Autonomous Haulage System Integration

Challenge / Problem: The primary challenge of this project was to integrate Roy Hill's (Hancock Iron Ore) bespoke Autonomous Haulage System (AHS) with the plant-wide Process Control System. The first part of this challenge was to provide ROM Bin level status to their driver-less dump trucks so that the trucks could safely dump rocks into the bins. The AHS vendor initially proposed a complex industrial solution involving the installation of hardware (a V2x interface panel) with radio antennae and ModbusTCP gateway(s) (for interface to the Rockwell Crusher PLC).

Without clear visibility of how signals and communications would be exchanged, there was a significant risk in proceeding directly to site implementation. Additionally, developing a reliable interface required bridging different communication protocols—ModbusTCP from the V2x Interface Box and Ethernet/IP used by the Crusher PCS—while ensuring data integrity and safe operations. Establishing a robust solution without disrupting ongoing operations was also a critical consideration.

Solution:  To address these challenges, a phased approach was adopted, starting with Phase 1: Proof of Concept and Bench Testing. Engineering design workshops were conducted with the AHS vendor to define the interface architecture and connectivity. Based on this architectural information, we proposed a simpler and more robust solution using Sparkplug B MQTT comms that leveraged the sites existing Ignition gateway. A dedicated test environment was established at Pivotal Engineering, allowing comprehensive type-testing and stress-testing of the communications interface before any site implementation.

Outcome / Results:  The Phase 1 activities successfully validated the feasibility of the interface between the AHS and Crusher PCS. Bench testing confirmed reliable communication across the proposed gateway. Detailed documentation, including the Interface Design Specification and Bill-of-Materials, was delivered, providing Roy Hill with a clear framework for future works. The proactive identification of connectivity requirements and potential challenges mitigated risks, ensuring that the next phases could proceed with confidence and minimal uncertainty.

Subsequent works included developing an "All-Stop" (A-Stop) solution at the CRO using Opto22 Groov RIO units to stop all autonomous vehicles if the AHS is un-responsive or compromised as well as automating and integrating boom gates and traffic lights around the mine site to open/close based on autonomous vehicles (resulting in un-manned and fully automated crossings).

Platforms Used: Ignition 8.1, Sparkplug B, Allen-Bradley Logix Controllers, Opto22 Groov RIO