Increasingly omniscient, OP Pro version 4.0-003 is a holistic life-of-mine solution, Hexagon reported. (Photo: Hexagon)
A slew of updates to the top systems offer more data, analytics, insights and options
By Jesse Morton, Technical Writer
Future fleet management systems (FMSs) will offer an array of powerful cloud-based tools, modes and add-ons. They will function as, or integrate into, a unified source of truth that will be accessed from the cab, the shack out back, or the boardroom atop a skyscraper a hemisphere away. The barriers to rapid process optimization will disappear, and the era of near-autonomous mining will truly dawn. So say the suppliers of the top FMSs. The latest round of updates ensures this future is increasingly less theoretical.
OmniPro Certified for Cloud Integration
With regulators emphasizing the importance of collision avoidance solutions, interest in and demand for OmniPro grows, Matrix Design Group said. “We are actively installing these at surface operations and mining warehouses for large companies,” said Brian Jones, vice president, sales and marketing.
The demand is also driven in part by anecdotes from successful deployments. Miners are improving safety, changing problematic processes and behaviors, and cutting operating expenses by deploying the award-winning, camera-based system, said Chris Adkins, sales manager, Matrix.
For example, a customer turned to Matrix after it “lost a couple pieces of equipment due to traveling too close to a void area,” he said. “The equipment fell down into this area on two different occasions.”
The system was trained to respond to signage, and a stop sign was installed near the void. “We installed the camera system on the machine and set it up to where, when it got close enough to the void, it would allow them to dump the material where it needed to go, but it did not allow them to get close enough to where the machine would go into the void area,” Adkins said.
More recently, a customer adopted the system to eliminate blind spots on 300-ton haul trucks. “We are effectively covering all of those areas with the VisionAI to alert the driver if people are in these blind spots,” he said. “Not only are we alerting the driver but the safety representatives can go in and see who was in the alert zone and what was the action of the driver or operator of the truck, and build a safety plan around that so they can change behaviors.”
Customer feedback shows the system offers superior accuracy and usability over competitor systems, Jones said. In its most basic form, OmniPro is a couple of artificial intelligence-leveraging cameras, an in-cab monitor, an in-cab gateway and alerting devices. Currently, the system is on the brink of receiving ISO-27001 certification.
OmniPro will reportedly attain ISO-27001 certification, readying it for integration into platforms for mine management. (Photo: Matrix)
The certification means “your information that we collect into a cloud environment is protected,” Jones said. “We’ll have the certification within a couple of months.”
The development is integral to the solution’s evolution. “OmniPro has become not only an on-site safety device,” Adkins said. “The data is shared into our cloud, which creates opportunities for safety representatives to go and look in and see what is going on and be proactive instead of reactive to potential safety hazards,” he said. “We are working with a lot of large companies that have very strict IT departments, so ISO-27001 is hugely important.”
The certification positions OmniPro for integration with third-party systems to create a unified, data-driven, collision-avoidance solution. “The platform is scalable to integrate into a lot of other systems,” Jones said. “We have CAN-BUS or different types of I/O that comes from the OEM machine, or you can integrate with third-party systems to do two things.”
First it can be used to create a single source of fleet management information. Second, it can integrate “different sensor sets to keep from being left behind in the technology curve,” he said. “You can add different sensor sets. You can evolve the cameras. You can integrate different things into the hub.”
For example, OmniPro with radar is currently in trials that started in 2024.
“Layering radar and other technologies into the current camera-based AI system will allow operators to have an unprecedented level of visibility and protection,” Adkins said. “If you get into certain conditions that may inhibit camera visibility, radar is not susceptible to heavy fog or other things that might block out a camera.”
Also within the last 18 months, the system’s “detection and identification models have been optimized to perform reliably across a wider range of environments,” Adkins said. “These crucial advancements have allowed OmniPro to perform more effectively and efficiently by increasing positive detections, reducing false positives, and overall optimizing the rate of accuracy.”
Jones said the optimization incorporates lessons learned from deployments to different mines, operations and environments. “We’ve been on a lot of different machines, and a lot of different applications, and we continue to evolve over time.”
The hardware also evolved. “Hardware improvements include more robust housing for large surface haul trucks and a redesigned XPE-5 enclosure for underground mobile haulage,” Adkins said. “The housing for the camera itself is IP67-rated” and mitigates “extreme cold, heat and abrasiveness.” The glass window for the camera “is etched for dust resistance” and supports “a type of self-cleaning mechanism.”
Camera processor updates “enable higher processing speed, increased resolution and larger models tailored for mining conditions,” he said. “The cameras are taking 30 frames per second, which is a lot of images.”
The capability “allows granularity in what we are detecting and on how we alert on what we detect,” Jones said. “If you have a faster processor, you have a better camera and you can increase the distance or resolution you can process at any one point in time.”
The increased computing capacity “allows us to bring in more training of models and different variations of those models for accuracy,” Jones said. “It gives you additional functionality,” he said. “We are also introducing a new low-light camera,” which is still in development.
