RI 9642 REPORT OF INVESTIGATIONS/1997

Accurate Navigation and Control of Continuous

Mining Machines for Coal Mining

U.S. DEPARTMENT OF HEALTH AND HUMAN SERVICES

Public Health Service

Centers for Disease Control and Prevention

National Institute for Occupational Safety and Health
Report of Investigations 9642

Accurate Navigation and Control of Continuous

Mining Machines for Coal Mining

William H. Schiffbauer

U.S. DEPARTMENT OF HEALTH AND HUMAN SERVICES

Public Health Service

Centers for Disease Control and Prevention

National Institute for Occupational Safety and Health

Pittsburgh Research Laboratory

Pittsburgh, PA

November 1997
International Standard Serial Number

ISSN 1066-5552
CONTENTS

Page

Abstract ...................................................................................... 1

Introduction .................................................................................... 2

Navigation ..................................................................................... 2

INS basics ..................................................................................... 3

The control system ............................................................................... 3

An expanded control system ........................................................................ 4

Pre-OP INS experiments ......................................................................... 4

Underground INS test shortcomings (1992) ........................................................... 4

METF INS test shortcomings (1997) ................................................................ 4

OP cooperator ................................................................................... 5

Automated CM position determination in an OP mine ...................................................... 6

The reference coordinate system ...................................................................... 7

Navigational requirements for the OP test ............................................................... 7

Field test system ................................................................................. 8

TRACKER ..................................................................................... 9

The mine plan ................................................................................... 9

INS initial installation and alignment to the CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INS operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Equipment setup procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Systems accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Data archiving methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Data analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

OP results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

File 09130927.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

File 09131309.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

File 09131522.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

File 09130928.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

File 09131307.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

File 09131450.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

File 09131525.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

File 09131600.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

File 09140933.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Highwall results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

File 09261449.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Appendix A.—In-depth description of the reference coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

ILLUSTRATIONS

1. HORTA ................................................................................. 2

2. Single laser ring gyro ....................................................................... 3

3. Control network, basic ...................................................................... 4

4. Control network, expanded ................................................................... 5

5. JOY 12CM .............................................................................. 5

6. Pit 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7. GPS and the OP ........................................................................... 6

8. OP CP's ................................................................................. 7

9. Control system OP ......................................................................... 8

10. Two 90-m cuts ............................................................................ 9

11. Stacking conveyor ......................................................................... 9

ii
ILLUSTRATIONS—Continued

Page

12. Haulage system ........................................................................... 9

13. Highwall ................................................................................ 9

14. RT and INS position file 09130927.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

15. RT and INS altitude file 09130927.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

16. RT and INS northing and easting difference file 09130927.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

17. RT and INS position file 09131309.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

18. RT and INS altitude file 09131309.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

19. RT and INS northing and easting difference file 09131309.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

20. RT and INS position file 09131522.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

21. RT and INS altitude file 09131522.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

22. RT and INS northing and easting difference file 09131522.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

23. RT and INS position file 09130928.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

24. RT and INS altitude file 09130928.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

25. RT and INS northing and easting difference file 09130928.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

26. RT and INS position file 09131307.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

27. RT and INS altitude file 09131307.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

28. RT and INS northing and easting difference file 09131307.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

29. RT and INS position file 09131450.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

30. RT and INS altitude file 09131450.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

31. RT and INS northing and easting difference file 09131450.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

32. RT and INS position file 09131525.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

33. RT and INS altitude file 09131525.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

34. RT and INS northing and easting difference file 09131525.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

35. RT and INS position file 09131600.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

36. RT and INS altitude file 09131600.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

37. RT and INS northing and easting difference file 09131600.sgu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

38. RT and INS position file 09140933.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

39. RT and INS altitude file 09140933.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

40. RT and INS northing and easting difference file 09140933.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

41. RT and INS position file 09261449.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

42. RT and INS altitude file 09261449.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

43. RT and INS northing and easting difference file 09261449.pcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

TABLES

1. Coordinates for CP1s in U.S. survey feet ......................................................... 8

2. Data file summaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
UNIT OF MEASURE ABBREVIATIONS USED IN THIS REPORT

cm centimeter m meter

cm/hr centimeter per hour mm millimeter

ft foot min minute

ft/hr foot per hour ppm part per million

ft/m foot per metert sec second

hr hour % percent

in inch ( degree

km kilometer

ACRONYMS USED IN THIS REPORT

CEP circular error probable MAPS Modular Azimuth and Position System

CID coal interface detection NGS National Geodetic Survey

CM continuous miner OP open pit

CP control point PC personal computer

EDMI electronic distance measuring instrument RCS real-time control system

GA grid azimuth RPU Remote Positioning Unit

GD grid distance RT robotic transit

GPS Global Positioning System RMS root mean square

HA horizontal angle SD slope distance

HARN High Accuracy Reference Network SDLC Synchronous Data Link Control

HD horizontal distance SEP spherical error probable

HI robotic transit height SF scale factor

HORTA Honeywell Ore Recovery and Tunneling Aid SGI Silicon Graphics, Inc.

HR signal height SPCS State Plane Coordinate System

IEEE Institute of Electrical and Electronics Engineers VA vertical angle

INS Inertial Navigation System ZRP zero-reference point

METF Mining Equipment Test Facility ZUPT Zero-Velocity Update

Mention of any company name or product does not constitute endorsement by the National Institute for Occupational Safety and Health.

