ACARP ACARP ACARP ACARP
Open Cut

Development Of Heavy Maintenance Manipulator For Dragline Jewellery Repair

Open Cut » Maintenance & Equipment

Published: February 14Project Number: C21027

Get ReportAuthor: Peter Milani, John Billingsley | University of Southern Queensland

The project's objective was to develop a tele-operated manipulator prototype, in order to separate workers from the hazards of heavy maintenance, in particular, dragline jewellery maintenance. Dragline jewellery maintenance presents a high level of HSEC risk to maintenance personnel.  By physically separating workers from the actual work during many of these tasks, the consequences of uncontrolled energy release can be reduced. This will result in the a reduction of overall risk.

 

The manipulator's physical design concept is that of a multi-axis device capable of a wide span of reachable positions and orientations. This supports the requirement for a field device that does not require a long setup time. This mechanical framework was supported by an equally broad software framework based on Robot Operating System (ROS) software libraries. In addition, due to the complexity of the device, effort focused on producing an operator interface that would simplify and make safe the operation of a potentially hazardous machine. Significant time was spent developing simulation in order to understand the core task requirements and to assist in the development of the control code for the machine.

 

Two main dragline jewellery maintenance tasks were targeted: rotation of hoist chains, and insertion of a pin into a clevis. Simulations were developed of the tasks and of the manipulator. The simulations modelled forces, collisions and actuator dynamics. These simulations were also the environments by which the operator interfaces would be tested. Three main interfaces were tested on coal mine workers. The definitive preference was for a joystick-based interface that controlled the manipulator tool in task-space coordinates. Successful achievement of the tasks in simulation, demonstrated the validity of the design decisions.

 

The successful interface allows an operator to specify a particular movement directions and causes the software to determine the required movements within the joints to achieve that direction goal. The software algorithms reduced the considerable mental effort that would otherwise have been required to correctly produce that transformation. The operator is then freed to concentrate on the task at hand and in maintaining a safe work environment. The successful development of an intuitive interface annulled one of the key project risks: that a manipulator would be developed without an interface with which to operate it safely.

 

A physical manipulator prototype was constructed so that field testing of the desired tasks could be undertaken. The development was challenged by the demanding specification. Particularly in the physical arrangement of of all the components to fit the size, strength and range of movement requirements. The key specification for the manipulator was a 250kg lift at a reach of 2.4m. The manipulator partially met its specifications, with some mechanical and control aspects requiring further attention. Nevertheless the manipulator was sufficiently rugged to support itself throughout its range of movement and is positioned to support further development.

 

This project developed the concept of a tele-operated heavy manipulator for maintenance tasks to a proof-of-concept prototype. Whilst the current level of capability is far from commercial, the project achieved some key capability milestones. The first being the development of an intuitive interface, which allows non-expert operators to effectively control the device. The second milestone is a full scale manipulator that partially achieved its design goals. This prototype is suitable for the continued development of technologies that support the manipulator concept.

Underground

Health and safety, productivity and environment initiatives.

Recently Completed Projects

C26061The Young’S Moduli, Poisson’S Ratios And Poroelastic Coefficients Of Coals

This report describes the measurement of coal (and rock) properties ...

C24015 Assessment Of Convergence Based Roof Support Design For Longwall Abutment Loads

The aim of Stage two of project C24015 was to develop a roof support...

C25072New Approaches To Mine Gas Analysis And Ratios

The spontaneous combustion of coal remains a hazard in underground c...

Underground

Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C26022Real-Time Prediction Of Coal Top Through Guided Borehole Radar Wave Imaging For Open Cut Blast-Hole Drilling

Damage to the tops of coal seams caused by incorrect blast stand-off...

C26027Using An Ecotoxicological Approach To Validate The DGT Technique For The Measurement Of Bioavailable Metal Concentrations

This project builds on the opportunity identified through Project C2...

C25039Prediction Of Long-Term Salt Generation From Coal Spoils

The release of salts from spoil piles has the potential to affect su...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C250083D Flotation Of Fine Particles

In this project a process for the continuous, selective agglomeratio...

C20052Full Scale Gravity - Desliming Using Cascading REFLUX Classifiers

Considerable quantities of fine coal are disposed of as part of the ...

C26007 Revised Dustiness And DEM Test Method (Update Of AS4156.6) Part 2:Preparation

In 2015 project C23054 investigated and reviewed the Australian Stan...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C25045Stage Two - Assessment Of In Situ High-Temperature Strength Of Cokes

Stage I of this project established a reliable and repeatable proces...

C27003Review Of ACARP Research To Support Marketing Of Australian Thermal Coal

In this project, researchers pinpointed issues relating to the use o...

C25044Trace Elements In Coal; Status Of Test Methods In Use And Their Applicability

 STAGE 1 REPORT

The key objectives of this stage...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C27008Selective Absorption Of Methane By Ionic Liquids

The connection of a ventilation air methane (VAM) abatement plant di...

C24061Proof-Of-Concept Photocatalytic Destruction Of Methane For Coal Mining Fugitive Emissions Abatement

Australia's fugitive emissions in 2015 were 41 Mt CO2-e (representin...

C23052Novel Stone Dust Looping Process For Ventilation Air Methane Abatement - Phase 3

This multi‐phase project is concerned with the mitigation of m...

Mine Site Greenhouse Gas Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community

NERDDC

National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook

NERDDC