As OmniPro evolved, so too did the capabilities of the support team dedicated to the mining space. “It is a strength of ours and differentiates us,” Adkins said.
“One of the companies we were working with evaluated Matrix versus another system,” he said. “The customer said the system was a little bit better than the competitive system, but the service was astronomically better.”
The service team “works closely with users to tailor solutions, conduct trials and onboard operators,” Jones said. “Installations are completed within hours, minimizing disruption to operations,” he said. “Post-install adjustments are straightforward, allowing OmniPro to adapt to various vehicle types and operational needs.” The team offers “training and full product-lifecycle support, developed specifically for mining operations.”
OP Pro version 4.0-003 employs an enhanced understanding of shovel status to develop more proactive truck assignments, Hexagon reported. (Photo: Hexagon)
Op Pro Evolving for AI, the Cloud
Hexagon’s Mining division released OP Pro version 4.0-003 in July. A Hexagon fleet management expert said the updates address the evolving and direct demands of surface mining.
“This update introduces substantial improvements across key areas, including fleet management efficiency, smarter dispatching algorithms, accelerated analytics processing, broader equipment integration capabilities and increased system stability,” said Jarym Kowalchuk, head of product, operations and autonomy. With safety, planning and reporting tools, “its integrated ecosystem delivers a holistic life-of-mine solution, outpacing other market offerings that often prioritize basic dispatching without equivalent depth in optimization.”
Helping optimize fleet efficiency, the system offers an “enhanced understanding of shovel status” and “enables more proactive truck assignments, reducing downtime, even in edge cases where equipment availability might fluctuate,” he said. “Refined shovel assignment priorities and feed-rate calculations optimize equipment utilization, while stricter adherence to route restrictions enhances both safety protocols and overall operational efficiency.”
Analytics information is more readily available to support decisions on the fly. “Key performance indicators now refresh in just two to four seconds, facilitating immediate insights and enabling quicker, data-driven decision-making in dynamic mining environments,” Kowalchuk said.
The new version is capable of being deployed to more makes and models of machines, “including Volvo trucks, Epiroc drills and crusher bay systems,” he said. It “promotes greater interoperability in mixed-fleet operations, allowing mines to leverage a variety of machinery without compatibility issues.”
OP Pro 4.0-003 is inherently more stable than previous versions. “Targeted fixes for socket overflows and rendering issues minimize system crashes and improve reliability under high-load conditions, ensuring consistent performance during peak operational periods,” Kowalchuk said.
The system benefits operators, engineers, maintenance, the plant and executives.
The operators will benefit from “quick status-change shortcuts, superior plant monitoring and refined dialogs,” he said. “These elements collectively enhance operational efficiency, provide better oversight and reduce the likelihood of errors through simplified data entry and clearer visibility into system statuses.”
The system supports engineers “in optimizing operations to align with production plans, thanks to improved shovel assignment priorities and precise feed-rate calculations,” Kowalchuk said. “The integration of real-time truck positioning and timely alerts for misrouting supports accurate production optimization and empowers engineers to refine processes effectively.”
OP Pro 4.0-003 delivers information to the plant that can be used for planning and optimization. “Plant personnel, particularly those involved in coal handling and preparation, gain enhanced operational confidence through better comprehension of plant targets and real-time updates via onboard monitoring tools,” he said. “This leads to improved alignment with production goals and more seamless coordination with fleet activities.”
Maintenance can benefit from the “heightened accuracy in tracking equipment availability and utilization, facilitated by status shortcuts and rapid analytics refresh rates,” Kowalchuk said. “This near-real-time data enables proactive scheduling and swift responses to equipment needs, ultimately reducing unexpected downtime.”
With the system, mine managers gain greater “operational visibility and efficiency, propelled by real-time analytics and intelligent dispatching,” Kowalchuk said. “The system’s optimization of truck and shovel assignments drives down costs and improves productivity, as evidenced in various case studies, while robust stability allows focus on strategic priorities rather than technical issues.”
Executives can use the system to facilitate “substantial cost reductions, safety measures and amplified productivity,” he said. “The platform’s scalability and seamless integration with varied equipment support sustained growth, complemented by sustainability-oriented features like optimized routing that align with broader environmental objectives.”
The new version represents an evolutionary step for a system with a storied legacy. The first version of OP Pro was a dispatching tool that, over time, was developed into “a comprehensive fleet management system designed specifically for open-pit mining,” Kowalchuk said. “Its initial strong adoption in Latin America, the USA and Canada paved the way for rapid expansion into Europe, the Middle East and Africa, as well as the Asia-Pacific regions.”
Incrementally, the hardware and software was updated, “improving onboard computing power and user experience, benefiting operators, controllers, maintenance teams and planners alike,” he said. Eventually, OP Pro became renowned for real-time analytics that could be used in optimization efforts. For example, a miner in Latin America replaced their fleet management system with OP Pro and “boosted productivity from 800,000 to 1 million tons daily by optimizing truck-shovel assignments and crusher bay coordination for a 25% gain.”
