Published in the August 2007 American Longwall Magazine

Established in South Africa, the virtual reality development firm began its line with a VR data glove. Now, nearly 15 years later, its offerings include both mining and non-mining-related products including the Virtual Reality High Voltage Yard Training Simulator, mine visualizer software and computer-based training for many of its products. 5DT now has operations in the US (Irvine, California) and Australia (Brisbane, Queensland).

The CMTS was released in 1998 and was a full software solution. At the time competing simulator concepts were based on a mechanical-scale model and included a camera that operated in a scale model of a mine section. Since its first buyer, South Africa's Sasol Mining took delivery of the system, more than 4000 workers have been trained for CM operation using its VR technology.

"This simulator enables the trainee operator to tram and cut with a virtual CM in a virtual coal, potash or salt mine," said company founder Paul Olckers. To do that, the user dons a head-mounted display (HMD) and controls the unit the same way he or she would an actual machine, using the actual Joy Mining Machinery controller.

Once the user becomes accustomed to the trainer, the system presents scenarios that vary from easy to advanced such as tramming and cutting; also, he or she can fill a virtual shuttle car-battery hauler, with the system measuring the cut material as well as any spillage. The unit is equipped for playback, recording and report generation.

Much like the CMTS, hardware required for the LWTS is just the HMD and a real Joy Mining Machinery longwall controller. The user starts up the virtual shearer and then uses the radio device to cut coal with it.

Primary and secondary boom control, cutting drums and direction, water sprays and cowels are all part of the training scenarios on the LWTS. Virtual roof supports can be controlled using the keyboard of the simulation computer.

"Apart from teaching the trainee how to control the shearer, this simulator is also very useful to teach trainees about the longwall process," Olckers added. "The trainee may virtually 'walk' up and down the long wall underneath the shields."

The equipment for trainees working with the RBTS is slightly more detailed, matching a true bolter's features. Three primary valve banks including a tramming valve bank, temporary roof support (TRS) valve bank and roof bolting boom valve bank are all part of the system, outfitted with a virtual tool table which allows specific tool selection.

RBTS-specific training starts off with the tramming valve bank. Once tramming is mastered, the trainee moves on to TRS deployment. Once comfortable with this second level, stab jacks can be activated to install bolts, and tool selection is available.

Olckers said the CMTS's release was the impetus for the industry requirement that would set the bar for the LWTS and RBTS. The first LWTS was sold to BHP Billiton's San Juan mine, and the first RBTS went to Anglo Coal's South African Goedehoop mine in 2004.

Olckers said the use of VR simulators for such complex jobs as those taken on underground is an advantage to the worker and the mine. An individual is more aware of safety issues, motivated and better prepared for the real thing; meanwhile, the operator can benefit from shorter training periods, an improved application of best practices, increased production and less damage and wear and tear.

When needed, 5DT provides off-site technical support, and some simulators are equipped with webcams so they can view issues remotely. "If our offline methods fail to resolve the problem we send one of our support engineers to the site," adding it does not provide training for operators, but focuses on training instructors instead.

As technology speeds ahead at light speed, Olckers said input from the industry is important. "We work hard to stay ahead of the pack. We try to listen to what the mining industry tells us - we are now working very closely with OEMs and machine users."

He also noted that 5DT sees a bright future ahead for training simulator use in mining. Feedback has played a large part in that prediction: In 1998, 5DT was asked, "What is a simulator?" or "Why do we need a simulator?" Nowadays, we are asked: "How many simulators would we need?" or "What type of simulator would we need?"

"The time of simulators in the mining industry has come. This has led 5DT's Vision and Cause to become: "To help operators worldwide to operate more safely and increase their productivity'."