Case Study
Precision Angle Monitoring for Vehicle-Trailer Safety
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For mining fleet operators, protecting high-value equipment through precise monitoring is crucial to maintaining operational efficiency and safety. In this case study, we explore how electrical engineering consultant BESC integrated Certus inertial navigation system (INS) technology into their fleet management system to deliver high-precision angle monitoring through an integrated sensor solution, replacing multiple separate sensors with a single robust unit while providing comprehensive early warning detection.
Key Points
- Real-time angle monitoring between prime movers and trailers with continuous operation
- Integrated fleet monitoring solution delivering 0.1° precision through advanced sensor fusion
- Consolidates multiple sensors into a single robust unit, simplifying fleet-wide installation and maintenance
- Seamless integration with existing fleet management systems
- Rapid deployment across fleet with localised support, delivered within three weeks of purchase order
BESC is a specialist electrical engineering consultancy that designs, supplies, programs, and commissions control systems for mining operations. As a trusted contractor to Piacentini & Son (OEM), they focus on developing innovative control solutions for specialised mining equipment, including low loader systems. Their expertise spans across system design, implementation, and ongoing technical support, making them a valuable partner in mining automation and control systems.
The Challenge: Protecting Multi-Million Dollar Mining Equipment
For mining operations running high-value equipment, precision matters. When operating heavy vehicles with trailers, maintaining accurate angle monitoring is critical for preventing equipment damage and operational disruptions. BESC’s low loader units required angle monitoring with 0.5° accuracy to prevent damage, as even small measurement inaccuracies beyond this threshold risked:
- Operational delays and costly equipment repairs
- Collisions between prime mover tyres and trailer infrastructure
- Excessive forces on trailer tyres during turning manoeuvres
- Hydraulic hose stress and failure
“The financial impact of equipment damage in mining operations can be substantial. When you’re looking at these kinds of repair and replacement costs, plus the associated downtime, we needed a solution that could reliably prevent these incidents before they occur.”
explains Richard Crone, Technical Lead at BESC.
The Solution: Enabling High-Precision Angle Monitoring With A Certus INS
BESC selected Advanced Navigation’s Certus for its high-precision angle monitoring capabilities in harsh mining environments, making it ideal for protecting high-value mining equipment. Advanced Navigation’s ability to deliver within three weeks of purchase order was also a key factor in the selection. The Certus solution delivered:
- Industry-leading 0.1° angle measurement accuracy for comprehensive equipment protection
- Simplified system architecture through sensor consolidation, improving reliability
- Direct integration with existing control systems
- Reliable angle monitoring from startup with no initialisation movement needed
The critical data from Certus enabled a comprehensive early warning system through a cab-mounted Human Machine Interface (HMI), providing:
- Real-time visual angle monitoring at 0.1° accuracy
- Pre-emptive audio and visual warnings with clear threshold alerts well before reaching critical angles
The system interface displays Certus data inputs (left), prime mover-trailer angle visualisation (center), and roll attitude indicator (right)
Operator control interface showing real-time angle, weight, and speed monitoring during trailer loading operations, with clear status indicators for safe equipment transfer.
Real-time heading comparison between prime mover and trailer units, demonstrating synchronised angle tracking.
Integration Process
The system was integrated with a cab-mounted Human Machine Interface, providing operators with:
- Real-time visual monitoring with configurable audio and visual warnings
- Purpose-built housing protecting the high-precision sensors
- Single calibration process with no ongoing maintenance needed
- Intuitive operator controls
“We were able to remove our previous inclination sensor and GNSS receiver, combining both functionalities into the Certus unit. This simplified our system while improving reliability, giving us the precise monitoring we need for safer operations.”
notes Crone.
Results and Benefits
The implementation has delivered measurable improvements across several key areas:
Operational Benefits:
- Continuous operation maintained during GNSS signal interruptions
- Standardised monitoring solution across fleet
- Simplified fleet maintenance with fewer sensors to maintain
- Consistent protection across all equipped vehicles
- Scalable solution for future fleet expansion
- Integration with existing fleet management infrastructure
Financial Impact:
- Significant reduction in tyre replacement costs
- Decreased maintenance downtime
- Protected investment in expensive equipment
- Potential for fleet-wide implementation savings
Currently deployed in Bauxite mines and scheduled for implementation in Iron Ore operations, the system has proven its value across different mining environments and conditions.
Related Applications
The precision and reliability demonstrated in BESC’s trailer monitoring system extends across several critical mining applications.
Fleet Management Systems (FMS)
Certus INS technology enables reliable navigation and positioning even during GNSS outages, ensuring consistent operation of autonomous truck fleets in deep pit, high wall, and satellite-obscured environments.
Surface Drill Rig Alignment
The system’s 0.1° precision enables automated drill positioning and collar alignment on Production and Blast Hole drill rigs, improving drilling efficiency and reducing costly errors.
High-Precision Machine Guidance (HPMG)
Delivering 0.1° orientation accuracy for precise equipment control on excavators, dozers, and graders, maintaining performance even in GNSS-degraded environments.
Certus
Certus combines temperature calibrated accelerometers, gyroscopes, magnetometers, and a pressure sensor with a dual antenna GNSS receiver. These are coupled in an AI-based fusion algorithm to deliver accurate and reliable navigation data. It features low SWaP-C (Size, Weight, Power, and Cost), internal data logging, and multiple communication interfaces for easy integration. Certus is available in both OEM and rugged packages and comes standard with license-free 1 cm RTK position accuracy.