To receive additional information about mining issues or other occupational safety and health problems, call 1-800-35-NIOSH (1-800-

356-4674), or visit the NIOSH Home Page on the World Wide Web at http://www.cdc.gov/niosh/homepage.html
ACCURATE NAVIGATION AND CONTROL OF CONTINUOUS 

MINING MACHINES FOR COAL MINING

By William H. Schiffbauer1

ABSTRACT

One of the safety and health research programs of the former U.S. Bureau of Mines Pittsburgh Research Center

was the evaluation of technology that will provide remote-controlled operation of mechanized equipment in

underground room-and-pillar mining. The purpose of this effort was to enable workers to be located away from the

hazardous and unhealthful coal extraction area (the face). As part of this program, advanced machine navigation

and control technologies were developed for underground room-and-pillar and highwall coal mining that can be

applied to commercially available mining equipment. These technologies use off-the-shelf components and a

flexible control software architecture to minimize the effort required to adapt them to mining equipment. An

accurate, reliable navigation system that can provide the mining machine's heading and location is a critical

requirement for a remote-controlled mining system. After investigating several different types of navigation sensors,

researchers selected the Honeywell Ring Laser Gyro Inertial Navigation System (INS) as showing the most promise.

It was installed on a continuous mining machine at our Mining Equipment Test Facility. Extensive testing at an

open pit (OP) site was also performed. This report describes the INS as it was employed on the mining machine in

the laboratory, in the field, and OP tests, and provides the accuracy and performance results of the OP and highwall

tests.

Electronics technician, Pittsburgh Research Laboratory, National Institute for Occupational Safety and Health, Pittsburgh, PA. 1
2

Figure 1.—HORTA.

INTRODUCTION

The purpose of the research program on remote-controlled basic efforts to enhance health and safety are much the same for

coal mining at the former U.S. Bureau of Mines Pittsburgh both: relocate the machine operators a safe distance away from 2

Research Center was to develop enabling technology that will areas where they are exposed to hazards, such as roof and

allow remote-controlled operation of all mobile mechanized highwall falls, respirable dust, and noise, and provide the operator

equipment normally used for room-and-pillar and highwall coal with enough information and technology to ef-fectively operate

mining while permitting workers to be located away from the the machines remotely. In highwall mining, operators are already

hazardous coal extraction area (face). The advanced navigation provided with a protected control center. In room-and-pillar sitand control technologies that were developed employ off-the- uations, a mobile skid, located in the vicinity of the section power

shelf hardware, thus minimizing the effort required to adapt the center, which in most cases will be less than 150 m from the face,

new technology to mining situations. Because the technology is could be used for the control center. From this skid, the most

modular, only those modules required for particular applications hazardous machine activities can be controlled and directed by the

need to be applied. Although there are differences between machine operators.

underground and highwall mining systems,

NAVIGATION

The most important requirement for a remote-controlled process with Honeywell, which made incremental changes to

mining system is an accurate, reliable navigation system that MAPS to improve accuracy. Satisfied with the MAPS perprovides the heading and location of the continuous miner (CM) formance at the conclusion of the underground test, the research

at all times. The navigation system provides information to the team redesigned the CM control system and made additional

machine control computer so that the cutting by the CM can be recommendations to increase the INS accuracy, to improve the

controlled to a predetermined mine plan. For room-and-pillar user interface for setup and data interpretation, and to provide for

mining, entries and crosscuts can be cut to required dimensions operation in a multiple computer environment.

and location. In highwall mining, a constant rib width can be

maintained between adjacent holes. Several different navigation

devices were evaluated in an effort to identify the best one for 3

use on CM's. After investigating the alternatives, the Honeywell

Inertial Navigation System (INS) was selected. This system,

known commercially as the Honeywell Ore Recovery and

Tunneling Aid (HORTA) (figure 1), will be referred to as "INS"

for the remai nder of

this report. The system was previously known as the Modular

Azimuth and Position System (MAPS) for military applications.

It is the best navigation device for this application known at this

time. The research team conducted several underground tests

[Sammarco 1993] of the MAPS on a CM during coal cutting.

This was an interactive and collaborative 

The safety and health research functions of the former U.S. Bureau of 2

Mines were transferred to the National Institute for Occupational Safety and

Health in October 1996.

Different types of navigation sensors that were evaluated include laser 3

ranging, ultrasonic, electronic compass, and linear potentiometers.
3

Figure 2.—Single laser ring gyro.

INS BASICS

The main sensing components of the INS are three gyroscopes

(or gyros) and three single-degree-of-freedom linear

accelerometers, all packaged in one box approximately 28 by 38

by 32 cm. The three gyro and accelerometer pairs are mounted

orthogonally on collinear axes. The gyro (figure 2) is a rateintegrating gyro that does not use a spinning mass. Instead, it

measures angular motion by measuring the frequency difference

between two contrarotating laser beams. Mirrors are used to reflect each beam around an enclosed triangular path, which produces a "laser-in-ring" configuration.

The resonant frequency of oscillation is a function of optical

path length. The two-laser beams have identical frequencies

when the gyro is at rest. When the gyro is subjected to an angular turning rate (rotation) about an axis perpendicular to the plane

of the two beams, one beam travels a longer path and the other

beam travels a shorter one [Savage 1991]. Consequently, the two

resonant frequencies change, and the frequency difference is

directly proportional to the

angular turning rate. The frequency difference is measured optically and converted to a digital output. The cumulative pulse

count is proportional to the angular change.

