Atlas Copco’s automated SmartROC Down-The-Hole and Top Hammer drill rigs have transformed the drilling procedure. Equipped with smart technology, these rigs help to drive down operational and maintenance costs, drive up efficiencies, increase safety and reduce carbon footprints for sustainable productivity and profitability in mines, quarries and plants.

“We believe that the success of automation technology lies in a holistic approach and therefore Atlas Copco’s Powered by Automation applies not only to equipment but also to systems, operations and services,” explains Hedley Birnie, Atlas Copco Mining and Rock Excavation Technique’s SED (Surface and Exploration Drilling) Business Line Manager.

Comprising four levels (monitoring, function, calculated optimisation and autonomy), Powered by Automation encompasses a range of automated operations such as remote control solutions, automatic safety features and systems, improved information integration and visualisation and control of operations. Atlas Copco designs, maintains and supports all hardware and software.

“The various automation offerings available on our SmartROC rigs optimise the drilling and blasting experience from end-to-end and improve productivity across-the-board,” asserts Birnie. Designed with leading-edge varied level automation technology and featuring full drill cycle automation, the Atlas Copco SmartROC drill rigs are capable of drilling holes semi-autonomously with extreme accuracy.

This smart technology leads to better planning, improved accuracy and fuel efficiency (up to 15% less fuel consumption), consistency in operation and quality, extended machine availability and equipment lifecycle, and enhanced operator safety and performance.

The planning office is able to communicate with the rig via a Wi-Fi network or data stick and drill patterns, hole angles and depths are sent to the rig with GPS coordinates.

The Hole Navigation System (HNS) enables the rig to locate the exact coordinates and drill precisely to plan and all the information is reported to the office. “This intelligent option delivers a faster set-up, improves precision and reduces non-drilling time, fragmentation and explosive quantities,” elaborates Birnie.

Rig Remote Access (RRA) sends drill patterns, hole angles and depths to the rig with GPS coordinates enabling the rig to drill holes semi-autonomously. The rig ‘knows’ to drill in the right place at the right depth, at the right angle and at the desired hole depth every time while drill tubes are added and extracted automatically. This automation also allows for automatic overburden drilling; with manual marking and surveying of hole positons now eliminated, operators and surveyors are removed from hazardous areas. Additionally it reduces the risk of manual error as well as potential safety hazards from dropping rods.

Rig Control System (RCS) is a built-in auto-rod handling control system that limits extreme usage and safeguards the rig against operator abuse, reduces wear both on the rig as well as on consumables, extends rig lifespan and improves uptime and availability.

With the BenchREMOTE function the operator can conveniently monitor progress from the comfort of a FOPS/ROPS approved cabin situated 100m away. With no pipework in the cabin, the operator enjoys a more ergonomic, spacious dry ‘office in which both noise and the risk of oil leakage are minimised. Decreased operator fatigue reduces errors and increases safety for improved operational efficiencies and boosted productivity.

Furthermore, up to three SmartROC drill rigs can be operated from one BenchREMOTE base station at a distance of up to 100m. “This in effect transforms the SmartROC into a dependable, low-maintenance co-worker on the bench and leads to significantly improved operational efficiencies,” notes Birnie. He adds that Atlas Copco office management systems such as ROC Manager give customers access to important statistics such as rig availability, actual drilling time, fuel burn, etc.

“We are continuously updating the automation technology of our SmartROC drill rigs to ensure the highest and most efficient rig performance possible,” affirms Birnie. Recent upgrades to the SmartROC T45 include longer drill rods, improved fuel burn and updated software. The lengthening of the drill rods and starter rods increases uptime due to fewer stops. A better drill control system improves performance in broken ground and provides better control of the GPS compass.

“Operators are also now able to turn the HNS (Hole Navigation System) on and off,” adds Birnie.

Atlas Copco offers theoretical and practical aftermarket technical and operator training to ensure correct operation of the drill rig for improved safety, reliability and performance. Maintenance support can be customised to meet customer requirements.

Alongside an extensive parts supply, a component rebuild facility housed at Atlas Copco’s Jet Park, Johannesburg head office, repairs components back to OEM standards; in addition to the Boom Rebuild Facility, there is a Rock Drill Rebuild facility which currently boasts a rebuild/repair capacity of 20 rock drills per week and an Axle Rebuild facility with a capacity to repair/rebuild five axles per week.

The SmartROC product line is backed by an extensive aftermarket support network of branches in Rustenburg, Middelburg, Lydenburg, Kuruman and Springbok which also support Botswana, Mozambique, Namibia and Zimbabwe. Aftermarket parts are supplied from the Jet Park Distribution Centre.

Birnie points out that while automation technology is still fairly new to Southern Africa there is an installed base of sixteen Atlas Copco SmartROC rigs – three in the Northern Cape, three in Limpopo and ten in North West Province.

“Interest in our rigs and their automation features is on the increase as mines and quarries are realising more and more that the implementation of automation technology is crucial to a sustainable and profitable future. The SmartROC delivers exactly what these industries need,” concludes Birnie.