Mining Science

Mining Science, vol. 24, 2017, 251–266 (Previously Prace Naukowe

Instytutu Gornictwa Politechniki
Wroclawskiej, ISSN 0370-0798)
ISSN 2300-9586 (print)
www.miningscience.pwr.edu.pl
ISSN 2353-5423 (online)
Received June 29, 2016; reviewed; accepted September 7, 2017

AUXILIARY INTELLIGENT OPERATING SYSTEM

FOR DRAGLINE STRIPPING EQUIPMENT
IN SURFACE MINING

Sun JIAN-DONG1*, Zhang RUI-XIN2

1
State Key Laboratory of Coal Resources and Safe Mining, China University of Mining and Technology
(Beijing)
2
North China Institute of Science and Technology

Abstract: In order to improve operation skill of the operators, the design of the auxiliary intelligent
operating system of the dragline was studied. Whereby the gyroscopes incorporated in smartphone and
data sequence filter algorithm, the automatic collection function of operation cycle, the rotation angle and
other parameters of the dragline are attained. In line with the relations among the rotation angle of
equipment operation, time-spent and the acceleration, the ratio of the acceleration and deceleration rota-
tion angle in full load rotation and non-loaded return stage are acquired respectively. The function of
bucket in rotation was realized. Comprehensive score calculation standard of the technique level of the
dragline-based operation was developed, and the function of automatic checking the operation level was
effectuated. Field experiment results indicated that the operators’ faults are markedly reduced as the
auxiliary intelligent operating system is employed. By using the system the operation behavior of low
power slow rotation in rain, snow, low atmospheric pressure and other severe weather conditions can be
reduced, assuring all-weather efficient and safe operation of dragline.

Keywords: dragline stripping; intelligent operating system; operational efficiency

1. INTRODUCTION

Dragline stripping is the method primarily used in surface mining in the United
States, Australia, Canada, Russia and other major coal-producing countries. The

_________
* Corresponding author: [email protected] (S. Jiandong )
doi: 10.5277/msc172413
252 Sun JIAN-DONG, Zhang RUI-XIN

dragline is at the core of equipment employed in this method, incorporating min-

ing-transport-dumping functions. Maximum bucket capacity of dragline reaches up
to 168 m3, the maximum operating radius reaches 120 m, and the maximum strip-
ping thickness is attained as 60 m. Practice indicated that the production cost
adopting this method was merely 1/2–2/3 of other methods, and the production
efficiency was 40%–60% higher than that of other methods (Gilewicz, 2000;
Ridley, Corke, 2001). The factors affecting operation efficiency and the measures
to increase equipment efficiency were ascertained through adopting qualitative
analysis, quantitative calculation and other methods regarding engineering practice
by Wang Gui-lin(2012), Chen Chun-yang (2014), Liu Tong (2014) et al. The dra-
gline operation cycle was elucidated whereby the detailed calculation and analysis
of Erdem et al. (2005; 2012), the distribution of cycle and idle time of dragline
operation was ascertained by Rai et al.(2000), Costello and Kyle (2004) established
the excavation attitude model of the dragline with dynamic simulation method, the
force of the bucket was anatomized to lay the foundation for optimizing the opera-
tion of dragline. Dragan Komljenovic et al. (2010) studied the dragline efficiency
evaluation method (OPI) with the hourly excavation amount and energy loss as the
main index, and on that basis a new idea was proposed to evaluate the efficiency of
the dragline. All of the foregoing research explicitly highlighted that the level
of the operation of the dragline was the crux affecting the stripping efficiency.
However, arising from complicated operating conditions and difficulties in data
collection, this study is confined into the qualitative discussion.
Given the foregoing situation, intelligent assistant operation system in the light
of sensor technology of smartphone was studied and designed. The automatic acqui-
sition of main equipment operating parameters, automatically prompts of equipment
in rotation, automatic evaluation function of operational level can be effectuated
whereby this system, which markedly elevate the skill level of the operator and the
equipment efficiency.