Inertial navigation is the process of calculating position and

velocity based solely on inputs from self-contained acceleration

sensing instruments. Accelerometers provide the acceleration

magnitude sensing function. Gyros provide the acceleration

direction sensing functions (i.e., define the direction of the

accelerometer sensing axes). The basic inertial navigation concept

is to integrate the velocity data to determine vehicle position.

As the INS moves (i.e., as the CM moves), it accumulates

velocity errors. Over time these errors can become large, rendering the CM position data invalid. A velocity error dampening

mode, called Zero-Velocity Update (ZUPT), is employed, which

mitigates the error buildup. By comparing the sensed velocities

to the zero velocity condition, the INS can correct the velocity

errors by setting them to zero. The INS automatically performs

a ZUPT when it determines that the CM has stopped or will

request a ZUPT if the predetermined ZUPT time interval has

elapsed. The mining machine real-time control system (RCS)

software developed by the research team responds to a ZUPT

request by pausing the CM activities. Once the CM is stopped,

a ZUPT will take approximately 10 sec to complete. Upon

completion of the ZUPT, the INS tells the control system

software to resume operation.

THE CONTROL SYSTEM

Continuous miner manufacturers offer radio or umbilical cord A second fieldbus network was added to provide data

control for their mining equipment for off-board, line-of-sight collection (data network) of the positions of all of the controllable

operation from close proximity to the machine. Rather than moving parts of the machine, as well as the status of the machine's

using this radio link for computer control, we developed a critical parameters, such as motor currents, hydraulic pressures,

fieldbus-style control network, based on BITBUS standards, that temperatures, and other relevant parameters. This BITBUS 4

allows non-line-of-sight control of all of the mining machine's network consists of sensors, signal conditioning modules, and a

moving parts. BITBUS employs the Synchronous Data Link microcontroller board on the CM, and a PC-AT card that plugs

Control (SDLC) protocol to ensure the integrity of the data into a passive backplane in the 19-in rack. The two ends of the

passing over the link. Also, BITBUS employs the IEEE RS-485 network are connected with a twisted-pair cable. The separation

electrical standard. of the control network from the data collection network was the

The control network (figure 3) consists of two microcontroller best way to integrate this system to obtain the greatest

boards connected by a twisted-pair cable. One of the boards performance. The third connection between the CM and the 19-

resides on the CM; the other resides in a 19-in rack at the remote in rack is two twisted-pair cables that connect the machinecontrol location and attaches to a personal computer (PC). mounted INS to a PC-AT card that is plugged into the rackBITBUS is a standard developed by INTEL Corp., Beaverton, OR. 4

mounted passive backplane. This data link is based on a

Honeywell SDLC protocol standard, and it employs the IEEE

RS-422 electrical standard.
4

Figure 3.—Control network, basic.

The control network, the data collection network, and the INS

are each hosted on their own 486 class single-board PC that is

mounted in the passive backplane in the 19-in rack. All three

single-board PC's share a common monitor and keyboard using

a video/keyboard switcher. A key element of this application is

the introduction of a shared-memory box and hardware that

allows the single-board PC's to intercommunicate through

extended-memory reads and writes.

The controller computer and the RCS software are the key

elements for providing the coal mining operations. By using the

data collected from all of the CM sensors and the INS and by

executing commands on the CM, the controller is able to perform

various coal-cutting scenarios. Scenarios now include premine

test, room-and-pillar mining, and highwall mining. The premine

tests perform a complete evaluation of all machine functions to

ensure that the CM is capable of performing its mining activities.

Room-and-pillar mining consists of cutting 40-ft (12-m) lifts in

two passes with 70( or 90( crosscuts while using shuttle cars to

load out the coal. A highwall scenario has also been created.

AN EXPANDED CONTROL SYSTEM

Many applications can and have been added to the design of performed at our Mining Equipment Test Facility (METF) during

the basic control system. Each module adds another level of 1997. Each testing situation had been performed with some

functionality to the system. Thus, we are capable of adapting limiting factor that restrained our ability to fully validate the INS

their technology to the simplest or most sophisticated application and the control system. It is important to note that to properly

simply by adding the modules required to suit the application. determine the accuracy of the INS, the INS must be subjected to

Figure 4 shows our control system's present capabilities. the motion and vibration to which it would normally encounter

The visualization system (VISUALIZATION) uses both in the act of mining coal.

collected and ongoing machine data to provide accurate threedimensional (3-D) graphic representation of the mining machine,

its past and present movements, and associated hardware relative

to the mine surroundings. The visualization system user's

interface permits the operator to zoom around the scene to view

any part of the process that may be of interest. Additionally, top

and side views of the CM for present and previous cuts can be

displayed.

The simulator application (SIMULATOR) generates a steady

stream of data that correspond to data that would normally be

provided by the mining machine sensors, including the INS.

This allows development and testing of the controller without

engaging the massive hardware, such as the CM or haulage

system. The haulage application (HAULAGE) provides control

and monitoring of the haulage system that is used in the system.

The coal interface detection application provides information

about the thickness of the coal on the roof and the floor; it can

also provide information about the thickness of a rib of coal (web

coal) for highwall applications.

PRE-OP INS EXPERIMENTS

Tests on the INS performed with our mining system centered

on determining the accuracy of the INS and the feasibility of the

control system. Some of the underground tests done in 1992

were referenced previously in this report. Additional tests were

UNDERGROUND INS TEST SHORTCOMINGS (1992)

1. The underground mine where the tests were performed

was closed before system improvements could be made and

tested.

