROBLEMY TRANSPORTU DOI: 10.20858/tp.2016.11.4.4

monorail; drilling; pneumatic loading; feedback;

automation; closed loop; open loop

Bunda BESA*
University of Zambia, School of Mines, Mining Engineering Department
P.O. Box 32379, Lusaka, Zambia
K. Emmanuel CHANDA
University of Adelaide, School of Civil & Environmental & Mining Engineering
Adelaide SA 5005, Australia
Mahinda KURUPPU
(Retired) Curtin University, Western Australian School of Mines, Faculty of Science & Engineering
Kent St., Bentley WA 6102, Australia
*Corresponding author. E-mail: [email protected]

AUTOMATION DESIGN FOR MONORAIL - BASED SYSTEM PROCESSES

Summary. Currently, conventional methods of decline development put enormous
cost pressure on the profitability of mining operations. This is the case with narrow vein
ore bodies where current methods and mine design of decline development may be too
expensive to support economic extraction of the ore. According to studies, the time it
takes to drill, clean and blast an end in conventional decline development can be up to
224 minutes. This is because once an end is blasted, cleaning should first be completed
before drilling can commence, resulting in low advance rates per shift. Improvements in
advance rates during decline development can be achieved by application of the Electric
Monorail Transport System (EMTS) based drilling system. The system consists of the
drilling and loading components that use monorail technology to drill and clean the face
during decline development. The two systems work simultaneously at the face in such
a way that as the top part of the face is being drilled the pneumatic loading system cleans
the face. However, to improve the efficiency of the two systems, critical processes
performed by the two systems during mining operations must be automated. Automation
increases safety and productivity, reduces operator fatigue and also reduces the labour
costs of the system. The aim of this paper is, therefore, to describe automation designs of
the two processes performed by the monorail drilling and loading systems during
operations. During automation design, critical processes performed by the two systems
and control requirements necessary to allow the two systems execute such processes
automatically have also been identified.

AUTOMATISIERUNGS-DESIGN FÜR MONORAIL - BASIERTE

SYSTEMPROZESSE
Zusammenfassung. Derzeit haben konventionelle Methoden der Abnahme
Entwicklung enormen Kostendruck auf die Rentabilität der Bergbau. Dies ist der Fall mit
engen Vene Erzkörper, wo aktuelle Methoden und Mine Design der Entwicklung des
Rückgangs kann zu teuer sein, um die wirtschaftliche Extraktion des Erzes zu
unterstützen. Studien zufolge kann die Zeit, die zum Bohren, Reinigen und Sprengen
eines Endes in einer konventionellen Abnahmeentwicklung benötigt wird, bis zu 224
Minuten dauern. Dies liegt daran, dass, sobald ein Ende gestrahlt wird, sollte die
Reinigung zuerst abgeschlossen werden, bevor das Bohren beginnen kann, was zu
30 B. Besa, K.E. Chanda, M. Kuruppu

niedrigen Vorschüben pro Schicht. Verbesserungen bei den Fortschrittsraten bei der
Entwicklung des Rückgangs können durch die Anwendung des Elektrohängebahn-
systems (EMTS) erreicht werden. Das System besteht aus den Bohr-und Beschickung
Komponenten, die Monorail-Technologie zu bohren und zu reinigen das Gesicht bei der
Entwicklung des Rückgangs. Die beiden Systeme arbeiten gleichzeitig am Gesichtsfeld
so, dass das pneumatische Ladensystem bei der Bohrung des Oberteils des Gesichts das
Gesicht reinigt. Um jedoch die Effizienz der beiden Systeme zu verbessern, müssen
kritische Prozesse, die von den beiden Systemen im Bergbau durchgeführt werden,
automatisiert werden. Die Automatisierung steigert die Sicherheit und Produktivität,
reduziert die Ermüdung des Bedienpersonals und reduziert gleichzeitig die Arbeitskosten
des Systems. Das Ziel dieser Arbeit ist es daher, Automatisierungskonzepte der beiden
Prozesse zu beschreiben, die von den Monorail-Bohr- und Beschickungssystemen
während des Betriebs durchgeführt werden. Während des Automatisierungsentwurfs
wurden auch kritische Prozesse identifiziert, die von den beiden Systemen durchgeführt
wurden, und Kontrollanforderungen, die erforderlich sind, damit die beiden Systeme
solche Prozesse automatisch ausführen können.

