- Machine Control and Guidance Products
- CMD FOR HAULING (S/N: CM41-UP; CM51-UP; AT61-UP)
Introduction
This document contains site positioning requirements to support Cat® MineStar System products. Products include, but are not limited to, Command for hauling. Detect proximity awareness and Command for drilling. These minimum requirements must be met to ensure Cat MineStar System capability sets will perform as designed.
Site Positioning referred to in this publication shall be described as the infrastructure required to support the various Cat MineStar System on-board positioning systems. The Site Positioning components consist of the GNSS Base (Reference) Station, the GNSS Truth Positioning System (TPS), and the GNSS Site Calibration (.dc file).
Caterpillar Inc. does not distribute or sell Site Positioning equipment. Technical support, training, and best practices utilized for installation, operation, maintenance, and troubleshooting of the Site Positioning hardware should be provided by the respective dealer of that equipment.
This publication shall provide guidance to an experienced site architect in selecting capable third-party site positioning components that will support successful integration with the Cat MineStar System.
Important Safety Information
Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed also.
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.
Ensure that the product will not be damaged or the product will be made unsafe by the operation. lubrication, maintenance, or the repair procedures that are used.
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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility. |
Customer Site Positioning Plan Review
The site positioning infrastructure plan is requiredto be reviewedand approved by the Cat dealer and Caterpillar Inc.. This review and approval is to ensure the products purchased and installed will have:
- The correct configuration
- Compatibility with the systems
- Met the requirements outlined in this document
Availability
Operation of Cat MineStar System requires the continuous availability of GNSS corrections. Loss of GNSS correction service to a single piece of equipment can translate into:
- Downtime
- Decreased performance
- Loss of functionality of the system
Loss of GNSS correction service site wide can translate into loss of functionality and downtime of the entire operation. Therefore the design, maintenance, and support plans for the site positioning system require careful thought and consideration.
Accuracy
The Cat MineStar onboard systems require that the GNSS reference station be referenced in the WGS84 coordinate system to provide both high and medium accuracy solutions. Reference Appendix.
Integrity Monitoring
Autonomous sites are designed with a positioning integrity feature built into Cat MineStar System. The positioning integrity feature works by monitoring position reports from the truth positioning system (TPS) mounted in a fixed, known location. The reported positions are continuously compared to the known position, an error is reported if the two positions deviate.
Redundancy
Based on the near direct relationship between GNSS correction availability and the uptime of operations, maintain backup site positioning components. The backup components should be pre-configured to match the primary components settings. Pre-configuring the backup components allows for easy and rapid replacement in the event of an issue or component failure.
Constellation Tracking
The GNSS Reference Station must be at minimum support tracking of the following constellation signals:
- GPS L1, L2-Legacy, L2-C, L5
- GLONASS L1-C/A, L1-P, L2-C/A(M), L2-P
- QZSS
- Consideration should be given to supporting future GNSS constellations (ex. BDS & Galileo)
- Reference Station must remove tracking of individual satellites.
Corrections
The GNSS Reference Station must support output in all the following format:
- CMR+ (RTK)
To support future constellation additions, the hardware must support output in the following format:
- CMRx (RTK)
Interface Protocols
Ethernet Port - The GNSS reference station must output correction streams via TCP and UDP over an Ethernet port, using both broadcast and unicast messaging.
Serial Port - The GNSS Reference Station must output correction streams via a serial port.
Wireless Radio (For Non-Autonomous Applications) - Some GNSS reference stations offer the option of internal radios (ex. 900 MHz or 450 MHz). An internal radio is not required for Cat MineStar System products that will be receiving corrections from the reference station using a site's broadband wireless network and the Ethernet port from the reference station.