2. The control system and software algorithms were not

mature enough to perform all of the tasks that were mentioned in

the section of this report entitled “The Control System."

3. ZUPT's were not handled by the software in the control

system; therefore, inaccuracies due to velocity errors were present.

4. Geological restrictions (the basic nature of room-and-pillar

mining) limited the tests that could be performed.

5. The transit (Leitz "Set 3") used as reference for accuracy

measurements was manually operated and required a number of

seconds to perform a position calculation. Because the accuracy

of the INS is time-dependent, the time for transit measurements

added to the accuracy uncertainty of the INS navigation data.

METF INS TEST SHORTCOMINGS (1997)

1. A valid test should be performed while cutting coal,

because the vibration of the machine while cutting coal can have

a great effect on the accuracy of the data provided by the INS.

The material used for testing in the METF—coalcrete— is not

a very good simulation for coal. It is much harder than coal and
5

Figure 4.—Control network, expanded.

Figure 5.—JOY 12CM with stacking conveyor as used in OP

experiments.

Figure 6.—Pit 20.

very abrasive, which causes excessive wear to the CM. A good

substitute to simulate real coal has yet to be found.

2. The amount of coalcrete available to perform tests is

limited.

3. A manually operated transit was used to provide the

reference for INS accuracy measurements. As mentioned

before, it added to the accuracy uncertainty of the INS-derived

navigation data.

The research team realized that an open pit (OP) mine

experiment and the use of advanced surveying technologies could

eliminate the limitations noted previously. First, the use of an OP

site would remove the geological restrictions and facilitate the use

of some verification method of the CM's position. Second,

automation of the process of verifying the position of the CM in

real time as it was moving would minimize the introduction of

errors in determining the accuracy of the INS.

OP COOPERATOR

After a 2-year search for a cooperator with the necessary resources to

perform the experiments, we executed a Cooperative Research and

Development Agreement in January 1996 with Interwest Mining Co.,

Salt Lake City, UT. The site selected for the experiments was the

company's Glenrock Mine in Wyoming. The test plan developed with

Interwest included the full use of Pit 20, use of its Joy 12CM continuous

mining machine (figure 5), and use of its haulage system (a Kloeckner

Beckorit). Pit 20 was approximately 600 m long by 45 m wide by

50 m deep (figure 6). Our research team provided the navigation and

control technology, which consisted of hardware installed on the CM and

in our control trailer. The benefit to us was the ability to gather performance data on the INS to evaluate data accuracy. The benefit to the

cooperator was to enable the company to evaluate remote control

technology to include highwall mining methods to recover coal at the pit

boundaries.
6

Figure 7.—GPS and the OP.

AUTOMATED CM POSITION DETERMINATION IN AN OP MINE

An investigation was conducted to find a system that could was expected to last about 1 month. When the quotes to perform

provide an accurate, continuous reference determination of the the required tasks came in, we decided to find another solution to

INS on the CM while it was mining coal, then provide those data the navigational needs of the experiment because of costs and

to a PC for archiving. We determined that there were two uncertainty as to whether GPS could do the job.

possible solutions that could meet those needs. The second system we considered was an automated transit

The first system we considered was a Real-Time Kinematic with a capability of tracking a moving target (active prism) and

Global Positioning System (GPS) (figure 7). The accuracies of transmitting the data to a receiver accessible by a PC. The autosuch a system are in the centimeter range, and position data could mated transit, sometimes called a robotic transit, will be referred

be provided every few seconds. However, there was some to as an "RT" for the remainder of this report. After a lengthy

question as to whether the system could track enough satellites search, several RT's were found that could provide millimeter

over a wide enough area and over a long enough time from accuracies, with position updates every 0.5 sec while the CM was

inside a 50-m-deep, 45-m-wide pit. After consulting several moving. We determined that purchasing an RT and performing

different companies providing GPS services, we concluded that the navigation tasks in-house were less expensive than hiring a

it might be feasible. Purchase of the required hardware and firm to perform the required tasks. The final choice of which RT

software to do the job was considered, but the cost was to purchase was primarily based on what was available on

prohibitive. The same GPS service providers who were Government Services Administration contract. The RT procured

previously consulted were given the opportunity of bidding to was a Geodimeter System 4000 with Remote Positioning Unit

perform the navigation portion on the job, which (RPU 4002).
7

Figure 8.—OP CP’s.

THE REFERENCE COORDINATE SYSTEM

Coordinate systems are the means of referencing geographic established a High Accuracy Reference Network (HARN) of

information to locations on the Earth's surface and are the reference points with positional accuracies of 0.1 m. These

reference to standard models of the Earth's surface represented by HARN points are referenced to the SPCS and can be used as

an oblate spheroid of revolution (a flattened sphere). There have reference locations for establishing secondary high-precision

been at least 14 different ellipsoids used to approximate the oblate points using GPS techniques.

spheroid best representing the size and shape of the geoid called The site of the OP experiments resides in Wyoming SPCS

Earth. The Clarke Spheroid of 1866 was chosen by Honeywell East Zone 4901, and it is based on a Transverse Mercator proas the reference model used in the INS (see appendix A for more jection. Two HARN points, BILL and Q32, are near the site.

details on the Reference Coordinate System). The Clarke's 1886 NAD27 is specified in U.S. survey feet, not in meters.

spheroid datum (a set of quantities used as a basis to calculate Therefore, the author was forced to keep most of the analysis data

other quantities) for the United States [Buckner 1993] is known and results in feet rather than meters for uniformity. For

as North American Datum of 1927 (NAD27), which is a State comparison purposes, there are 3.280833333 ft/m for the U.S.

