Underground explosives ignited via custom control system

Challenge

Orica’s existing control systems for underground mining application was becoming obsolete and new technologies were available to bring new capabilities to their operations.

Time was limited and Orica required a new fit-for-purpose solution to meet their customers’ needs across the globe.

As a leading provider of explosive products and blasting services to the mining and tunnelling industries, with customers in over 50 countries, it is critical for Orica to provide products able to withstand the worlds most rugged environments and support their commitment no harm and zero accidents of any kind.

Solution

SAGE Automation was engaged and immediately undertook an extensive User Requirement Study from which to design a system.

The result is a system which will meet the global needs of today’s and tomorrow’s surface and underground mining operations.

Hardware

• PLC housed in readily available off the shelf components, carefully selected for ruggedised mobile equipment conditions
• Withstand -20 to +75 degree operating temperatures
• IP67 ratings
• 8-32V device operating ranges
• The use of large, quick connect cam lock fittings allows for accessibility even wearing gloves
• HMI, CAN BUS keypad, enclosure, cable system, encoders and high speed decentralised I/O controller
• USB – for data download and program upload
  
  

Software

• CANBUS network topology
• Flexible coding
• Free open protocol
• CANBUS interface into diesel engine
• Software libraries – screens and information templates available
  
  

Outcome

Off the back of this project, SAGE Automation received a Commendation at the Engineers Australia Excellence Awards in the category of Control Systems, Networks, Information Processing and Telecommunications for the Orica LOADPlus U control system.

Key features:

• The plug and play concept provides a control system that is easy to install, fault find and replace components, meaning cost-effective install times and right first time commissioning practices
• Simple system operation enables broader use - years of experience to operate is no longer necessary
• Ease of switching from a fully automated delivery sequence to a manual delivery service
• Multi-language programming and measurement units changeover for global application
• Screen colours suit above and underground usage as well as illuminated keypad
• Ability to use keypad wearing safety gloves
• Graphical real-time visual display
• Auto sequencing and minimal HMI interaction
• The unit can be carried like a briefcase and is incredibly robust. The protective cover acts as a hood during operation, shielding the components from water, mud and small rock-fall