E-mail Alerts
The GNSS Reference Station must support the ability to send SMTP-based e-mail alerts for the following conditions (at minimum):
- Alert when no satellites are tracked
- Alert if a TCP/IP link or other communication link fails
- Alert if a user attempts to log on and is denied access
- Alert when the receiver controls are changed
- Alert when the receiver starts or stops using the internal battery
- Alert when the receiver is about to shutdown due to low power
- Alert when the receiver operating temperature is getting too high or too low
- Provide a daily tracking/status summary
Configuration Interface
The GNSS reference station must support a web-based (configuration and status) user interface. A web-based user interface allows for monitoring and configuration of the station by an administrator who is physically remote from the device.
Language Support
The GNSS reference station must provide interface software and documentation translated to the local language.
Uninterrupted Power Supply (UPS)
The GNSS reference station should either have an Internal Backup Battery or be installed with an Uninterruptible Power Supply (UPS).
Internal Backup Battery - If the GNSS reference station does not have a UPS in place, the station must have an internal backup battery that:
- Continuously charges from the primary fixed power source
- Activates automatically in the event of loss of the primary fixed power source
Data Logging Option
The GNSS reference station should be purchased with a data logging option. This feature is utilized when setting up the receiver and for troubleshooting purposes.
NTP server (Network Time Protocol)
The Base needs the capability of being configured as an NTP server.
Selection and Configuration Requirements
Primary GNSS Reference Station
Manufacturer/Model - The specific model and manufacturer of the primary GNSS reference station must be selected based on the ability to meet the above outlined requirements.
Configuration Settings - Refer to the GNSS reference station manufacturer documentation for the appropriate configuration settings.
All "Autobase" or automatic station positioning features should be disabled.
Truth Positioning System (Autonomous Operation Only)
Selection - The specific hardware and manufacturer of the truth positioning system must match the primary GNSS reference station. However, the TPS shall be configured as a high precision rover as opposed to a base station.
Configuration Settings - The truth position system must be configured to receive GNSS corrections from the primary GNSS reference station. The system must be configured to calculate an RTK FIXED position as a Rover. The system must be configured to report positions via an NMEA message in local site coordinates to the Cat MineStar System server via the local Ethernet network.
Physical Placement
Refer to the GNSS reference station manufacturer documentation for the appropriate considerations when installing the primary GNSS reference station and the truth positioning system (where applicable).
The final antenna installation location must be surveyed regarding the WGS84 coordinate system.
Minimum considerations also should include:
- Placing the Antenna
- Provide the GNSS antennas as clear a view to the sky as reasonably possible based on site-specific conditions. The antennas must be positioned so that the antennas will always see a superset of the possible GNSS satellites that mobile equipment will see.
- Mount the antenna with appropriate spacing from other RF transmitting devices. Some examples are: radar, cellular and 2-way radio.
- Clear sky from the zenith to the horizon to a
100 m (328.0 ft) radius, in all directions (360 degrees) - Mount
1.5 m (4.92 ft) above any nearby signal reflectors. - Separation of at least
300 m (984.2 ft) from radio signal transmitters. - Mount stability that is not influenced by thermal expansion, wind loading, or soil expansion/contraction.
- Do not place the GNSS antenna near the following sources of electrical and magnetic noise:
- Gasoline engines (spark plugs)
- Televisions and computer monitors
- Alternators and generators
- Electric motors
- Equipment with DC-to-AC Converters
- Fluorescent lights
- Switching power supplies
- Arc welding equipment
- Placing the Receiver
- Mount the receiver in a location that meets the various environmental specifications of the receiver including, but not limited to: operating temperature, humidity, and exposure to environment.
- Also for Autonomous Operation - Mount the Truth Positioning system antenna in a physically and structurally different location from the primary GNSS reference station antenna.
The locations must be selected so that any possible movements of one antenna will not affect the other antenna.(example: physical shifting or settling of a building)
Power Supply
Fixed Power - A primary fixed power source must be provided for the site positioning components.
Backup - A backup generator power must be provided as well for the site positioning components.
UPS - Either a UPS or an internal battery should be installed with the site positioning components (Refer to "Uninterrupted Power Supply (UPS)").
Lightning Protection
Refer to the GNSS reference station manufacturer documentation for the appropriate considerations when installing the device to account for lightning protection.