Plane Coordinate System (SPCS). With the advent of the survey foot. There is also an international survey foot; it is

satellite-based global positioning system (GPS) technology, the 3.280839895 ft/m.

United States

NAVIGATIONAL REQUIREMENTS FOR THE OP TEST

A geodesist [Hamilton 1996] was hired to help define the WEST and EAST. The method would consist of placing GPS

navigational requirements of the test and to implement them. The receiver 1 (RCV1) and GPS receiver 2 (RCV2) at the following

plan developed consisted of three parts: placing three solid combination of sites: BILL-WEST, WEST-EAST, and WESTnavigation control points (CP's) in Pit 20, establishing the points Q32. When placed in the OP, however, the GPS receivers could

in the Wyoming SPCS East Zone 4901 using GPS, and then only pick up three satellites, which were not sufficient for a

using the points as a reference for the RT. position fix. Additionally, there was concern about multipath

The OP selected (Pit 20) for the experiments was approxi- effects from the highwall, which would degrade the accuracy.

mately 600 m long in the east-west direction and about 45 m The plan was modified in the field to provide two additional CP's

wide in the north-south direction. The three CP's were placed on the top edge of the OP. One was placed on the western side

close to the southern edge of the OP and placed approximately (called A); the other, on the eastern side (called B) (figure 8).

180 m apart in almost a straight line. The CP's consisted of 8-in These points were used to tie the OP to HARN. The method

(20.32-cm) diameter, 8-ft (2.44-m) long steel pipes buried to 4 ft consisted of placing RCV1 and RCV2 at the following

(1.22 m) and set in a mass of concrete. Four feet (1.22 m) of the

pipe protruded vertically. The top end of the pipe had a flat 10-in

(25.4-cm) diameter, 0.5-in (1.27-cm) thick steel circular plate

welded to it and a 5/8-in (1.58-cm) #11 all-thread rod welded to

the center of it. The threaded rod protruded about 0.5 in (1.27

cm). These CP’s—designated WEST, MID, and

EAST—provided us with a stable reference for the INS

evaluation.

The plan was to connect these three CP's into higher order

existing control stations in the Wyoming SPCS. The chosen

control stations were Station BILL and Station Q32. BILL was

located near the town of Bill, on the right of way of State

Route 59. This is a distance of approximately 50 km from the

project. Q32 was located about 10 km north of Casper along

Interstate Highway 25, which was about 43 km from the project.

These two stations are of the HARN type. A direct tie was made

by the National Geodetic Survey (NGS) between BILL and Q32

in 1993 using GPS. Since NGS did this, all observations can be

rigidly checked by loop closures. The method that was to be

used to tie the OP CP's into HARN was the double occupancy

method using two dual-frequency GPS receivers. Only two of

the CP's (WEST and EAST) were to be tied in using the GPS

receivers; the MID point would be tied in using the RT from the
8

Figure 9.—Control system OP.

combination of sites: BILL-A, A-B, and B-Q32. Each site was using the RT to minimize measurement errors. The RT two-face

occupied for an amount of time related to the distance between D bar method was used to minimize transit errors. The

the receivers for each occupation. The final results of the measurements consisted of placing the RT on CP's A and B and

positions utilized the precise ephemeris, which was available placing the target on the WEST, MID, and EAST CP's. The

approximately 7 days after the observations. The coordinates of actual sequence was: A to B, A to WEST, A to MID, A to

the A and B were computed on three datums using the two EAST, B to A, B to EAST, B to MID, and B to WEST. All of

HARN stations as a reference. The estimated accuracy of the new these readings were processed by the geodesist in a least squares

points, with respect to the existing datums, was 0.05 m on adjustment, who derived the coordinates as listed in table 1.

NAD83 93, 0.2 m on NAD83, and 1 m on NAD27. To These coordinates were used throughout the experiments

associate the three CP's in the OP with A and B, the RT was used. performed at the OP.

A combination of measurements was made

Table 1.—Coordinates for CP's in U.S. survey feet

 Northing Easting Altitude

A (NAD27) .......................... 861474.19 323804.92 —

A (NAD83) .......................... 922188.7 479827.37 5731.64 (NGVD29)

A (NAD93) .......................... 922190.35 479825.63 5734.53 (NAVD88)

B (NAD27) .......................... 860186.26 327109.09 —

B (NAD83) .......................... 920900.73 483131.57 5340.28 (NGVD29)

B (NAD93) .......................... 920902.38 483129.85 5348.17 (NAVD88)

EAST (NAD27) ...................... 860686.413 325520.155 5557.638 (NGVD29)

EAST (NAD83/93) .................... 921402.576 481540.859 5560.532 (NAVD88)

MID (NAD27) ........................ 860867.346 324938.305 5567.319 (NGVD29)

MID (NAD83/93) ..................... 921583.513 480959.013 5570.213 (NAVD88)

WEST (NAD27) ...................... 861084.255 324445.770 5573.685 (NGVD29)

WEST (NAD83/93) ................... 921800.425 480466.482 5576.579 (NAVD88)

FIELD TEST SYSTEM

The control and data acquisition system constructed for the cameras and monitors provided a video reference of all of the exfield tests is shown in figure 9. The system consisted primarily periments. TRACKER (described below) provided a data link to

of the parts described in the section of this report en- the RT, data acquisition, data archival, and plotting functions.

titled "The Control System." A combination of video
9

Figure 10.—Two 90-m cuts. 