2. RESEARCH BACKGROUND

Heidaigou surface mine is located in the middle of Zhunge’er coalfield in Inner

Mongolia Autonomous Region, China. In 2007, Heidaigou surface mine applied
dragline stripping technology for the first time, the dragline was manufactured by
the Bucyrus Company, with 90 m3 bucket capacity and 100 m maximum operating
radius. In excess of 40 m thick rocks above the top of the No 6 coal seam (thickness
is about 30 m) were stripped by the dragline after blast casting. Dragline stood on
the blasting pile which flatted by shovels and bulldozers. The broken material was
dumped to the emptied pit by dragline. The main elements of working face are ex-
hibited in Fig. 1.
 Auxiliary intelligent operating system for dragline stripping equipment in surface mining 253

The coal production of Heidaigou surface mine reached 34 million t/a after the
application of dragline stripping and blast casting technology, which made the
mine to be the largest and most efficient modern surface mine in China. The suc-
cessful application of the dragline stripping technology in Heidaigou surface mine
has evidently elevated the production efficiency and markedly reduced the produc-
tion cost, and it also boosted the development of the surface mining technology in
China. However, surveys indicated that the average production capacity of Bucyrus
8750-65 type dragline employment in Heidaigou surface mine was currently less
than 16 Mm3/a, a data not reaching 65% of the designed annual production capac-
ity. The dragline stripping system was equipped with a shovel, 4 trucks to assist
dragline stripping operations, the amount of auxiliary work is about 13Mm3/a. Op-
erators operated only whereby the accumulated experience and the deficient theo-
retical guidance regarding equipment operation skill. There were even no effective
assessment standards for dragline operation.

Fig. 1. In-place view of typical dragline operating condition

(1 – high bench; 2 – keycut; 3 – coal roof; 4 – coal ditch; 5 – extended bench; 6 – spoil pile)

The mining operation time of dragline was approximately 4000 h per year. If the aver-
age cycle time is acquired as 70 s, the number of operating cycles is 205714 times. If the
average cycle time is shortened as 1s, the operation cycle of the equipment shall increase
57.14 h (about 2.4 days) throughout the year, and annual production capacity of dragline
shall rise approximately 156,000 tons (about 230,000 m3). The increase of dragline pro-
duction capacity shall simplify the assistance conducted by the shovel-truck technology.
The current overall production cost of dragline was about 13.07 yuan/m3, and shovel-
truck production cost of the stripping system was about 18.56 yuan/m3. For this reason,
about 1.26 million yuan can be saved per year in stripping if average job cycle time can be
shortened as 1 s. Therefore, it is of great significance to elevate the skill level of the op-
erator (Sun Jiandong 2016).
254 Sun JIAN-DONG, Zhang RUI-XIN

3. AUTOMATIC ACQUISITION METHOD

OF EQUIPMENT OPERATING PARAMETERS

The long-term and continuous field collection and measurement are required by the
time statistics in the rotation process of equipment operation. At present, manual rec-
ords were extensively adopted in the domestic and international research, and the col-
lected data had characteristics of discontinuous, few of samples, more mistakes, etc.
Rare studies adopted the database of programmable logic controller (PLC), structured
query language (SQL) and other methods required to be supported by software and
hardware of dragline control system (Komljenovic et al., 2010; Demirel, ., 2011). Yet
arising from the long period of research and development of software and hardware,
and a high cost, these methods have not yet been extensively employed. This paper
proposed a new method of using gyroscopes incorporated in a smartphone to achieve
monitoring and recording the operation condition of equipment (Pan Quan, 2007;
Chen Chun-Yang, 2014), which could effectively resolve many problems encountered
in data collection. The “Huawei Glory 6” smartphone which adopted LSM330-type
gyroscopes was adopted in the research. In data acquisition, smartphone was incorpo-
rated in driving cab of dragline horizontally. Through running the data acquisition
software developed by Android system, the angular rate data should be automatically
recorded by the software and stored in the memory card. Meanwhile, the camera was
incorporated in the driving cab. The real-time operating situation was recorded for
comparison with the sensor data.
As certain error existing in the gyroscopes incorporated in smartphone itself,
the actual value of the system was set in a certain moment as Xg and the measured
value as X. Accordingly the absolute error e of the sensor measurement is defined
as

e Xg − X . (1)

Through running the angular rate acquisition software under the static condition
(Xg = 0), the absolute error of the sensor measurement data can be attained. The aver-
age absolute error of the sensor in n time’s measurement is defined as

n
1
e=
n ∑e .
i =1
i (2)

