The Challenge
Komatsu provide heavy machinery across the globe to power a range of industries from forestry to construction and mining. Komatsu introduced their first bulldozer in 1931, since pioneering many industrial products and innovative machines that now stand at the forefront of the construction and mining equipment industry. Many contemporary mining operations utilise an array of machinery known as a Longwall Mining System, which Komatsu produce for clients over the world.
Due to the difficulty of observation and dangers of the underground environment, Komatsu had a requirement for a visualisation system for this equipment that would allow above ground engineers to observe the longwall and the status of the various components; most notably the face, shields, and shearer.
The Solution
Vivato worked closely with the Komatsu engineering team to create a 3D visualisation tool that runs on live data from within an operational mine. This simulation used the Unity 3D engine to combine fully rigged CAD models with in built physics simulation and data parsing to render and simulate the full face.
Modelling
The initial build required the inventor models to be parsed into Unity and rigged to allow accurate movement based on sensor data, the Vivato team worked closely with Komatsu engineers to ensure that each part of the longwall was correctly mapped and rigged, allowing for like for like movement to be translated from data being exported from the mine to be accurately represented in the simulation.
Physics Simulation
Each Longwall operation comprises over 400 individual machines that are each controlled independently of one another. This movement is fed to the system, which can translate that movement into the simulation. Upon movement, the individual roof supports impact one another and cause a chain reaction of movement that is not captured in any sensor data and therefore required modelling from a physics simulation. This requirement meant that each model had to be correctly weighted and collidable to ensure accuracy.
Data Feeds
The Longwall runs a connection that parses and exports the data from each support and pan, as well as the shearer and other mine-wide information. The format of this needed to be translated into information that was usable by the Unity 3D engine. Once this configuration was achieved, data was also sent to the mine connection as well for two way control in some instances.
Global Markets
Due to the fact that Komatsu provide services to markets around the globe, the product needed to be localised across a variety of languages to ensure correct understanding. This included the tool itself, as well as dynamic localisation of incoming data from the mine sensors.
Optimisation
Rendering 400+ detailed inventor models posed a challenge to the systems optimisation requiring a balance of system and rendering capacity. This was balanced by working with the Komatsu engineering team and using Level Of Detail scaling alongside code side optimisation to ensure the system ran smoothly, even when being rendered in it's entirety.
The Outcome
The solution became a staple Komatsu product that is shipped alongside it's Longwall mining operations. It has been deployed in mines across the globe and continues to provide great value to these locations. The tool allows for greater oversight of mine conditions while requiring lower numbers of engineers in situ on the coal face, therefore increasing the safety of the operation.
The success of the initial build began a strong partnership between Vivato and Komatsu that has continued for over 8 years. The 3D Visualisation tool has grown and changed over that time frame with the expansion into different areas, with bespoke modelling and updates for mining operations across three continents.