Figure 11.—Stacking conveyor.

Figure 12.—Haulage system.

Figure 13.—Highwall.

TRACKER

In the process of setting up all the hardware and software RCS. This was addressed by adding a PC to the control system

necessary to run the OP experiments, we identified a need to see and creating a piece of software called TRACKER to perform the

the position output of the RT and the position output of the INS required functions. TRACKER was developed by a team

in real time to ensure that all systems were working correctly. member for the Windows 3.1 operating system using a standard

Additionally, there was a need for software in a PC to collect and C++ compiler.

archive all pertinent data from the INS, RT, and

THE MINE PLAN

The research plan was to cut into the coal seam (underfoot), CM from getting buried. The coal being cut was dumped back

which had its overburden removed. Later highwall cuts were to into the trench. A Kloeckner Beckorit haulage system (figure 12)

be made into the bottom edge of the OP. The actual experiments was used behind the CM while it was performing the highwall

consisted mostly of two 90-m cuts into the floor of Pit 20 (figure cuts (figure 13). The stacker conveyor was towed by the CM,

10) and two cuts into the highwall (12 m and 18 m, respectively). and the Kloeckner Beckorit was manually operated by umbilical

A stacking conveyor (figure 11) was used behind the CM on the pendant independent of the CM control system.

90-m cuts to prevent the back of the
10

INS INITIAL INSTALLATION AND ALIGNMENT TO THE CM

The INS was installed inside of a large steel box in what is 2. The CM zero-reference point (ZRP) is inputted. The ZRP

normally the operator’s compartment of the CM. The placement

of the INS in reference to the target was accounted for to

eliminate offsets in the position calculations. The INS was then

initialized using the CM installation data. Software that acts as

the "user interface" and communicates with the CM-mounted

INS, facilitated this operation. This software is called AHITS

(provided by Honeywell), and it executes in the HORTA PC.

The steps taken to initialize the INS with the CM installation data

were:

1. Select a "Coordinate Frame Code." This code associates

the orientation of the INS as it is installed on the CM in X, Y,

and Z orientation. For this installation, +X pointed toward the

CM cutters (machine forward), +Y pointed toward the right side

of the CM (the operator side), and +Z pointed upward. The code

entered was 34.

for this installation was the center of the target. The parameters

entered into AHITS were X, Y, and Z, which represented

offset measurements from the ZRP to center mark on the top of

the INS. These measurements were 	15 in for the X, 	7.5 in

for the Y, and +64.5 in for the Z.

3. Enter the INS/CM Boresight Angles. These parameters

compensate for the alignment differences between the INS and

CM in azimuth, pitch, and roll (altitude). For example:

INS... azimuth 
 95.0(, pitch 
 5.0(, roll 
 	3.2(

CM... azimuth 
 97.0(, pitch 
 3.2(, roll 
 	1.2(

The parameters for this installation were all zero.

4. Command an INS shutdown. This causes the installation

parameters to be stored in the INS’s electrical erasable programmable read only memory.

INS OPERATION

After each INS power-up operation, the INS must be 3. Enter survey mode. This mode begins as soon as aligninitialized in the following steps: ment is completed. Newer or updated position data can be

1. Perform a ZRP position update. This position update 4. When the INS is to be powered down (for any reason), it

provides the INS with its starting position coordinates for should be commanded to shut down via the AHITS software.

alignment. The data required include the SPCS NAD27 grid The reason for this procedure is that while the INS is operational

code (for Wyoming it was 4901) and a measured northing, it continuously refines its internal calibrations and accuracies.

easting, and altitude for the target on the CM. The INS was designed to learn the characteristics of the machine

2. Wait for alignment to complete. The INS has a built-in on which it is installed and, in so doing, helps to improve INS

alignment mode that minimizes system errors. This alignment performance. Executing a commanded shutdown stores all of the

mode takes about 25 min to complete. Upon completion, learned information in the INS EEPROM; an uncommanded

AHITS provides an alignment completion message. shutdown does not.

entered at any time during the survey mode.

EQUIPMENT SETUP PROCEDURES

The RT was mounted on top of a CP, and a target was affixed The HA, VA, and SD obtained from the target on the CM were

to the top of a second CP. The RT was initialized according to entered into the spreadsheet to generate the corrected SPCS for

the manufacturer's requirements. The RT height (HI) above its the CM. These coordinates (northing, easting, and altitude) were

CP's top plate, as well as the signal height (HR) above its CP, was entered into the INS, RCS, and the Silicon Graphics, Inc., (SGI)

measured and recorded. The raw data (horizontal angle (HA), computer for the initial starting reference for the experiment. As

vertical angle (VA), slope distance (SD), and horizontal distance the coal was cut, data from the RT, INS, and RCS were recorded

(HD)) to the second CP were recorded. Next, the RT was put in triplicate by TRACKER, RCS, and SGI for redundancy.

into the remote mode (called RPU), and it was set to search for

the target that was placed on the CM.
CEP 
 1.1774

RMSn  RMSe

2 ,

RMSx 


M

N

i	1

X2

i

N

1/2

,

SEP 
 1.538

RMSn  RMSe  RMSa

3 ,

11

SYSTEMS ACCURACY

Honeywell cites an estimated two-dimensional (2-D) position SEP takes into account the altitude data and effectively

accuracy of 25 cm/hr circular error probable (CEP) and an provides a 3-D accuracy factor. SEP is the radius of a sphere,

azimuth accuracy of 0.028( with an azimuth oscillation of centered about true, such that any measured position, selected

0.0055( from the initial gyro-compass azimuth. The altitude from the total sample population, has a 50% probability of lying

accuracy of the INS was not specified. In the OP tests, only the inside the sphere. A 3-D normal distribution is assumed.