From formulas (1) and (2), it can be acquired that the average error of gyroscopes
measurement value of Huawei Glory 6 was 7.497e-3 rad/s.
During the operation of dragline, the machine was being constantly vibrated. Ac-
cordingly the data monitored by the sensor is encompassed by the real signals gi and
 Auxiliary intelligent operating system for dragline stripping equipment in surface mining 255

the noises εi, and it conforms to the following formula:

fi = gi + εi, i = 1, 2, ..., n. (3)

Given that noise shall exert certain influence on the accuracy of the data sequence,
it shall be eliminated as much as possible. Wavelet transform has the time-frequency
localization and multi-resolution properties. It could effectively reckon with the acqui-
sition of the original filter to extract the real signal. The specific steps are as follows
(Sun Jian-Dong et al. 2016; Liu Zhi-Cheng et al. 2007).
(1) Select the appropriate wavelet and number of decomposition layers, using
Mallat algorithm for orthogonal transformation of noise data sequences:

c j,k = ∑ h ( m − 2k )c
m
j −1, m , k = 0, 1, ..., n − 1 , (4)

d j ,k = ∑ g (m − 2k )C
m
j −1,m , k = 0, 1, ..., n − 1 , (5)

where, cj,k and dj,k are scale coefficients and wavelet coefficients, respectively, j is the
number of decomposition layers, n is the number of sampling points, h and g is the
paired orthogonal mirror filter banks.
(2) The threshold of the wavelet coefficients which attained by decomposition was
processed.
(3) The wavelet coefficients acquired from the second step was reconstructed, which
attained the optimal estimation of the original signal.

c j −1,m = ∑c
k
j ,k , h( m − 2k )c j −1,m + ∑dk
j ,k , g ( m − 2k ) . (6)

In line with the response characteristics and filtering requirements of the rota-
tional angular rate of the dragline, the Meyer wavelet was perceived as the mother
wave, and the data was decomposed by 5 layers whereby the C language program,
and the optimal estimation of angular rate in the actual operation of dragline was
effectuated.

4. ANALYSIS OF EQUIPMENT OPERATING PROCESS

4.1. ANALYSIS OF THE TIME-SPENT OF OPERATING CYCLES

The dragline operating cycles comprise five stages: excavating, rotating with full
load, dumping, non-loaded rotating and bucket adjustment (Fig. 2). Stages of
256 Sun JIAN-DONG, Zhang RUI-XIN

dumping and bucket adjustment can be completed in the process of the equipment
rotation. For this reason, the latter four stages can be summarized as the rotation
process.

Excavating area Dumping area

Excavating Bucket adjustment Dumping

Rotating with full load Non-loaded rotating

Fig. 2. Dragline operation cycle trajectory division

Table 1. The statistics of cycle of dragline operation under different operation content
Operation content Average of time-spent/s Ratio to operation cycle
Coal ditch Excavating process 12.13 16.50%
excavation Rotating process 61.5 83.50%
Excavating process 12.04 20.00%
Maincuting
Rotating process 48.11 80.00%
Excavating process 13.16 21.90%
Keycuting
Rotating process 46.82 78.10%
Coal ditch excavation: excavate the materials near the bottom line of spoil pile.

In line with the 1200 groups of the dragline operation data samples collected on
December 20th –30th, 2014, it can be acquired that time-spent of rotation for opera-
tion cycle accounted for 83.5%, 80%, 78.1% respectively in coal ditch, maincut and
keycut excavation (Table 1). Therefore, total time consumption of equipment rotation
is not only deemed as an important factor affecting the efficiency of equipment opera-
tion, but also an important indicator to identify and assess the condition of the opera-
tor's operation skill (Sun Jian-dong et al. 2016).

