Reliable Software Solutions has created a weighing and scanning system to improve mining operations.
A mine’s primary goal is to move a volume of material out of the ground. However, instead of volume, the trucks that are used to move this material are managed by payload capacity. The critical link between these two factors is material density.
Reliable Software Solutions has developed a system that combines volumetric scanning with weight measurements to give mines essential insights into their operations.
“Our Truck Scan I.T. product determines the volume, while the scale provides the weight,” Reliable Software Solutions managing director Andrew Sheppard said.
“This combined dataset allows mine operators to calculate the true material density and monitor changes in real time, which is particularly important for managing materials of varying density. If a truck moves 240 tonnes daily under normal conditions, but heavy rainfall increases material weight, it could result in reduced actual volume being transported. Real-time density monitoring prevents such inefficiencies from going unnoticed and enables proactive decision-making.”
Combining volumetric and weight data
Many mine sites now use custom-built trays to reduce truck weight and increase payload capacity. These trays are often designed for specific materials with a target density.
Theoretical calculations can differ from real-world performance.
Sheppard said the ability to measure and validate tray design using volumetric scanning is invaluable.
“Let’s say a mine designs a tray for a material with a density of 1.7 SG, ensuring the load is balanced with one-third at the front and two-thirds at the back,” he said.
“After a few initial loads, our system can verify whether the tray is performing as expected. This validation helps prevent costly errors, such as purchasing 20 trays that later prove to be poorly suited for the material being hauled.”
Without this verification, payload monitoring systems may provide inaccurate data due to weight distribution imbalances. Early-stage validation through volumetric scanning helps operators avoid inefficiencies and improve overall fleet performance.
Addressing carryback issues
Carryback – the residual material left in a truck after unloading – remains a common challenge across mine sites. It reduces payload capacity and increases unnecessary truck movements, resulting in higher fuel consumption and wear on equipment.
In the past, operators could sense when a truck felt heavier due to carryback, but in autonomous fleets, such subjective assessments are no longer possible.
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“Our system scans each tray as it passes under the scanner and compares it to an empty target,” Sheppard said.
“Some may argue that onboard payload monitoring systems can detect carryback, but these systems have limitations. They only operate within a narrow weight range and often fail to detect carryback beyond a certain threshold. Furthermore, they rely on pressure sensors that require regular maintenance, making them prone to errors.”
Volumetric scanning provides a more reliable and maintenance-free alternative, measuring carryback in terms of cubic volume rather than weight.
By identifying the precise volume of material remaining in a tray, mines can address carryback issues proactively and optimise haul truck efficiency.
Improving loading practices
Optimising loading processes is another key benefit of volumetric scanning. The system helps mining companies assess whether operators are loading trucks efficiently, ensuring material is distributed correctly within the tray.
“The scanner quantifies how much material is on the left, right, front, and rear of the tray,” Sheppard said.
“This allows mines to identify training opportunities for loader operators, ensuring that trucks are loaded according to optimal weight distribution. Additionally, mines can validate whether the chosen loading tool matches the trucks, reducing unnecessary truck movements and maximising payload efficiency.”
Ensuring data accuracy
Reliable Software Solutions ensures the data collected through its volumetric scanning technology is accurate and trusted by site managers.
The system uses highly precise distance measurement sensors that are factory calibrated to provide reliable and accurate readings.
To validate its software algorithms, the company has conducted extensive repeatability tests as well as third-party verifications.
“We’ve compared our data with market leaders in the drone scanning space by conducting parallel studies,” Sheppard said. “For example, we scanned a load in a truck, dumped it on the ground, scanned it again, and ensured the measurements matched. We’ve also tested our system against tray design specifications to confirm its accuracy.”
The system provides immediate feedback, unlike drone-based stockpile assessments that require lengthy data processing.
“With our system, a truck drives under the scanner, and within five seconds, we have the answer,” Sheppard said. “This enables real-time decision-making, ensuring mines can respond swiftly to any material discrepancies.”
Flexible deployment options
Reliable Software Solutions offers two deployment modes for its volumetric scanning system.
The first is a point-in-time study, where a temporary setup provides short-term insights into material density and loading efficiency.
The second is a semi-permanent system, which remains on-site for extended periods, offering continuous monitoring and feedback.
“The semi-permanent setup is similar to a fixed scanner used for stockpiles, but it’s tailored for haul trucks,” Sheppard said.
“Whether a mine needs short-term validation or long-term operational improvements, our system delivers the accuracy and efficiency required to optimise haulage performance.”
Reliable Software Solutions can integrate volumetric data with existing weigh bridge solutions or can provide a complete turnkey solution.