2-D position and altitude accuracy were measured. We combined Honeywell does not provide an SEP for the INS, but we derived

the altitude and the position data into a factor called spherical SEP1s for the OP test data. The SEP is computed as follows:

error probable (SEP) in order to present 3-D data.

CEP is the radius of a circle, centered about true, such that any

measured position, selected from the total sample population, has

a 50% probability of lying inside the circle. A 2-D normal

distribution is assumed. CEP is computed as follows:

where RMS is the RMS error of northing, RMS is the RMS error of altitude, n

RMS is the RMS error of easting, and 1.538 is the radii of 50% probability spheres (SEP). e

and 1.1774 is the radii of 50% probability circles The RT, which provided the base line for accuracy meas-

 (CEP). urements at the OP, has an accuracy factor (when operated in the

RMS error is the square root of the mean of the sum of the also has built-in software that provides for correction of

squared errors, relative to the reference value(s), for all meas- collimation, tracker collimation, and horizontal axis tilt errors.

urements in the sample population. RMS error is computed as In preparation for the OP tests, the RT’s electronic distance

follows: measuring instrument (EDMI) was checked for accuracy at an

where N 
 total number of measurements in the of Wyoming. The RT was tested at a distance of 150 m and

 sample, 430 m. At the 150-m marker, the RT measured 149.9878 m; at

and X 
 error in the i’th measurement with results include compensation for temperature, pressure, and transit i

 respect to the reference value. induced errors.)

RMS can also be thought of as the sample standard deviation.

where RMS is the RMS error of northing, n

RMS is the RMS error of easting, e

a

tracking mode) that is expressed as ±(10 mm  5 ppm). The RT 5

NGS base line site. An NGS program provides surveyors with

a means to detect and correct errors in EDMI’s at any of 300

EDMI calibration base lines throughout the United States. These

highly accurate base lines provide a locally accessible standard for

length measurement. We tested the RT against the CASPER

calibration base line near Casper, WY. This base line was

established in conjunction with the Professional Land Surveyors

the 430-m marker the RT measured 429.91999 m. (The RT

DATA ARCHIVING METHODOLOGY

Originally, data were to be collected by three different systems

(PC, SGI, and TRACKER). For a variety of reasons, data were

mainly taken by the PC, sometimes by the SGI, and never by the

TRACKER. For the data files taken, a file naming convention

was adopted. The first two characters of the file name were the

month (e.g., 09 
 September), the next two were the day (e.g., 13


 13th day of the month), the next two were the hour in 24-hr

format (e.g., 15 
 3:00 p.m.), and

Geodimeter System 4000 user manual. 5

the final two were the minutes (e.g., 22 
 22 min after the hour).

There was no particular convention used for the file extensions

until the data files were prepared for final analysis. The PC files

were given .pcu extensions and the SGI files were given .sgu

extensions.

The data collected were copied from shared memory. Each

block of data saved was composed of 39 elements. The elements
12

were delimited with a comma, and the block was ended with a CM state 1

carriage return. The elements were: CM state 2

INS easting CM center of rotation easting

INS northing CM center of rotation northing

INS altitude INS cross track

INS azimuth INS along rack

INS pitch INS delta azimuth

INS roll TRACKER easting

INS time in service TRACKER northing

INS status 0 TRACKER altitude

INS status 1 TRACKER HA

INS status 2 TRACKER VA

INS status TRACKER SD

INS alert 0 TRACKER time of day

INS alert 1 TRACKER temperature

INS alert 2 TRACKER barometric pressure

INS alert 3 CM current

CM state 0 CM conveyor swing angle

CM state 3

CM pan angle

CM shear angle

CM conveyor elevation angle

CM hydraulic pressure

Data were collected on about a 2-sec interval; this interval varied

somewhat.

DATA ANALYSIS

The objective of the OP test was to compare the primary 3. Reduce the SD to an HD.

output of the INS (northings, eastings, and altitude) to the values 4. Reduce the HD to the ellipsoidal surface.

derived from the output of the RT. Used at sea level, one can 5. Reduce the ellipsoidal surface to the grid. (The regenerally take the position output of the RT and directly compare duction of HD to the ellipsoidal surface and then to the grid can

it to that of the INS depending, of course, on the level of be combined into one "scale factor," depending on the level of

accuracy required for the analysis. The worksite altitude, accuracy required of the survey).

however, was over 1,500 m. Thus, temperature, pressure,

reduction of the HD to the ellipsoidal surface, and the reduction The following procedures described here generate the

of the HD from the ellipsoid to the grid had to be factored into coordinates and altitude:

the data reduction to calculate the resultant northings, eastings,

and altitude. Data required from the RT to perform these 1. The grid azimuth (GA) to the target is determined by

calculations are the HA, VA, and SD. Additionally, known adding the HA to the known GA from the RT to the CP.

coordinates (CP’s), must be used as reference. The temperature 2. Knowing the GA and the grid distance (GD) to the

and pressure also must be included. The corrections are only target on the CM, the coordinates of the target on the CM can be

applied to the SD, but the other parameters (HA and VA) are computed.

needed to calculate the coordinates and altitude. The corrections 3. Knowing the HD and the VA to the target on the CM,

to SD are described below: the altitude of the target can be computed.