4.2. ANALYSIS OF EQUIPMENT OPERATING STAGES

Given the video record, the device rotation process and the excavating process were
split in the filtered data sequence. In Figure 3, the angular rate of “rotating with full
load” stage was indicated to be positive, and the angular rate of “non-loaded rotating”
stage was denoted to be negative.
 Auxiliary intelligent operating system for dragline stripping equipment in surface mining 257

Fig. 3. Analysis of data sequence of angular rate

As the bucket slid in the normal direction of the excavation direction, to avoid drag
rope strain, dragline would generally be rotated in a small amplitude. In the process of
“full-load rotating”, the equipment first maintained similar uniformly accelerated ro-
tation, and thereupon carried on similar uniformly decelerated rotation. When the dra-
gline rotated approaching to the F point, the discharging operation was carried out and
completed during the rotation process, and thereupon dragline returns with no load in
the reverse direction.
Operating behavior of equipment acceleration and deceleration played a decisive
impact on the efficiency of the rotation process. In line with angular rate changes in
the equipment operation, the operation behavior can be subdivided into the following
categories:

(1) The early deceleration

When the equipment reduced speed in advance, the deceleration must be reduced
to ensure the bucket fell in next mining position at the termination of rotation,
which increased time-spent for cycle. As exhibited in Fig. 3, in line with the char-
acteristics of the equipment operation, the maximum speed of dragline in “full load
rotating stage” can be reached at point B and completed at point D. But arising from
operational error, equipment reduced the acceleration at point A, and reduced the
deceleration at point E in advance, which led to the time-spent increased about 2 s
in the stage.

(2) The lagging deceleration

When the equipment decelerated in lag, the bucket would cross the predetermined
mining point, which increased time-spent of adjustment. As exhibited in Fig. 3, in line
with the characteristics of the equipment operation, “non-loaded rotating” stage shall
be decelerated at point G, finished stage operation at point H. The operators’ mis-
258 Sun JIAN-DONG, Zhang RUI-XIN

judgment caused equipment decelerated in lag, which resulted in bucket exceeded the
predetermined mining position. He had to readjust the bucket position to finish the
cycle at point J. time-spent increased about 7 s in the stage.

(3) The low speed rotation

Low speed rotation was common in actual operation. Because of large linear di-
mensions of dragline and far distance of driving cab from the bucket, it was difficult to
judge the relative position from bucket to bench and spoil pile for operators by naked
eye when encountered rain, snow, low atmospheric pressure and other weather condi-
tions. To avoid the occurrence of safety accidents, “slow-power & slow rotation” op-
eration shall be generally adopted by the operator, and a single operation cycle time
can be up to 80–100 s. It markedly reduced the operating efficiency, and this situation
is particularly evident at night;

(4) The standard operation

In the standard operation, the ratio of accelerating and decelerating rotation an-
gle was approximately 3/2 which shall be kept in “rotating with full load” stage.
And the ratio was 4/5 approximately in “non-loaded rotating” stage. In this kind of
operation, equipment operated efficiently, and the operation ability has been fully
exploited.
In line with the above analysis, it can be seen that the crux to elevate the efficiency
of dragline operating cycles was to increase the proportion of the standard operating
cycles to total cycles. But the level of equipment operation was affected by compre-
hensive influence, such as operating personnel working experience, attention, external
environment, and other aspects.
During the operation, the operator cannot guarantee the high concentration of the
spirit of the long time, so it is necessary to design a set of intelligent auxiliary opera-
tion system to assist the manual operation.

5. DESIGN AND IMPLEMENTATION

OF INTELLIGENT AUXILIARY OPERATING FUNCTION

5.1. PROMPT FUNCTION OF THE EQUIPMENT IN ROTATION

Prompt function of the equipment in rotation was first to determine equipment’s rota-
tion angle from the excavating area to dumping area. On that basis, the turning point
of acceleration and deceleration was acquired automatically in line with the average
acceleration and deceleration, and prompting the operator to perform the correspond-
 Auxiliary intelligent operating system for dragline stripping equipment in surface mining 259

ing operation whereby sounds and vibrations. Specific design and research processes
are as follows:

(1) Calculation of rotation angle of equipment operation

The relative position change is negligible in contrast with the previous time, and
the rotation angle of each operation is determined by the preceding operation. There-
fore, the first operation of the dragline requires a complete cycle, the rotation angle of
the operation shall be automatically determined by the auxiliary operating system, and
the next operation cycle shall start the prompt function. In line with the data sequence
collected by the sensor, the actual rotation angle of the dragline is:
j
(Wi + Wi +1 ) (ti +1 − t )
θ =∑ , (7)
i =1 2

where: Wi is the angular rate of equipment rotation at time ti, t1 is the start time of full
load rotation, tj is the finish time of full load rotation.

