MOBILE ASSETS TELEMATICS AND SIMULATION

Asset telematics solutions

• Integrated architecture for mobile asset data collection allows miners to remotely gather information from mobile mine equipment and understand how mining vehicles and operators are performing in real-time
• Collects the data, aggregates it, and displays information for informed decision-making
• Utilizes an open and scalable visualization and analytics platform that can be expanded across the entire mine operation - from mine to port

Haulage/Route simulation

• Simulate route alternatives to determine the best approach to optimizing performance or before committing significant capital or resource expenditures
• Understand performance based on key metrics such as costs, throughput, cycle times, equipment utilization, and resources
• Determine the impact of uncertainty and variability on system performance. Run "what-if" scenarios to evaluate proposed process changes
• Visualize results with 2D and 3D animation

ASSET HEALTH MONITORING AND PREDICTIVE ASSET
RELIABLITY

Asset Intelligence for Mining

Asset Health

• Early failure detection of critical components of an asset
• Remaining Useful Life (RUL) estimates
• Recommendations on how to address and take action

Asset Performance

• Apply out of the box asset performance calculations
• Receive alerts and notifications triggered on KPI thresholds
• KPI trend extrapolation

Condition Monitoring and Sensing

• Integrated condition monitoring system for critical loads
• Condition monitoring sensors
• Edge-based machine learning supervisory application that uses data from existing plant devices to monitor asset behavior, detect and identify anomalies, and notify customers of predicted equipment failures

MAINTENANCE ACTIVITIES MANAGEMENT

Digital platform for maintenance work, parts, costs, and schedule planning

• Cloud-based, AI-powered Computerized Maintenance Management System™  (CMMS). It helps mining companies manage all their maintenance, including thousands of assets, work orders, and parts, in one place, with just a few clicks for mining
• Simple and easy to use
• Cloud-based
• Collect, analyze, and act on maintenance data
• Create, complete, and record work orders
• Keep track of the parts and supplies needed for maintenance

SMART STOCKYARD MANAGEMENT SYSTEM

Stockyard and stockpile mangement system

• Optimally manage and automate the inbound receipt and outbound delivery of mined material
• The system enables the stockyard, stockpiles and machines to be viewed in a highly accurate real time 3D visualization interface. Material, quality and age can be tracked in small fraction blocks throughout the stockyard. Core components of the System include:
• Short-term machine planning and anti-collision features
• Stockpile modelling
• Real-time monitoring and visualization
• Quality tracking
• Machine optimization

INTEGRATED REMOTE MONITORING AND OPERATIONS

Data and operations integration

• Aggregates, cleans, and contextualizes disparate data sets, real-time and historical, directly or indirectly related to physical assets, in a single unified location
• Integrates planning chain from mine to market (mine, process, transport)
• Unified Maintenance and asset management activities
• Integrates / centralizes control rooms (monitoring, control and operations)
• Centralized video surveillance

Industrial cybersecurity solutions and services

• A proactive approach to industrial cybersecurity
• Identifies risks to OT networks, systems, apps, data and services
• Helps protect infrastructure
• Detects threats before they cause disruption and downtime
• Responds to incidents and quickly contain impacts
• Recovers quickly and increase cyber resilience

MINE TO MARKET VISIBILITY AND OPTIMIZATION

Scalable, fit-for-purpose Mine Operations Management platform specifically designed for mining

• Leverages existing site infrastructure  (ERP, Historian, LIMS, FMS…) to provide a single source of truth and models data in the context of the value chain
• Multiple architectural options to suit on-premise, centralized, cloud-hosted, or hybrid as best suits each site's infrastructure constraints
• Add applications at your own pace and easily expand to address additional requirements:  
• Production & performance reporting
• Asset utilization / OEE
• Downtime / Loss accounting
• Inventory management and storage balances
• Statistical Process Control (SPC) 
• Short interval control

INTEGRATED ROBOTIC INSPECTION SYSTEM

Remote inspection, data sampling and image capture of infrastructure, high-value/critical assets

Flexible

• Fully integrated system designed to accelerate inspection solutions. Flexible configuration capabilities enable technology groups to develop solutions quickly for specific needs

Automate data collection

• Manual and autonomous missions with easy navigation in various environments - control over the internet with a web browser
• Adapts to changes in the environment to find paths around obstacles. Specify repeatable autonomous missions through a graphical user interface to perform inspections and gather data

Inspection ready

• Built-in front and rear driving lights, pan-tilt-zoom camera, front and rear stereo cameras, or 3D LiDAR to capture high-quality data - Additional sensing integration: Such as  optional thermal camera or microphone
• Process data on the fly or download data and post-process at the end of a mission

MINE AUTOMATION

Validated architectures and dedicated functionalities for underground mining applications

• Ventilation control and optimization
• Compressed air systems - multi compressor management and surge control
• Safe and reliable hoisting control
• Crusher control
• Material handling automation
• Dewatering control
• Network Systems
• Unified backbone across the mine sub-systems
• Reliable communications from the under-ground operations to the above-ground systems

STACKER RECLAIMERS OPTIMIZATION AND CONTROL

Automation and power for stockyard equipment

• Manual, semi-automatic, or automatic modes
• Integration with positioning systems (machine location, speed, collision avoidance)
• Seamless network integration with both Rockwell Automation devices and third-party equipment, including wireless systems, belt scales, video cameras, 3D vision systems, encoders and sensing technologies
• Speed drives for smooth acceleration and deceleration – and less wear and tear on drive components
• Predictive diagnostics and maintenance settings that can monitor drive and motor operating conditions to help analyze system health