1. INTRODUCTION

The monorail system consists of a track of jointed section rails, which could easily be extended to
the desired length and suspended by chains or rigid brackets to roof bolts or support beams. Figure 1
shows the conceptual monorail drilling and loading systems operating in a decline.
The system shares many of the advantages of floor mounted rail, but overcomes the bulk of that
system’s limitations [2, 9, 5]. The monorail train has the capabilities to negotiate gradients of up to
36° (theoretically) and vertical and horizontal radii of curvatures of 10m and 4m, respectively [9].
Other advantages include:
• Reduction in the size of excavations leading to greater economy in assessing ore bodies and
improved stability of underground excavations. Small excavations lead to less rock-generated
heat with the associated reduction in ventilation and air conditioning requirements;
• Reduced power consumption due to low-friction monorail transport, which results in low
haulage costs per tonne per kilometre;
• Fewer fire hazards compared to a truck haulage system;
• Environmentally friendly technology – no diesel fumes;
• Multipurpose haulage system for personnel, material and rock;
• Small and medium sized ore bodies can be mined with less initial investment; and
• The system has the potential for automation – reduced labour.
The monorail drilling system is fitted with two independent drilling units used to drill out the
ground in decline development. The system has its own attached power supply with two horizontal
and two vertical hydraulic stabilisers acting as supports during drilling operations.
The loading system consists of an incline suction pipe that is connected to a storage hopper.
A high-pressure fan is connected to the hopper and draws into it blasted rock fragments from the
development face [2]. The monorail loading system also serves as a means of transporting ore and
waste from underground to the surface. Personnel and material may also be transported by connecting
riding and material carriers to the system. The monorail train has a total weight of 92 tonnes and can
carry up to 6 containers with a total payload of up to 30 tonnes including the weight of the
container [9].

2. PROCESS CONTROL ENGINEERING

Control engineering has evolved over time. In the past, humans were the main method for
controlling a system [4]. More recently, electricity has been used for system control and early
Automation design for monorail-based system processes 31

electrical control was based on relays. According to [9], these relays allow power to be switched on
and off without a mechanical switch. It is also common to use relays to make simple logical control
decisions. The development of low-cost computer paved the way for Programmable Logic Controller
(PLC). The advent of the PLC began in the 1970s and has become the most common choice for
manufacturing controls. Furthermore, operation of today’s modern mining machines is carried out
with PLC systems [4]. The PLC controls most operational processes of the machines. Based on the
logic implemented in the program, PLC determines which actions need to be executed with output
instruments. Thus, many complex operational tasks have been solved by connecting PLC and possibly
a central computer [9]. Besides connections with instruments like operating panels, sensors, switches,
valves, etc, the possibilities for communication among instruments exist and they allow high levels of
process coordination as well as greater flexibility in realizing any process control system. PLC has the
following advantages:
• Cost effective for controlling complex systems.
• Flexible and can be reapplied to control other systems quickly and easily.
• Trouble-shooting aids make programming easier and reduce downtime.
• Computational abilities allow more sophisticated control.
• Reliable components make PLC likely to operate for years before failure.

Fig. 1. Conceptual monorail drilling and loading system

Fig. 1. Konzeptionelles Einschienenhängebohr- und Beschickungssystem

3. DEFINITION OF AUTOMATION

In [3] automation is defined as a technology in which a process or procedure is accomplished by

means of programmed instructions, usually combined with automatic feedback control to ensure the
proper execution of the instructions. The effectiveness of any automation system depends entirely on
the quality of its underlying electrical, mechanical and control engineering. This means that all
32 B. Besa, K.E. Chanda, M. Kuruppu

systems that qualify as being automated must include the following three components (see also
Fig. 2):
1. Power to accomplish the process.
2. System program.
3. Feedback control.

Fig. 2. Components of an automated system; dotted lines indicate feedback control system [3]
Fig. 2. Bestandteile eines automatisierten Systems; Punktierte Linien zeigen Rückkopplungssystem an [3]

3.1. Power to Accomplish the Process

The action performed by the automated system to accomplish its functions requires power. Most
power sources used in automated systems are based on electrical energy [1-3, 5].

3.2. System Program

System program refers to the architecture and design of the application and services that make up
an operating system or another control program. The actions performed by an automated system are
determined by a program of instructions normally without human intervention. The instructions
contained in the program specify the details of each action that must be accomplished and the
sequence in which the actions must be performed.

