Global advanced training simulator provider ThoroughTec is delivering its new Cybermine Soft Rock mining simulator range to mining major BHP Billiton’s Khutala colliery, one of South Africa’s biggest collieries, in Mpumalanga.

The Cybermine Soft Rock range of mining simulators includes a continuous miner simulator, a shuttle car simulator, a load-haul-dumper (LHD) simulator and a bolter simulator.

Predominantly aimed at the underground coal market, these latest ThoroughTec simu-lators are high-fidelity training simulators designed to operate like the real vehicle, but without the high costs and inherent risks, says ThoroughTec global business development executive VP and director Greg Lew.

“These simulators aim to provide effective training for operators of continuous miners, shuttle cars, LHDs and bolters. They are vital in enhancing productivity, improving safety and reducing operating costs in mining,” he says, adding that the simulators train mine equipment operators in machine functionality and operation, mine-specific operating procedures and emergency scenarios.

The Cybermine continuous miner accu-rately simulates the propelling, sumping, shearing, brow-cutting and undercutting, trimming and loading of the artificially intelligent shuttle car. It is remote-control operated, enabling the learner to operate the simulated vehicle as he would in the actual underground mine.

“All simulated vehicle behavioural dynamics are based on detailed mathematical models that use original-equipment manufacturer specifications to provide accurate behavioural realism. ThoroughTec’s high-fidelity simulators are designed to be as realistic as possible, from the appearance of the cab to the authentic replication of the operator interfaces,” Lew explains.

He notes that the simulators operate in a three-dimensional virtual mine world in which general and operational areas are enhanced for performance and training value.

The simulator base units and the first set of simulator cabs have been delivered to the colliery, with the final cab to be delivered in the coming months, Lew says, noting that all Cybermine simulators are designed and manufactured at ThoroughTec’s headquarters in Umhlanga Ridge, Durban.

Simulation Training
Lew explains to Mining Weekly that trainees undergo training from inside a replica machine cab, fitted with the necessary con-trols, with the simulator’s high-definition projectors realistically displaying the mine environment and the vehicle in operation on 270° or 360° screens that surround the inside of the machine cab. The operator learns about the mine site’s operating procedures by steering and directing the vehicle through the various tasks one would have to perform in an actual mine.

The simulator base unit comprises a motion platform capable of three degrees of freedom (DOF) movement, for underground vehicles, or six DOF movement, for surface vehicles, onto which the interchangeable vehicle cab is fitted.

Meanwhile, the instructor or supervisor can create, initiate, control, monitor, record and evaluate training exercises from the instructor station located next to the simulator base unit.

ThoroughTec has supplied the simulators in their fixed-facility cube configuration, designed to be used in a dedicated training facility, to the Khutala colliery. These are ideal for classroom situations, or where a large number of operators need to be trained together. ThoroughTec can also deliver simulators in a containerised format which is easily transportable and ideal for remote mine sites. The simulator base unit, cab and instructor station are all contained within a 6-m-high cube shipping container.

Industry Needs
Lew stresses the need for the mining industry to increase simulator use and integrate simulation into training programmes in the local coal mining industry, especially for complex equipment, such as continuous miners and draglines. “Nevertheless, while demand has typically been for dragline, haul truck and shovel simulators, there will be increased demand for underground coal mining simulator products.”

He believes these needs can now be met using the Cybermine simulators and, with ThoroughTec continuing to encourage increased simulator use in the local coal mining industry and throughout Africa, the company demonstrated its new Cybermine continuous miner and dragline simulators at Electra Mining Africa 2014, which took place in Johannesburg from September 15 to 19.

ThoroughTec has delivered its Cybermine dragline simulator to customers in Australia and South Africa, the most recent delivery arriving at the Wesfarmers Curragh coal mine, in Queensland, Australia. The mine received the latest fourth-generation Cybermine simulator and a virtual Curragh mine world through a collaboration with ThoroughTec.

The dragline simulator, based on the Bucyrus-Erie 1570-W, was customised specifically for Curragh’s mine site and operating procedures.