PLANT-WIDE AUTOMATION

A common automation platform to seamlessly integrate mine areas (processes, equipment and utilities)

• Unified process and power systems to create one operating environment and information database
• Connectivity from sensors to business functions (OT/IT) with open standard technologies
• Analytics capabilities with dashboards to quickly monitor asset and process metrics

Process optimization and analytics for mineral processes

• Reduce variability of mineral processes that not only improves throughput and quality, optimizes chemicals, energy, and water usage, but also leads to a reduction in waste material generated from the process
• Proven solutions for:
• Crushers
• Grinding circuits
• Concentration plants
• Material handling

ELECTRICAL DISTRIBUTION

Intelligent Packaged Power

• The Intelligent Packaged Power offering helps reduce risk by delivering motor control devices, and all elements of the electrical distribution system, in one package 
• Digitally integrate all devices, regardless of which manufacturer supplied the device. This can provide plant personnel with total access to all information in the substation:
• Better load management and energy management
• Real-time monitoring of electrical and process systems from anywhere
• One network, visualization, archiving, and reporting platform
• Access to synchronized, time-stamped data from a single source
• Faster and easier system modification and expansion

CONVEYOR AUTOMATION AND SAFETY

Automation and elecrification for conveyance systems

• Power and control integration helps speed design – and ease configuration, operation and maintenance

Next generation drive systems

• High-performance control for precise speed and torque
• Adaptive Control helps keep equipment running at optimal performance 
• Predictive analytics provide equipment repair and replacement alerts

Integrated safety solution for conveyors

• Delivers safety requirements while reducing complexity and costs:
• Single solution for standard and safety control systems
• Distributed cabinets connect safety switches and traditional sensors using a fail-safe communication network 
• Safety Distributed Inputs / Outputs (I/O) modules - Including IP67-rated solutions
• Microprocessor-based cable pull switches reduce false trips – and ease installation, diagnostics and repair
• Safe Torque Off option for variable speed drives where the de-energized state is considered the safe state. Removes rotational power to the motor without shutting down the drive

AUTONOMOUS SYSTEMS

Execution Management (EM) Solution for Train Loading Systems (TLO)

• The execution management (EM) solution orchestrating the TLO decision-making process with less human intervention
• Integration with ERP and/or the site’s job management system to automatically generate a list of all equipment needed to correctly execute the job
• Improves conformance to plan and scheduling through standardization of operational processes
• Reduces unscheduled process delays thought the efficient preparation of key equipment (stackers, reclaimers, TLO conveyors)
• Bolsters accountability for critical control, safety and machine protection through integration with the existing plant control system and processes

INTEGRATED PROCESS CONTROL

Distributed Control System (DCS)

• Powerful project design tools
• System emulation
• High availability systems
• Native process capabilities
• Powerful devices integration (process safety, instruments, power)
• I/O built for process
• Operator awareness and effectiveness  - such as: multi-lingual support, multiple user modes, integrated reporting tools, trends, effective alarm management, and virtualization tools
• Integrated analytics
• Cyber secure

Process optimization and analytics for metal refining

• Advanced process control increases production rate, reduces variability, optimizes fuel and energy usage and reduces emissions per ton produced

Advanced Continuous Emissions Monitoring

• Model-based, Predictive Emissions Monitoring System (PEMS) that provides a certifiable, cost-effective solution as an alternative to hardware-based Continuous Emissions Monitoring Systems (CEMS)

DIGITAL WORKFORCE

Knowledge capture and management

• Experts can capture step-by-step procedures and best practices as they work
• Transforms those insights into reusable processes, job aids and training materials
• Delivery of augmented 3D work instructions to frontline workers to optimize inspections for quality, safety, and field maintenance use cases

Workforce collaboration and assistance

• Interactive, digital elements to a live, real-world environment
• Remote assistance powered by augmented reality (AR)
• Advanced AR collaboration tools with real-time video communications
• Connects a field technician with an expert so that they can both see and discuss the situation at hand

ENERGY MANAGEMENT

Energy awareness with contextualized analytics

• Aggregate and contextualize energy data from disparate sources
• Monitor analyze and compare energy performance in real time across the enterprise
• Prebuilt real-time energy performance dashboards
• Energy consumption, demand, and energy intensity
• Energy cost allocation
• Emissions tracking
• Reporting
• Notification management

RENEWABLE MANAGEMENT

Green hydrogen production

• Integrated process control, power, safety, and analytics from a single vendor

Solar / Wind automation

• Control automation and condition monitoring for solar and wind generation systems

Power management system

• The supervisory control and data acquisition (SCADA) system performs data acquisition, updates the system status through alarm processing, updates the user interface, and executes control actions

EMISSIONS MONITORING AND ANALYTICS

Reporting and analytics software for environmental data

• Air Quality Analytics software enables pollution source identification, air quality management, regulation, and forecasting, positively impacting infrastructure, planning and human behaviors

Advanced Continuous Emissions Monitoring

• Model-based, Predictive Emissions Monitoring System (PEMS) that provides a certifiable, cost-effective solution as an alternative to hardware-based Continuous Emissions Monitoring Systems (CEMS)

WATER MANAGEMENT

Smart pump control

• Operates all the pumps at their most efficient speeds to meet demand while saving on energy consumption
• Remotely monitor and control pumping stations with real-time visualization and automatic alert system

Water metrics and balances

• Water inflows and outflows associated with the site, including water withdrawal, discharge, and consumption
• Key water flows and dynamics internal to the site, including process water use/reuse/recycling and change in storage

Real-time water quality monitoring systems

• Remote real time water quality monitoring systems specializing in drinking water, surface water, groundwater, process water and wastewater

KEY SOLUTION(S)

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