3.3. Feedback Control

Feedback controls can be defined as the use of different signals determined by comparing
the actual values of system variables to their desired values as a means of controlling a system or
process [9]. These controls are widely used in automated systems to ensure that the programmed
commands have been properly executed. Feedback control is, therefore, a basic mechanism by which
systems, whether mechanical, electrical, or biological, maintain their equilibrium or homeostasis [3].
Feedback control system consists of the following components:
1. Input signal.
2. Process.
3. Output.
4. Feedback sensing elements.
5. Controllers and actuators.
The input signal represents the desired value of the process output while the output is some
variable that is being measured and compared with the input, e.g. pressure, temperature. Generally,
Automation design for monorail-based system processes 33

the output value is a function of the process. Sensing elements close the loop between output and
input while controllers and actuators compare the output with the desired input and make adjustments
in the process. Since the system output is used to regulate its input, such a device is said to be
a closed-loop control system [3]. Thus, feedback control, in this case, is used in closed-loop control
systems.

4. REASONS FOR SYSTEM AUTOMATION

In many mining situations, manual operation requires that several repetitive operations be executed
by the operator, thus, reducing the efficiency of the system. Therefore, the most obvious advantages
of automating the system are its ability to increase the safety (i.e., removal of workers from dangerous
and hazardous environments), efficiency (i.e., increase in effective working hours) as well as a
reduction in labour costs. According to [3], the following arguments can also be raised in support of
automation in designed systems:
1. The system is safe since automation tends to remove humans from direct participation in the
operations.
2. Human errors in operations are minimised using automation.
3. Automation also increases system reliability.
4. In industrialised nations where there is a shortage of labour, automation of systems is an
alternative to an increase in production with lower labour force.

5. AUTOMATION DESIGN FOR MONORAIL SYSTEM PROCESSES

Using the Theory according to [4, 9, 10], the description of automation design for the monorail
drilling and loading system processes is explained. Automation design for monorail drilling and
loading systems begins by identifying and describing critical processes performed by the two systems.
This Section is intended to provide details of the automated processes performed by the two systems.

5.1. Overview of monorail system processes

Details of processes performed by the two systems i.e., monorail loading and drilling systems [2]
are:
• Monorail loading system process.
• Monorail drilling system process.

(a) Monorail loading system processes

There are two critical processes performed by the monorail loading system that are automated:
pneumatic loading and material discharge processes.

(i) Pneumatic loading process

This process involves automatic loading (suction) of rock fragments from the development face
into the hopper. Automation of this process is such that, once the suction pipe is connected to the
hopper, upon pressing a loading button on the control panel (located in the driver’s cabin) the high-
pressure fan/pump is activated, which creates negative pressure inside the hopper. The negative
pressure enables automatic loading of material in the hopper. Since the negative pressure created
inside the hopper should be monitored and controlled to ensure that the pressure inside the hopper is
correct, a closed-loop control system is used during the process. It is assumed that the maximum
negative pressure equal to the absolute atmospheric pressure that is created is sufficient to suck most
of the fragmented rock into the hopper.
34 B. Besa, K.E. Chanda, M. Kuruppu

(ii) Material discharge from the hopper

The loading process is stopped automatically when the required tonnage is loaded after which the
suction pipe is disconnected from the hopper. The hopper is connected to the monorail train, which
pulls the loaded hopper to the position of an empty monorail container where an automatic discharge
of rock fragments takes place. Therefore, automation involves an automatic discharge of material
from the hopper into an empty container. This means that when the discharge button is pressed on the
control panel, the material is discharged under gravity from the hopper into an empty container. The
hopper will have an open and close mechanism at the bottom that will allow discharge of material to
take place. Hydraulic system will be used for the opening and closing mechanism of the hopper. Since
there is no direct connection between the output (material discharge) and the input (hydraulic pressure
needed for the open/close mechanism), open loop control system is used during automation design of
this process. Sensing the hopper in its full and empty positions as well as to stop the process of
material loading and discharge is done manually.

(b) Monorail drilling system process

Automation of the monorail drilling system consists of the process of automatic face marking
using laser beams projected onto the development face. In conventional mining, once cleaning of the
development face is completed, face marking is done manually using paint. Manual face marking
normally takes longer (than face marking using laser technology) and increases the total drill-blast-
load-haul cycle time. Therefore, to reduce the markup time and the total drill-blast-load-haul cycle
time, it is suggested that the monorail drilling system be equipped with drilling pattern laser
projection technology [11]. This technology will enable the monorail drilling system project laser
spots of the desired drilling pattern onto the development face. The projected laser spots will indicate
precisely the location of drill holes on the development face. Because the projected drill pattern needs
to be aligned properly on the drill face i.e. the input signal (desired drill pattern) is related to the
output signal (position of drill holes on the face), a closed-loop control system is used during the
design of the automation system.