Network Connection
A network connection is required at the primary GNSS reference station. For autonomous sites, a network connection is also required at the truth positioning system (TPS).
Security
Security is important. Tampering with site positioning components could have unintended effects on the Cat Minestar System.
Access to the site positioning system components should be limited and secured.
The components must have the capability for secured user name / password access.
Only qualified and trained individuals should have access.
A site positioning champion should be identified at each site to administer the security.
Access control should apply to the primary GNSS reference station and the truth positioning system (where applicable).
GNSS (and TPS) receivers and antennas should be in secured marked areas with restricted access.
Development
A site must have a Local Site Coordinate System established before installing and/or integrating site positioning hardware. This local site coordinate system should not change throughout the life of the mine site.
Note: If the local site coordinate system changes, the Cat MineStar System mine model will be requiredto be recreatedto match the new changes. If the Cat MineStar System mine model does not match the local site coordinate system, the Cat MineStar System may experience unpredictable errors that could have major site implications. A mine site shall utilize the services of a local qualified licensed surveyor to establish the local site coordinate system. The surveyor must meet the local regional survey standards.
Site Calibration
Each site is required to develop a site calibration file. The site calibration file converts the world GPS coordinates into the mine's local coordinate system. A licensed professional surveyor to develop the site calibration file is recommended. The site calibration must not be based on state planes and must not include geoids. The site calibration file must be developed against the primary GNSS reference station, which has been referenced in the WGS84 coordinate system.
The site calibration should cover the current and future area of the mine site. The site calibration should cover anywhere that GPS equipped systems will be tracked through the life cycle of the mine.
File Format
The site calibration file must be available in the *.dc file format for use on all equipment on the site that has GNSS receivers including, but not limited to:
- Autonomous equipment
- Equipment equipped with Terrain
- Vehicles with proximity awareness
Configuration Management
Once the site calibration file is developed and distributed, a process must be established to ensure that all equipment on site is using a common file.
Site Positioning Support Personnel
Champion - A site positioning champion must be identified at each customer site. The champion should be made responsible to ensure the consistent operation of the site positioning equipment.
Technician Support - Given the critical nature of the site positioning components, having technician support on site that can respond to any issues with the components during all working days and hours is important. Technician abilities must include the ability to troubleshoot issues and replace components as needed.
Introduction
GNSS provides geographic positions (latitude and longitude, together with ellipsoidal heights) that must be transformed and projected to be compatible with local mine coordinate systems. A GNSS "site calibration", or simply "site cal", provides the transformation parameters necessary to convert the GNSS positions to local positions. This document provides some basic information and guidelines that apply to Cat MineStar System installations and the selection of qualified third-party survey consultants.
Control Points (or Just "Control")
Physical points in the ground that are semi-permanent and assumed to never move, with known coordinates:
1D Points - Have only known elevation and are frequently referred to as benchmarks.
2D Coordinates - Have only Easting, Northing or x, y known.
3D Coordinates - Have Easting, Northing, Elevation or x,y,z all known.
In ideal cases, horizontal (x,y) control points are located near or beyond the perimeter of the mine and are located on at least three sides of the work area
Vertical (z) control points are also evenly distributed around the site and should ideally cover the extreme heights or depths of the site.
Site Calibration
Site Calibration has three distinct definitions:
Field Survey - performed after base station is set up to occupy (survey) control points that exist around the mine.
File Created From The Results Of The Field Survey - Latitude, longitude, and ellipsoid height (LLH) on each point, relative to the base station, come from the GNSS; projected grid positions (x, y or Easting, Northing), plus elevation (z) are known (come from previous survey and should be provided by the mine surveyor).
Transformation Parameters that are Applied to GNSS positions ("WGS84") - Convert the parameters to the local mine coordinate system.
*.dc ("DC") File
A file that is used to put on the site calibration parameters to a Cat Terrain system.