(2) Judgment of turning point of equipment acceleration and deceleration

Through analysis of dragline operation cycle process, it could determine that the
rotation process was similar to the uniform acceleration movement. The average an-
gular acceleration from time t1 to t j in a certain stage was as follows:

j
1 Wi +1 − Wi
a=
n ∑
i =1 ti +1 − ti
. (8)

The angular rate data series of the 100 groups of operating cycles of dragline were
statistically analyzed, and the average acceleration (Table 2) in full power rotational
state of equipment was attained.

Table 2. Average acceleration of dragline rotation

Type Rotating with full load Non-loaded rotating

Average acceleration/rad·s–2 0.0096 0.0145
Average deceleration/rad·s–2 0.0144 0.0117

The maximum speed of acceleration and deceleration process of the dragline was
the same in full load rotation or return with no load, and it satisfied the following
formula:
260 Sun JIAN-DONG, Zhang RUI-XIN

Vmax = a1t1 = a2t2 , (9)

where: a1 and a2 denote the angular accelerations, angular deceleration of dragline in

one rotation stage, t1 and t2 are acceleration time and deceleration time of dragline in
one rotation stage respectively. Therefore, the ratio of the rotation angle of the accel-
eration and deceleration process is:

W1 a1t12 a2
= = . (10)
W2 a2t 22 a1

In line with Table 2 and formula 10, it can be acquired: that the rotation angle ratio
of acceleration and deceleration shall be maintained about 3/2 in “rotating with full
load” stage; the rotation angle ratio of acceleration and deceleration shall be main-
tained about 4/5 in “non-loaded rotating” stage.

5.2. MODEL OF OPERATING SKILL LEVEL ASSESSMENT

Intelligent auxiliary operation system can evaluate the skill level of the operator, on
the one hand to assist the operator to correct bad operating practices, on the other
hand it can be used as a staff performance appraisal reference. In the study, data of
the time-spent and the corresponding rotation angle in rotation process was col-
lected. The relationship between the rotation angle and time-spent of 500 groups of
cycles has been acquired. As exhibited in Figs. 4 and 5, in line with the relationship,
the operational level was split into 4 grades, specific calculation method including
three steps:

45
F1(x)
Time-spent (S)

40
35 F3(x)
30
F2 (x)
25
20 F1(x) = -0.0011x2 + 0.4267x
15 F2 (x) = -0.0009x2 + 0.3242x
10 F3 (x) = -0.001x2 + 0.3755x

5
0
0 50 100 150 200 250
rotating angle (°)

Fig. 4. Cartogram of the relationship between rotation angle and time

in “rotating with full load” stage (maincut excavation & keycut)
 Auxiliary intelligent operating system for dragline stripping equipment in surface mining 261

45
40
Time-spent (S) 35 F'1 (x)
30 F'3(x)
25 F'2(x)

20
F'1 (x) = -0.0011x2 + 0.3916x
15
F'2 (x) = -0.0009x2 + 0.3328x
10 F'3 (x) = -0.0007x2 + 0.2738x
5
0
0 50 100 150 200 250
rotating angle (°)

Fig. 5. Cartogram of the relationship between rotation angle and time

in “non-loaded rotating” stage (maincut excavation & keycut)

(1) Set a certain operation cycle as (θ, ti), take 10° as the rotation angle range (such
as 50°–60°, 60°–70°). The cycle time in each rotation angle interval can con-
stitute a set respectively: T1, T1, ..., Tj, ..., Tm, and Tj = {tj1, tj2, ..., tji, ..., tjm}. Set
m m
high t j = 3 / 4 ∑1
t ji and low t j = 1 / 4 ∑t
1
ji , it can be attained m of hightj and m

of lowtj. Take θ i′ as median (for instance, take θ i′ = 55) when rotating angle
ranged from 50° to 60°) of rotation angle range where the number sets placed,
(θ i′, high t j ) and (θ i′, low t j ) were fitted respectively. On that basis, two fitting
curves of F1(x) and F2(x) were acquired. These two curves represented the ap-
proximate level of the optimal operation and poor operation set, respectively
(Ma Xin-gen & Sun Jian-dong 2015; Sun Jian-dong et al. 2016).
(2) Calculate the curve F3(x) to splite the area between the curve F1(x) and F2(x), In
this regard:
For θi ≤ F2(ti), the operation cycle is defined as the first-grade operation;
For F2(ti) < θi ≤ F3(ti), the operation cycle is defined as the second-grade opera-
tion;
For F3(ti) < θi ≤ F1(ti), the operation cycle is defined as the third-grade opera-
tion;
For θi > F1(ti), the operation cycle is defined as the fourth-grade operation.
(3) K is defined as comprehensive score of N times operations, and can be acquired
via the formula:

K = 100 ( w1 ∗ N1 + w2 ∗ N 2 + w3 ∗ N 3 + w4 ∗ N 4 ) , (10)
N
262 Sun JIAN-DONG, Zhang RUI-XIN

where: N is the total number of cycles; N1, N2, N3, N4, are operated times from first-
-grade to fourth-grade respectively and can be counted auto matically by sensors;
w1, w2, w3, w4 are the weights from first-grade to fourth-grade and we can take the
valves in line with the specific requirements of the assignment. The weights in this
study are 1, 0.9, 0.8, and 0.7.

5.3. DESIGN AND IMPLEMENTATION OF THE SYSTEM

The auxiliary intelligent operating system was encompassed by gyroscopes incorpo-

rated in smartphone and data acquisition software. The main program flow chart was
illustrated in Fig. 6.

Initialize
program

Collect angular
velocity Wi
Timing start，
Calculate rotation
angle θ1 Wi>0.002
(θ1=∫Wi dt)
Rotation angle C=0

-0.002<Wi<0.002
No

Calculate and storage Timing start,

Timing stop，
out put t1 and θ1 operation level Calculate η1 (η1=∫Wi dt)

Vibrating motor for η1=3/5C

Timing start，Calculate notifications
rotation angle θ1 (θ2=∫Wi dt)
End integral
Wi>0.002
Wi>0.002
Calculate and
Timing stop， storage
out put t2 and θ2 Timing start，
operation level Calculate η2=∫Wi dt

Calculate current
rotation angle: Vibrating motor η2=4/9C
C=½(θ1+θ2) for notifications

End integral

Operator log out

Export operation
report

End

Fig. 6. Flow chart of the auxiliary intelligent operating system

 Auxiliary intelligent operating system for dragline stripping equipment in surface mining 263

6. FIELD TEST RESULTS AND ANALYSIS

To verify the effect of intelligent operation assistance system, the study carried out
a field experiment. In the experiment, each operator operated 100 groups of operating
cycles under the same operating conditions (maincutting mode). The prompt function
of the auxiliary operating system was effectuated only in later 50 groups of operating
cycles.

1) Operating efficiency of the first 50 groups

Statistics of operator’s operation are exhibited in Table 3. In line with the results of
the comprehensive score, it can be seen that the operating level presented A > C > B,
and 50%–80% of the operating cycle reached the first-grade or second-grade opera-
tional level. Given the angular rate data sequence curves recorded by the operating
auxiliary system, the reasons for the third-grade and fourth-grade operation were
summarized in Table 3, the suggestions regarding operation elevation were given as
follows: A shall easily mistake the early decelerate in the “rotating with full load”
stage, and the acceleration time shall be increased appropriately. B often made the
mistake of lagging decelerate in the deceleration phase of “non-loaded rotating” stage,
and the acceleration time shall be shorten appropriately in the stage. Taking into ac-
count that the increase of time-spent caused by lagging deceleration is markedly in
excess of the early deceleration, C shall increase acceleration time in “rotating with
full load” stage and reduce the acceleration time in “non-loaded rotating” stage.