5.2. Description of automation design for the monorail loading process

Fig. 3 shows the description of automation design for the monorail loading process. The main
components of the automation design are:
• Control panel.
• Feedback display monitor.
• Surface control.
Since the control panel of the monorail loading system is an interactive and menu driven device,
once the loading process is selected on the control panel, the process being executed is displayed on
the feedback display monitor located in the driver’s cabin as well as on surface monitoring control
unit. All operations of the loading system are monitored on the feedback display monitor. Sensors will
be used to send information/communicate with operators in the surface control room.

(a) Control panel

The control panel is located in the driver’s cabin of the monorail train. The operation of the system
is done from the control panel. It is also used as an interactive input device by the operator to select
processes to be accomplished by the system. The control panel is also linked to the feedback display
monitor for the purpose of monitoring whether the processes currently being executed by the system
are being done correctly.

(b) Feedback display monitor

The most basic tool of control engineering is the feedback loop. For the monorail loading system,
the output signal (i.e. the actual negative pressure in the hopper) during the loading process is
Automation design for monorail-based system processes 35

displayed and viewed on the feedback display monitor. The output signal is compared with the input
signal (i.e. the desired negative pressure in the hopper) and adjustments are made via the PID
controller if the output signal deviates from the desired input signal. The feedback monitor is used to
monitor and control the dynamic behaviour of the loading process. Other advantages of feedback
monitoring include:
• Indication whether the system is functioning properly or not.
• Showing the current operation being executed by the system.

Fig. 3. Schematic description of automation design for the loading process

Fig. 3. Schematische Beschreibung des Automatisierungsdesigns für den Ladevorgang

(c) Surface Controls

The monorail system is also linked to the surface control unit where all operations and processes
being executed by the drilling system are monitored and may be controlled. This means that all
signals resulting from the operator’s instructions as well as feedback from system process are viewed
on the feedback display monitor (in driver’s cabin) as well as on surface control monitors. The
following are some of the benefits and/or advantages of having monorail system surface control units:
• Monitoring, controlling and recording of operations of the monorail drilling and loading
systems, thus increasing the safety of the system.
• Acquiring and recording of production data (e.g. drilled metres, number of holes drilled, tonnes
loaded etc.).
• Serving as a communication centre for monorail system operations and Automatic transfer of
production data to the mine management network. This will be done by wireless connection or
36 B. Besa, K.E. Chanda, M. Kuruppu

some protocol may be necessary if the control function is available to both the operator and the
ground staff simultaneously.

5.3. Description of automation design for the monorail drilling system

As highlighted in Section 5.1, automation design for the monorail drilling system involves
automating face marking using laser technology. The description of the layout (Fig. 4) is similar to the
loading system but with the addition of components 4 and 5, i.e. drilling pattern and laser projection
with video sensor, respectively.

Fig. 4. Schematic description of automation system for face marking

Fig. 4. Schematische Beschreibung des Automatisierungssystems für die Gesichtsmarkierung

The drilling pattern component (4) includes programming of different drilling patterns for the
operator to choose from. Thus, before face drilling commences, the system operator will select the
required drilling pattern from the drilling pattern database, depending on the size of the face being
drilled. Alternatively, drilling patterns can be saved on a USB flash drive from which the operator can
select the desired pattern. The selected drilling pattern can be viewed on the feedback display monitor
as well as on a surface control system. Alignment of the drill pattern on the drill face is done using the
controller. The system is also equipped with a drill pattern laser projection technology with video
sensor. The technology allows the selected drilling pattern to be projected onto the development face
using laser beams. The controller compares the position of projected drill holes with the desired drill
pattern and any deviation is corrected. Thus, the exact position of drill holes on the drill face is
indicated by laser spots from the projector.
Automation design for monorail-based system processes 37

6. PROCESS CONTROL FLOW DIAGRAMS FOR MONORAIL SYSTEM

In this Section, process control flow diagrams for monorail system automated processes are
developed.

