Vale applies robots to improve operational safety

The robots used by Vale are either developed by the Mining Department of the Vale Institute of Technology or purchased from the market.

The fantasy scene described by science fiction writers of robots working side by side with humans is becoming a reality in Brazil's Vale mining area. Vale invests in a variety of robots that can assist employees in maintenance operations to help employees stay away from hazardous working environments and help the company achieve its goal of becoming a safety benchmark in the mining industry. At present, Vale mainly uses three types of robots, two of which are developed by the Mining Department of the Vale Institute of Technology and look like a "wheelbarrow"; the other is an ANYmal robot purchased from an international supplier, which the company affectionately calls a "puppy".

Founded in 2010, the Vale Institute of Technology ((ITV)) has a department specializing in the development of robotics, drones and artificial intelligence operation solutions. In 2015, the Vale Department of Cave Research launched the "Cave Robot (SpeleoRobot)" project, which was taken over the following year in partnership with (UFMG) of the Federal University of Minas Gerais. The cave robot is a remote-controlled robot with a camera and lighting system, which can walk on rugged terrain. It was designed to help Vale cave researchers by mapping caves near the operating area.

In 2017, researchers began testing the application of cave robots to other job scenarios, such as testing confined environments that are inaccessible to people. The scope of inspection includes not only factory equipment such as ball mills and crusher tooth plates, but also pipes, passageways and sewers. Cave robots have been used in more than 15 different service scenarios in the Brazilian states of Minas Gerais, Espiritu Santo and Para. The cave robot has an interchangeable motion system that can use wheels, tires, pedals or brackets to move according to different terrain, while its sensing system supports high-resolution detection, 3D map generation and other modular functions.

The Vale Institute of Technology recently delivered some of its robot sensing modules to (NASA) of the National Aeronautics and Space Administration. "researchers are currently verifying the possibility of using these modules in an international underground robot challenge." Said Mayla Saboya (Maira Saboia), a researcher at the Vale Institute of Technology.

The institute is building three robots of the same model, which will be used in copper mines in the state of Para and iron mines in the cities of Victoria, Espiritu Santo and Itabila, Minas Gerais. Responsible for testing mills, pipes and other airtight environments.

The Institute also collaborated with (UFRJ) of the Federal University of Rio de Janeiro to develop the "testing Service Robot (ROSI)". Since the beginning of the project, ROSI has been used as a testing tool in the Vale operating area, mainly responsible for testing the conveyor belt, which is an important part of mining equipment. To this end, ROSI is equipped with a robotic arm that can operate flexibly in an operating environment, repositioning sensors and collecting samples in hard-to-reach areas. The research and development of ROSI began in 2017 and is now in the testing phase.

"these robots are independently developed by Vale employees, and their technology is constantly upgrading." Gustavo Percin (Gustavo Pessin), a researcher at the Vale Institute of Technology, said, "the development of robots is open source, completely open from hardware to software, and uses a modular structure. All the development results can be applied to other robots and equipment, and can be applied to new scenarios or new functions through the use of Vale's resources. "

ANYmal robot

In addition to developing robots in Brazil, Vale also plans to purchase the quadruped robot ANYmal from Swiss company ANYbotics. The robot has previously been used in other industries and is now being adjusted for mining operations with the support of the Vale team. This year, the Cau ê mining area in Itabila, Minas Gerais, completed a proof-of-concept of the ANYmal robot, and the success of the test led Vale to confirm that it would buy the robot.

In the process of proof of concept, the ANYmal robot moves around the platform and overcomes obstacles such as going up and down stairs. It draws and displays the digital map of the detection area, plans the route and determines the direction of progress, completes the focus of specific objects and instruments, transmits the image, and records the thermal image through the temperature measurement device.

The use of robots can not only remotely detect assets and collect data, so as to improve the efficiency of decision-making, but also avoid people from entering dangerous areas to the greatest extent. "Robots allow us to eliminate risks arising from inspection operations, such as rotating equipment parts, noise and dust." Renard Teixeira (Rayner Teixeira), Vale's operations commissioner for ANYmal robot suitability adjustment, said, "Robots also allow us to eliminate ergonomic risks, such as those that require employees to perform in uncomfortable positions. The robot can also work in a confined space, such as inside a mill. "

The robot will perform grinding equipment testing and 3D mapping tasks in Gaoying mining area. In addition to making employees safer, it is expected to reduce downtime, reduce maintenance costs, and improve the reliability of test results and data collection, so as to better control the operation of assets in real time.

Vale Institute of Technology

Established in 2010, the Vale Institute of Technology is a non-profit organization dedicated to developing technological and scientific solutions to help Vale address the mining and sustainable development challenges facing the region in which it operates. The three major tasks of the Institute are research, training and entrepreneurship.

Vale Technology Research Institute consists of the Department of Sustainable Development, located in Belen, Para, and the Mining Department, located in Orupreto, Minas Gerais. Its objectives include exploring future-oriented solutions through scientific research and technology development, as well as expanding business knowledge and business frontiers in a sustainable manner. In addition to applying the research results to Vale, the Institute also carries out master's degree and professional level training programs.

Safety innovation

Innovation is the key to Vale's concerted efforts with society to improve life and change the future. Vale focuses on safety, reliability, a low-carbon agenda and the creation of shared value. Ongoing safety innovation projects aim to eliminate or reduce employee risks through the use of technologies such as autopilot devices, identify and address causes of accidents in mobile and energy devices through fatigue detection systems and approach alarm devices, and eliminate various risk situations.