Table 3. Statistics of operator’s operation

Operator
A B C
Grade
first-grade 32 19 25
second-grade 48 37 37
Grading statistics
third-grade 14 20 15
fourth-grade 6 14 13
average time of cycle(s 64.5 68.6 67.1
Average time and score
comprehensive score K 90.6 78.1 79.4
early deceleration 13 8 12
Reason caused third-grade or fourth-grade operation lagging deceleration 3 24 10
other reasons 4 2 5

2) Operating efficiency of the latter 50 groups

Statistics of operator’s operation are exhibited in Table 4. In contrast with the first
50 groups of operation, the operators' faults in the operating process such as early
deceleration, and lagging deceleration were markedly reduced. And about 90% of the
264 Sun JIAN-DONG, Zhang RUI-XIN

operating cycle reached the first-grade or second-grade operational level. The average
time of operating cycle was shortened by 1–3 s. Experimental research was conducted
under normal weather conditions, when there was rain, snow and low atmospheric
pressure and other harsh conditions, intelligent auxiliary operating system could also
effectively reduce the low-speed rotation, we can ensure that the full power operation
of the dragline, the experimental comparison effect shall be more significant.

Table 4. Statistics of operator’s operation

Operator
A B C
Grade
First-grade 61 66 59
Second-grade 32 23 35
Third-grade 5 11 2
Fourth-grade 2 0 4
Average time of operating cycle (s) 63.2 63.0 63.8
Comprehensive score K 95.2 95.5 94.9

(3) Problems and Prospects

In fact, results presented in Table 3 was collected under very ideal conditions. we
found that dragline cycles were mainly swing-dependent, however, as digging got
deeper, cycles became hoist-dependent. In particular, the materials near the bottom
line of spoil pile had a low digging point and a high dumpping point, so the dragline
must rotate slowly to wait for the lifting process to finish. In addition, few some cycles
were drag-dependent when the operators want to strip from a far point on the cut face.
The use of gyroscopes could get better results when assist swing-dependent cycles
than others.
In view of these situations, we think 3D images, laser modeling and other tech-
nologies should be used to determine the target location of digging and dumpping
point, then we could use the gyroscopes to control the rotating process, so as to obtain
better auxiliary effects.

7. CONCLUSION

In order to elevate the skill level of the dragline operators, automatic acquisition
function of dragline operation parameters was realized whereby smartphone sensors,
and the operation level assessment criteria were quantified in line with the sensor data.
A case study was conducted to compare the equipment efficiency changes before and
after employing the intelligent auxiliary operating system. Conclusions were obtained
as following:
 Auxiliary intelligent operating system for dragline stripping equipment in surface mining 265

1. Time-spent of dragline rotation process accounts for about 80% in operation cycle,
and it is the key factor affecting the efficiency of equipment. Elevating skill level of
dragline operators to shorten the cycle time saves stripping cost drastically.
2. Whereby the gyroscopes incorporated in smartphone, the real-time automatic col-
lection of cycle time, rotation angle and other parameters in the process of dragline
operation were achieved. Additionally, the problems existing in the operation can
be grasped intuitively. In line with this method, the operating behaviors fall into
4 categories: the early deceleration, the lagging deceleration, the low speed opera-
tion, and the standard operation. The crux to elevate the cycle efficiency is to in-
crease the proportion of the standard operating cycles to the total cycles.
3. The rotation angle ratio of acceleration and deceleration should be maintained
about 3/2 in “rotating with full load” stage; the rotation angle ratio of accelera-
tion and deceleration should be maintained about 4/5 in “non-loaded rotating”
stage. On the basis of this, the auxiliary intelligent operating system was de-
signed, which realizes prompt function of the equipment rotating operation and
the assessment of operstor’s skill level.
4. Field experiment results showed that after the application of intelligent auxiliary
operating system, the operators’ faults in the operating process of the situation
of early deceleration, lagging deceleration are markedly reduced. And about 90%
of the operating cycle reaches the first-grade or second-grade operation level.
The average time of operating cycle is shortened by 1–3 s.
In a nutshell, the application of intelligent auxiliary system is of critical importance
in improving the efficiency of draglines. However, the dragline is one type of versatile
large machines and its field operation conditions are complicated, in the paper merely
the normal operations of the dragline are studied under standard operating conditions,
the use of gyroscopes could get better results when assist swing-dependent cycles than
others, so more operating conditions and complicated operating practices should be
taken into account in the future studies.

ACKNOWLEDGEMENTS

The authors would like to express their appreciation to the staff at the Heidaigou open-pit mine for
their valuable assistance. Among the authors, Zhang Rui-xin designed the experiments; Sun Jian-dong
performed the experiments, analyzed the data and wrote the paper. The authors declare no conflict of
interest.

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