Reliable Software Solutions, a software development company, has created the RSS Auto Scan volumetric scanning system, which is being used across the bulk material handling industries.
When train loading becomes inefficient, it can hamper output and affect the site’s overall productivity and profitability.
This was the dilemma facing a mine, which was not meeting the target payload for each train wagon.
“The site used a track scale to determine that the loaded trains, consisting of over 200 wagons each, were consistently falling short of the desired payload. This shortfall directly impacted the mine’s overall output,” Reliable Software Solutions managing director Andrew Sheppard said.
“The team knew that understanding the volume of material in each wagon might reveal the underlying issues. By calculating the material density using weight and volume, they aimed to identify inefficiencies and determine a path forward.”
The initial objective was clear: measure the volume of material loaded into each wagon to gain actionable insights into loading processes and identify areas for improvement. The development of the RSS Auto Scan volumetric scanning system emerged as a solution.
Overcoming technological hurdles
The transition from a semi-automated to a fully automated system posed technological challenges. Initially, the site employed older LIDAR sensors to collect raw data. This data, in its rudimentary form, required extensive processing to extract meaningful insights.
“The data we received was essentially a cloud of points,” Sheppard said. “We needed to interpret, clean, and develop algorithms to convert that raw data into actionable metrics, such as train speed and material volume.”
Early trials relied on manual processes, with data being collected and processed post-collection. However, the system’s limitations necessitated a shift to newer LIDAR sensors and a more sophisticated data engine.
This upgrade enabled near real-time feedback, delivering results within five to 10 seconds after a wagon passed through the scanner.
Ensuring the accuracy and repeatability of the measurement system was another critical hurdle. External validation and rigorous accuracy testing were conducted to ensure the system could reliably deliver precise measurements.
“Once we confirmed the data engine’s accuracy, we integrated modern sensors and linked the outputs to the site’s programmable logic controller system for seamless operation,” Sheppard said.
Real-time decision making
The integration of LIDAR technology and a live Modbus interface changed real-time decision-making for loadout operators.
“Operators could finally see exactly what was happening during the loading process,” Sheppard said.
Metrics such as the amount of remaining space in each wagon, both front-to-rear and side-to-side, provided invaluable guidance.
With this information, operators could fine-tune loading processes to achieve optimal wagon fill.
By leveraging the feedback from the volumetric scanner, operators adjusted loading techniques to maximise the payload while staying within design limitations for axle and bearing loads.
“Previously, the site struggled with low-density material, which made it impossible to meet target payloads,” Sheppard said.
“The system revealed unused capacity, enabling the site to adjust and consistently hit target payloads, adding significant value without interfering with existing processes.”
Broader applications and benefits
The success of the auto scan system for train wagons paved the way for its adaptation to mining haul trucks.
“Many of the fundamentals apply to both trains and trucks,” Sheppard said. “The ability to scan in motion and provide near-instant feedback is crucial.”
For haul trucks, the system offers unique benefits, such as facilitating tray studies. Customised trays are often designed for specific materials, and the volumetric scanner helps validate their performance by providing density and volume data.
Sheppard said a notable carry-back study where four different tray designs were tested for their effectiveness in reducing material sticking.
“We scanned each tray before and after use to quantify the amount of material left behind. The results were instrumental in identifying the best-performing tray and monitoring carry-back over time.”
In addition to point-in-time studies, the system is also capable of 24–7 operation, making it suitable for continuous monitoring near crushers or dumps.
This flexibility allows mining operations to adapt the technology to their specific needs.
Expanding market reach
Despite the proven benefits of the RSS Auto Scan system, Sheppard said that its adoption has been limited to a few sites.
“We’ve primarily worked on a project-by-project basis. While the system has been implemented successfully at multiple sites, we aim to broaden our exposure and reach other potential users who may face similar challenges.”
The system’s ability to deliver actionable insights, improve efficiency, and maximise payloads makes it a valuable asset.
“We believe there are many operators out there who could benefit from this technology but aren’t aware of its capabilities,” Sheppard said.
As mining operations face increasing pressure to optimise performance and reduce costs, innovations like the RSS Auto Scan system play a crucial role in achieving these goals.
By providing accurate, real-time data and enabling informed decision-making, the system not only addresses existing inefficiencies but also opens the door to new opportunities for improvement.