Version 4.0-003, was developed to address trending challenges, “such as escalating operational costs, increasingly stringent safety regulations and the growing prevalence of mixed and electric vehicle fleets.” It was also developed to answer “broader industry shifts toward advanced real-time analytics, artificial intelligence integration and sustainable practices, establishing OP Pro as a forward-looking solution in the fleet management landscape.”
Future development of OP Pro will center on integrating it with Hexagon’s planning, collision avoidance and fatigue management products. The goal is “minimizing hardware requirements and elevating safety via targeted optimizations for fatigued operators,” he said.
“Looking ahead, future developments will incorporate cutting-edge machine learning and artificial intelligence technologies to refine optimization processes and deliver deeper production insights, accessible even through natural language queries,” Kowalchuk said. “These enhancements will further broaden interoperability and enable greater cloud-based scalability, ensuring OP Pro remains at the forefront of mining fleet management innovation.”
Using Wencomine FMS, shovel operators can monitor payload compliance and signal short moves, the supplier reported. (Image: Wenco)
Wenco Launches FMS Module for Cloud
Wenco International Mining Systems and Motium celebrated the 15th anniversary of their strategic partnership. Since 2010, Wenco’s fleet management systems operating over Motium’s rugged computers have been deployed at surface mines in the Americas, Africa and Australia.
The partnership withstood the test of time because it proved worthy of widespread trust, Wenco said. “Mining operators count on reliable, integrated systems that work under the toughest conditions,” said CEO Yoshi Furuno. “Our collaboration with Motium has delivered exactly that, time-tested fleet solutions that scale across the globe.”
An expert with Wenco said the companies’ solutions have evolved synchronously over the years. “As Wenco’s mining fleet management platform has grown more powerful, Motium’s rugged hardware has evolved in lockstep, delivering increased computing power, improved connectivity and unmatched durability,” said Reid Given, product line manager. “This synergy between reliable hardware and innovative software is a direct result of continuous collaboration and customer-driven design, enabling operators to run even the most complex features smoothly in the field.”
The first deployments in 2009 and 2010 revealed “the need for glove-friendly touchscreens, simplified interfaces and sunlight-readable displays,” he said. “Motium responded with improved tactile feedback and rugged screen technology tailored for mining environments.”
The year 2013 brought the need for higher data processing rates. “Operators requested faster load times and smoother navigation,” Given said. “Motium upgraded onboard computing power to support real-time analytics and responsive user interfaces.”
By 2017, managers wanted “better integration between onboard hardware and back-end systems,” he said. “This led to enhanced connectivity, remote diagnostics and streamlined data flow between field devices and enterprise platforms.”
In 2023, the new generation of operators were demanding “smartphone-like responsiveness in rugged environments,” Given said. “Projected capacitive (PCAP) touch became the standard,” he said. “An upgradeable PCAP solution delivers this with strengthened glass, a water-repellent surface and multi-touch clarity, making it a smarter, tougher upgrade for Wenco’s fleet technology.”
The timeline points to today’s Wencomine FMS. The OEM agnostic system “ingests high-precision GPS and OEM telemetry from all mobile equipment, processes it through proven optimization algorithms, and surfaces actionable intelligence via role-specific dashboards,” Given said.
It offers “a single source of truth for equipment activity and cycle times,” he said. The data can be used to optimize processes across an operation. “Time-synchronized measurements on activities, like loading and dumping, feed algorithms that evaluate thousands of assignment permutations.” The algorithms “minimize shovel hang and truck queues while honoring shift constraints such as blend targets and crusher throughput.” The recommendations and assignments “feed back into the control loop, enabling continuous adjustment to real operating conditions and preserving data fidelity for downstream analysis.”
Operators receive real-time performance data. For example, “shovel operators can monitor payload compliance and signal short moves, while truck operators receive clear, map-based route guidance,” Given said. Equipment faults are logged and relayed. Operator anomalies are detected and reported.
The base system’s capabilities expand through specialized add-ons tailored to specific operational challenges. For example, Dynamic Dispatch seeks to maximize truck-shovel productivity. “Dynamic Dispatch alone increases output 5% to 11% without additional equipment investment, while real-time variance-to-plan visibility enables corrective actions that keep production on target,” said Brady J. Marcus, customer success manager, Wenco.
One customer, “an iron ore operation, achieved an 11% productivity increase through Dynamic Dispatch implementation,” he said. Other sites “report a 30% reduction in shovel queue times with optimized dispatching.”
PitNav with Fleet Awareness offers GPS navigation and proximity detection. “PitNav guides operators along optimal routes and away from hazards, particularly critical for new drivers or in poor visibility conditions,” he said. At one large surface mine, “a PitNav implementation reduced off-route incidents by 60%.”
Fuel Dispatch works to reduce refueling wait times. One customer, “a coal mine, reduced fuel costs by 8% using Fuel Dispatch optimization,” he said.
Activity Dispatch is designed to minimize disruptions from shift changes and blasting. Some sites have reported “documented productivity gains of 5.9% and adding 45 minutes of working time per day,” Marcus said.
Source: www.coalage.com
