Every day, room and pillar miners work in an environment that requires endurance, awareness, and adaptability. Each shift is a commitment to navigating intricate underground passages, operating heavy machinery and adapting to the mine’s ever-changing geological conditions.
To address key operational needs, mining companies around the world are integrating automation into their underground operations. This shift is driven by the desire to enhance safety, boost productivity, improve equipment reliability, and ensure consistent product quality.
Recognizing these needs, Komatsu has made worker safety a driving force behind its innovations.
“We’re leveraging automation to increase safety, as well as efficiency, automating repeated tasks to drive consistency and increase operator alertness,” says Toby Cressman, director, controls and automation for Komatsu Mining.
This commitment translates directly into Komatsu’s focused efforts on automating continuous miners (CMs) and haulage systems, prioritizing the well-being of those who work in these demanding environments while streamlining operations and enhancing performance.
Komatsu offers a suite of continuous miner automation (CMA) levels, ranging from manual operation to fully automated sequences and heading control.
“We’ve integrated a flexible conveyor train (FCT) with our 12HM46 CM in an autonomous state,” says Cressman. “This automated process is designed to help mining companies streamline their material haulage, reduce manual intervention, and improve overall efficiency by enabling continuous cutting and conveying with minimal downtime.”
This integration represents a significant step toward making room and pillar operations safer and more productive. Using ultrawide band (UWB) sensors, the FCT’s “follow-me” functionality keeps it synchronized with the 12HM46 as it sumps and shears. This seamless trailing results in a continuous material flow, which is crucial for enabling operators to work from remote management centres (RMC) located away from the face.
Safety remains a core value at Komatsu.
“Our goal is to create a more controlled and predictable environment for miners,” says Cressman. “The FCT working in conjunction with the 12HM46 in an autonomous state is intended to help reduce the number of mobile machines and personnel in hazardous areas.”
When operated with automated sequences, the 12HM46 CM performs cutting cycles (sumping and shearing) with precise consistency, helping to reduce variations that can occur with manual operation due to fatigue or differing skill levels. This can result in smoother ribs, floors, and roofs, which can help minimize the need for rework and reduce material waste.
Komatsu’s autonomous system builds on this foundation, enhancing control and predictability while reducing operational variability. Automated cutting cycles and precise heading control can help enable consistent extraction, while the FCT maintains a steady material flow, potentially reducing traditional haulage disruptions. In addition to productivity gains, the system is designed with safety in mind.
By automating material transfer, the system helps minimize spills, while sensor-based navigation works toward reducing collision risks. Limiting personnel exposure near the face enhances worker safety, and optimized operations with fewer mobile machines can help contribute to lower dust and noise levels.
Automation can also help reduce operator fatigue, allowing operators to focus on high-level tasks like monitoring and data analysis. The system’s intuitive interface delivers real-time diagnostics, helping operators quickly identify issues, monitor performance, and manage operations effectively. Additionally, the system generates valuable data for optimization and predictive maintenance, driving continuous improvements in efficiency and safety.
“We’re seeing a real shift in how automation is being perceived,” Cressman adds. “It’s not just about efficiency; it’s about creating a better work environment for miners. Customers can use their data to refine their processes so they can achieve both high productivity and foster a supportive work environment.”
Komatsu’s system helps pave the way for “lights-out” mining, where automation minimizes human intervention. This integration is a crucial step toward fully autonomous operations, allowing operators to monitor multiple sections from remote control rooms. Komatsu’s ongoing research in AI and robotics promises further advancements, with intelligent systems adapting to dynamic underground conditions.
Automation also enhances sustainability in room and pillar mining by optimizing resource use and reducing waste. For instance, the automated 12HM46 minimizes material waste through precise cutting, while the FCT reduces spills during material transfer. Automated haulage can help lower dust and noise, too, reducing potential exposure to dust and noise. Data analytics from these systems further support mine planning and reclamation.
“Sustainability is a key part of our innovation strategy,” Cressman emphasizes. “Our automation systems are designed to help mines reduce their environmental footprint while maintaining productivity.”
Komatsu’s integrated FCT and 12HM46 CM system marks a pivotal advancement in room and pillar mining, helping to deliver new levels of efficiency and safety through autonomous operation. This technology exemplifies Komatsu’s unwavering commitment to innovation, prioritizing worker well-being and sustainable mining practices. By automating critical processes and reducing human intervention, this system is designed to reshape underground operations — working to make mining safer, more productive and environmentally responsible.
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