Typical parameters in a site calibration "DC" file include:
- Ellipsoid definition
- Datum definition
- Projection
- Horizontal adjustment
- Vertical adjustment
Note: For Cat MineStar System applications, the "DC" file must not contain a geoid model, should be created with no geoid model, and should include a vertical adjustment based on the designated survey control points.
Note: A "DC" file may also have other data, such as list of control points, or results of field surveys (for example, topographic data), or even road designs. However, Cat Terrain (and other Cat 3D GNSS machine control systems) only requires the site calibration data.
Real Time Kinematic (RTK)
RTK refers to the GNSS processing technique used to derive positions on machines, survey rovers, or other properly configured GNSS-equipped assets. The term RTK is used across many industries and is understood in GNSS surveying and GNSS machine control, RTK implies centimeter-level accuracy relative to a GNSS reference station
Infrastructure
In a GNSS sense, Infrastructure includes the following:
GNSS Reference Station - Permanently installed GNSS antenna, receiver, radio, and power supply, should only be installed, located, and configured by a qualified GNSS surveyor / consultant.
Radio or Other Wireless Communication - Used to transmit RTK corrections from the GNSS reference station to Terrain machines, typically 900MHz, 450MHz, or 2.4GHz Wi-Fi
GNSS Site Calibration - The necessary mathematical parameters used to convert the GNSS machine positions to positions in the local mine coordinate system.
Design - The digital model of the mine for grade control or ore control.
Ways to Create a DC File
A DC file may come from various utilities and products. The most common tools used to create DC files for Cat Terrain are:
Handheld Controllers with Trimble Software (TSC1, TSC2, TSC3, Trimble Tablet)
SCS900 - Software on handheld controllers, designed specifically for non-surveyors, and available through Trimble Heavy Civil Construction dealers (SITECH), version of software may vary with the controller (TSC1 and TSC2 are no longer sold)
Survey Controller - Discontinued software running on most TSC1 and TSC2 controllers used in the survey market, software is optimized for surveying applications, including control surveys, previously sold through Trimble survey dealers (not SITECH).
Trimble Access - Current software running on handheld controllers, designed for the survey market, sold through Trimble survey dealers (not SITECH)
Note: The user interface in SCS900 is different from Survey Controller and Trimble Access (both of which are similar), be sure that you know which product you have before calling Trimble for support.
Office Software
Business Center / HCE (Heavy Construction Edition) - Includes ability to compute a site calibration, based on input LLH and NNE information, and export in DC file format.
AccuGrade Office - Software previously sold through Cat dealers, includes utility to compute site calibration directly, based on input LLH and NNE.
When is a Site Calibration Required?
A site calibration, in the form of a DC file, must be applied on each Cat MineStar System asset or machine, to convert the GNSS position to a position in the local mine coordinate system. The field survey to generate this site calibration file must be performed after the GNSS reference station at the mine has been installed, assigned a starting position, and is configured to broadcast RTK corrections across the mine site.
If a separate reference station is to be used, one of two processes must be followed:
- Using initial site calibration file, first survey the new reference station position relative to the original reference station, then configure the new reference station to broadcast RTK, in this case, the original site calibration should still be valid
Note: A qualified surveyor should verify this by checking other control points on the mine site
- If the original reference station is not operating, or if for any reason is not possible to locate the new reference station relative to the original, then a new, second site calibration will be required. In this case, the second reference station must be configured to broadcast RTK, and then the second site calibration survey should be performed
Note: In this case, the new DC file is required on all Terrain machines
What to Look for in Consultants
Generating site calibrations and determining base station positions for mine installations requires deep understanding of GNSS geodetic surveying issues. In addition, there may be liability questions. For these reasons, setting base station positions and providing site calibrations should be contracted out to survey consultants with experience in GNSS surveying. The consultant should have demonstrated experience in the following:
- Datum transformations, coordinate systems, and geoid models
- ITRF and WGS84 Realizations
- GNSS Site Calibrations for machine control in construction or mining
- Ability to generate site calibrations in the "DC" file format (consultant may use non-Trimble equipment for their own use, but need to provide the mine site with "site cal" in .dc format)