December 8, 2009
Heiko Elsholz looks totally relaxed. A remote control unit hanging from his neck, he is standing in front of the large drilling vehicle he is steering. The heavy equipment operator, who normally works at the Hattorf-Wintershall mine, Germany, is busy refining his skills in operating this special piece of large equipment. An unusual sight to behold: Elsholz wears neither safety helmet nor his normal work wear. The reason: The depicted drilling vehicle is not real, but is projected onto a 10- meter-long curved screen. It is part of the new aboveground drilling vehicle control platform at the Herfa location of the Werra works, Germany, which now allows for virtual-reality-training of trainees and of experienced staff.
Heiko Elsholz, during a virtual drilling training session (photograph: K+S)
Already in 2007, the first prototype of a drilling vehicle control platform (SIMLAB) was installed at the Zielitz potash mine – however, this prototype was located belowground. The objective was to offer interactive training in machine operation and understanding of drilling processes, to future and to already experienced drilling experts alike. Due to the excellent experiences made with the Zielitz SIMLAB, K+S decided to set up a second control platform at the Werra works, this time above-ground. The new SIMLAB was realised after an18-month period of planning and construction, explains Johann-Christoph Thiele from the Functional Area Mining in Kassel. The core of this training environment is a 3-m-high and nearly 10-m-wide projection screen, on which the drilling process is depicted and simulated, and which allows for stereoscopy.
Charged with the realisation of both simulation centres was the Berlin company Datenflug, which provided a team of engineers and computer scientists, all of them experts in the fields of simulation, programming and web design. In order to be able to “feed” Datenflug with as much information as possible for a detailed representation of the surrounding underground environment, all district-specific drilling sites were scanned and recorded, and their data entered into a 3D-library.
In a second step, the drilling vehicles used were visualised and their functions were simulated. Depending on training requirements, the training environment may then be adapted to realistically represent the desired rock mass situation, drilling vehicle behaviour, and the demands made on drilling engineers. The secret of the project’s success lies in the productive and smooth cooperation between the K+S management, the KALI works, Datenflug and machine manufacturer SMAG. Another characteristic of the cooperative development was the cross-locational inclusion of drilling engineers and professional training specialists, in a series of workshops.
Looking through special glasses, viewers enjoy a whole new 3D-perspective (photograph: K+S)
Representation of the drilling site and of the virtual drilling machinery is done stereoscopically, i.e. “in stereo”, on a projection screen. These 3D-effects allow users to spatially experience the training contents mediated in the simulation lab. The simulated machine is controlled by a true-to-the-original remote control, reactions to steering manoeuvres are directly experienced. This creates a truly interactive training situation for handling machinery. The advantage of a training system based on virtual reality is clear: challenging situations and operating errors may be recreated without risk to machine or trainee. This shortens training time, is easier on the machine park and results in significant savings when it comes to maintenance of equipment.
The new drilling vehicle control platform is cared for by Olaf Frömel and Wolfgang Schäfer, two experienced drilling engineers. They are fully convinced of the new concept, and are glad it has been unilaterally accepted by their colleagues. This year, 59 employees have been trained using this equipment, – and the tendency is increasing. Training is suited for initial training of prospective as well as of already active mining engineers, from the Werra location as well as from the sister locations Neuhof-Ellers and Borth, while the Zielitz SIMLAB is used for training employees working at the locations Zielitz, Sigmundshall, Braunschweig-Lüneburg and Bernburg.
For one week, apprentices practice proper operation of the machine, while for experienced miners one shift is usually enough to refresh their drilling skills. Works manager Peter Euler is enthusiastic about the new SIMLAB at the Werra works. “I am really excited to have this centre for qualifying trainees and experienced drilling engineers right here at the Herfa-mine of the Werra works. I’m glad the project turned out so well”, he stated at the occasion of the presentation of SIMLAB to journalists.
For the near future, new extension modules (sound, service, etc) for the drilling vehicle control platform are conceivable, as are modules for other large machinery, such as loaders.