6.1. Process control flow diagram for monorail loading process

Based on Fig. 4, the process control flow diagram for the monorail loading process is described
and shown in Fig. 5. A closed-loop control system is used during the design.
For the loading process, the output being controlled is the negative pressure inside the plant
(hopper) while the control variable is the fan/pump speed which influences output negative pressure.
According to the process control flow diagram, the required negative pressure in the hopper is set
using the pressure gauge knob in the driver’s cabin. Using the servo-valve or valve actuator, the speed
of the high-pressure fan/pump that gives the required negative pressure in the hopper is set. The PID
controller has the task of controlling the pressure in the hopper and to keep it as close as possible to
the value of the set pressure, i.e. it compares the actual pressure in the hopper with the set pressure
and minimises the error (difference between set value and actual value). The operations of the
monorail loading process are also monitored on surface control system through a feedback display.

Fig. 5. Process control flow diagram for the monorail loading process
Fig. 5. Ablaufdiagramm der Prozesssteuerung für den Einschienenhub-Ladevorgang
38 B. Besa, K.E. Chanda, M. Kuruppu

6.2. Process control flow diagram for material discharge process

Figure 6 shows the process control flow diagram for material discharge process for the monorail
loading system. The open and close mechanism of the hopper is spring-loaded and is connected to the
hydraulic system.

Fig. 6. Process control flow diagram for the monorail discharge process
Fig. 6. Ablaufdiagramm der Prozesssteuerung für den Einschienenhubentladungsprozess

Control of opening and closing of the hydraulic discharge mechanism at the bottom of the hopper
is by means of a control valve along the pressure line. The opening mechanism is such that when the
pressure valve is open, the hydraulic fluid is forced to open the open/close mechanism at the bottom
of the hopper. Since the mechanism is spring-loaded, once the material is discharged, the closing of
the hopper is accomplished by cutting out the pressure supply to the hydraulic system, i.e. by closing
the pressure valve and the spring forces the mechanism to close. A hydraulic pressure gauge is used to
indicate the pressure in the hydraulic system during the open mode. However, to stop discharge
manual observation is required. This automated control action is capable of manual override by the
operator. This provision gives the monorail system some flexibility in case of a problem with an
automation system. Figure 7 shows the combined process control flow automation diagram for the
monorail loading process and material discharge.

6.3. Process control flow diagram for face marking process

Since the feedback is required to ensure that the projected drill pattern is aligned properly onto the
drill face, a closed-loop control system is used to design the automation system for laser projection
face marking. Figure 8 shows the process control flow automation diagram for face marking using
laser projection technology.
Automation design for monorail-based system processes 39

Fig. 7. Process control flow diagram for the monorail loading and discharge processes
Fig. 7. Ablaufdiagramm der Prozesssteuerung für Einschienen- und Entladevorgänge

As shown in Fig. 8, the required drilling pattern is selected using the drill pattern selection panel
(A) on the control panel. The selected drill pattern is displayed on the display monitor in the driver’s
cabin as well as on the surface control system. Once the laser projector and video camera are switched
on using the control panel (B), the selected drill pattern is projected onto the drilling face. Laser spot
would indicate the precise location of drill holes on the development face. The video camera located
within the laser projector is used to send images of the projected drill pattern onto the feedback
display monitor and surface control unit through video sensors.
40 B. Besa, K.E. Chanda, M. Kuruppu

Fig. 8. Process control flow automation diagram for face marking

Fig. 8. Prozesssteuerung Flow Automation-Diagramm für Gesicht Mucking

7. CONCLUSION

This paper has demonstrated that automation of monorail loading and drilling system processes is
possible. The ultimate aim of automation design is to increase the safety and improve the efficiency of
the two systems. The proposed automation system increases productivity by improving operator
performance through control of the system processes. Automation of the monorail drilling and loading
systems will reduce the total drill-load-haul cycle time hence improving the efficiency of the systems.
It is also envisaged that monorail surface controls will have the following advantages:
• Monitoring, controlling and recording of operations of the monorail drilling and loading
systems, thus increasing the safety of the system.
• Improving the accuracy of the desired processes by making use of feedback control systems.
• Acquiring and recording of production data (e.g. drilled metres, number of holes drilled, tonnes
loaded etc.).
• Automatic transfer of production data to the mine management network.
• Serving as a communication centre for monorail system operations.

Acknowledgements

The authors would like to thank the Minerals and Energy Research Institute of Western Australia
(MERIWA) and Newmont for financial support of the monorail research project at Western
Australian School of Mines (WASM) and Scharf Mining Solutions for providing technical data and
cost information on the Electric Monorail Haulage System (EMTS).
Automation design for monorail-based system processes 41

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Received 14.05.2015; accepted in revised form 18.10.2016