Volumetry April 21, 2022

Accurate stockpile volumetric measurement with intelligent perimeter security

Precise stockpile volumetry and intelligent perimeter monitoring with 3D vision

Overview

EL ABRA coarse stockpile challenges:

Sociedad Contractual Minera El Abra is a major copper producer. Its coarse yard faced three core issues:

Inventory blind spots: no live pile volume—downstream lines idled and capacity was lost;
Dozer risk: delayed hopper level awareness led to stuck equipment and costly shutdowns;
Dust and patrols: manual rounds were slow and unsafe; many sensors failed in dust.

For EL Abra, HEGANG YUNCHANG deployed a 3D dynamic pile monitoring and perimeter warning system with three modules:

Multi-sensor modeling: six LiDAR units plus thermal imaging refresh a full-field 3D model about every 30 seconds;
Live inventory visualization: automated volume with about ≤1.5% error and threshold alerts on the operations wall;
Replenishment decisions: integrates with production management to open work orders before critical low stock.

2. Dozer safety dual protection

Equipment positioning and terrain: UWB + RTK fused with hopper 3D maps;
Dynamic safety fence: ~5 m electronic zone around the discharge with audible/visual alarms and dispatch push;
Historical tracks to refine push routes and reduce stuck-equipment events.

3. Perimeter monitoring under dust

Anti-interference algorithms: LiDAR penetrates dust; AI suppresses clutter for intrusion cues;
Multi-level alarms to field, vehicles, and central control;
Large reduction in manual patrol frequency and related OPEX.

Efficiency and safety improved together after the system went live.

Inventory: pile data refreshed to minute-level cadence; downstream idle rate under about 3%;
Safety: dozer incidents driven toward zero with major monthly savings;
Operations: roughly 80% fewer manual patrols.

📌 "Our control room now sees the whole yard in one place—throughput and safety are the best we have seen in ten years." — Carlos Mendez, production director

Core value tags: #smartmonitoring #safety #unattendedpatrol #Industry40