Digital Solutions for Ensuring Safety in Mining Operations

Specific Risks in Operating Heavy Mining Equipment

Operating large-capacity mining dump trucks involves critical risks: the wheel height of the machine reaches three and a half meters, and any loss of driver vigilance turns the equipment into an unpredictable threat. In the mining industry, the problem of microsleeps and distracted driving requires systemic technological solutions that eliminate the human factor. Alexey Leonov, Director of Production Control and HSE at Tugnuisky Open Pit JSC, analyzes the practical experience of implementing a complex of digital systems aimed at monitoring driver conditions and preventing collisions in mining allotments.

Machine Vision Against Fatigue: Implementing a Video Analytics System

Initial attempts to monitor driver conditions using fitness bracelets that react to a drop in heart rate proved ineffective due to the individual physiological characteristics of the workers. The presentation details the transition to machine vision systems that read the driver's eye condition and facial expressions.

Infrared sensors and video recording cameras were installed in the dump truck cabins. The system detects eye closure, distraction from the road, use of a phone without a headset, as well as sabotage attempts (taping over or turning the cameras away). When signs of falling asleep are detected, the algorithm emits a sharp sound signal in the cabin to wake the driver, and simultaneously transmits a notification to the industrial safety dispatcher's console. If several fatigue signals are received within five minutes, the dispatcher has the authority to promptly suspend the operation of this dump truck to prevent fatal consequences.

Collision Prevention and Blind Spot Control

Due to the impressive dimensions of mining equipment, drivers physically cannot control all blind spots, which creates a risk of running over light vehicles and personnel. The speaker demonstrates, using the example of integrating proximity detectors, how this risk can be minimized.

The solution is built on equipment interaction: a base unit is installed in the dump truck cabin, while light vehicles and personnel are equipped with special tracker tags. When approaching a dangerous distance (10 – 15 meters), the system gives audio and visual signals to the dump truck driver, indicating the type of obstacle and its location zone. At the same time, an external loudspeaker on the dump truck itself is triggered, warning people outside, and the worker's personal tracker begins to vibrate.

Smart Positioning and Hazardous Zone Control

To meet the requirements for personnel positioning in mining operations, the enterprise implemented GPS trackers integrated with the access control and management system (ACS). Before the start of the shift, the worker applies their pass to the automated terminal, which automatically links the issued tracker to their profile.

The trackers perform several functions:

• SOS Button: if feeling unwell, the worker holds the button for 3 – 4 seconds. A signal with exact coordinates is sent to the dispatcher, who can contact the worker via voice communication through the tracker itself and dispatch help.
• Protection against entering hazardous zones: rock deformation areas and drilling and blasting zones are highlighted on the digital map of the open pit. If a person or equipment crosses the virtual boundary of a hazardous zone, the tracker vibrates, and the dispatcher receives an alarm signal to immediately stop work and evacuate the violator.

What you will learn from this webinar:

• Why smart bracelets for heart rate monitoring proved ineffective in monitoring driver fatigue?
• How to organize a prompt response from the dispatch service to video analytics signals with a fleet of 80 – 90 dump trucks?
• How to justify the legality of video surveillance in the dump truck cabin in case of personnel complaints to the State Labor Inspectorate?
• How the positioning system integrates with the ACS for personalized tracker issuance?
• How to automate access control of equipment and people to drilling and blasting zones?