The Problem
Surface mining of metals, quarrying of rock, and construction of highways requires the efficient removal of massive quantities of soil, ore, and rock. Human-operated excavators load the material into trucks. Each truckload typically requires several passes, each of which in turn takes 15–20 seconds. The operator’s performance peaks early in the work shift but wears down with fatigue. Scheduled idle times, such as lunch and other breaks, also diminish production across a shift.

Safety is another important consideration. Excavator operators are most likely to be injured when mounting or dismounting the machine. Operators tend to focus on the task at hand and may fail to notice other site personnel or equipment entering the loading zone.

The Solution
Automating the excavation and loading process would increase productivity and improve safety by removing the operator from the machine and by providing complete sensor coverage to watch for potential hazards entering the work area.

Recognizing this opportunity, NREC scientists and engineers developed a system that completely automates the truck loading process.