1. The observed distance should be corrected for any target Although the above listed procedures can always be used to

or RT offsets. generate coordinates and altitude from the raw values (HA, VA,

2. The distance is corrected for atmospheric delays (varies and SD) supplied by the RT, the method can be simplified as

with temperature and pressure). In order to maintain an accuracy described below, which are the procedures we employed to

of 5 ppm (i.e., 1.5 mm over 305 m), it is necessary to measure the generate coordinates and altitude. A sample set of calculations is

temperature to an accuracy of 4 (F and a pressure to 0.25 in Hg provided later.

(305 m is used in many of the examples because this was the Measure the known distance between two CP points, such

distance between two of the CP's). as WEST to EAST, whose separation is accurately known. By

  


 	  	




13

comparing the HD against the known distance, a correction factor B. Determine the CM position

can be computed that combines the atmospheric effects on the

EDMI, which varies with temperature and pressure and the 1. Using the RT on MID, sight in the target on the CM,

reduction from HD to the ellipsoid and to the grid (the latter two and record results. The RT values obtained were HA 


of these corrections are constant). 292(111402, VA 
 89(201552, SD 
 298.133 ft, HI 
 0.935 ft,

By comparing the VA against the known difference in and HR 
 0.0 ft.

altitude, the coefficient of refraction can be computed. However, 2. Convert HA and VA to radians (HA 
 5.09975511158

we decided to ignore the coefficient of refraction because of a and VA 
 1.55942744597).

negligible impact on accuracy. If the temperature and pressure 3. Calculate HD:

were not compensated for, an error of 1.8 cm per 305 m of

distance would result. If the reduction to the ellipsoid (sea level HD 
 SD • sin(VA ) 
 298.133 ft • sin(1.55942744597)

on NAD27) and the reduction to the grid were not performed on

HD, an error of 10 cm per 305 m of distance would result. The 
 298.113733146 ft

coefficient of refraction is less crucial and was not factored into

the result. Ignoring it results in an error of about 0.3 mm per 4. Correct HD to HD using SF:

305 m of distance.

A sample set of calculations that was performed is as follows: HD 
 HD • SF 
 298.113733146 ft • 0.99978420607

A. Calculate the Scale Factor (SF) 
 298.049402012 ft

1. Put the RT on the MID CP and the target on the WEST 5. Determine the horizontal azimuth and convert it to

CP, and take a reading. The CP coordinates are MID (northing radians:

860867.346 ft, easting 324938.305 ft, altitude 5567.319 ft) and

WEST(northing 861084.255 ft, easting 324445.770 ft, altitude HAZIR 
 MODULO(HA ,%) 
 MODULO (5.09975511158,2%)

5573.685 ft). The RT values obtained

were HA = 0(001032, VA = 89(231042, SD = 538.325 ft, HI 
 
 5.09975511158

0.935 ft, and HR 
 0.3 ft.

2. Convert VA to radians (VA 
 1.55942744597). 6. Calculate the northing: r

3. Calculate the scale factor (SF): SF 
 GD/HD, where

GD is the true grid distance between CP's and HD is the measured Northing 
 860867.346 ft  HD • cos(HAZIR)

distance. Northing 
 860867.346 ft  298.049402012 ft •

(See equation at bottom of this page.) 7. Calculate the Easting

HD 
 SD • sin(VA ) 
 (538.325 ft) • sin(1.55942744597) Easting 
 324938.305 ft  HD • sin(HAZIR) r


 538.293932933 ft sin(5.09975511158)

SF 
 538.177772842 ft / 538.293932933 ft


 0.99978420607

r

r

r

c

c

r

c

 cos(5.09975511158)

Northing 
 860979.934463 ft

c

Easting 
 324938.305 ft  298.049402012 ft •

Easting 
 324662.338908 ft

C. Calculate the Altitude

Altitude 
 5567.319 ft  HD • cos(VA ) c r  HI-HR

Altitude 
 5567.319 ft  298.04940201 ft •

 cos(1.5594274459)  (0.935 ft 	 0)

Altitude 
 5571.642 ft

OP RESULTS

The data from the OP were primarily taken over 2 days

(September 13 and 14) and consisted of nine data files. The PC

collected data over both days; the SGI, only on September 13.

The PC generated three files on September 13 and one file on

September 14; the SGI generated five data files on September 13.

The first 90-m cut was performed on September 13; the second
14

Figure 14.—RT and INS position file 09130927.pcu.

Figure 15.—RT and INS altitude file 09130927.pcu.

90-m cut, on September 14. The data file collected and the 
 89.2306(, SD 
 538.33 ft, HI 
 0.935 ft, and HR 
 0.3 ft.

details of each are described below. The calculated SF was 0.99978825238. With the RT on MID and the

File 09130927.pcu

The RT was placed on the MID CP, and the target was

placed on the WEST CP. The RT data were HA 
 0.0(, VA

target on the CM, the RT data were HA 
 291.1544(, VA


 88.1948(, and SD 
 403.588 ft. The calculated coordinates of the

starting point of the CM were northing 
 861013.611 ft, easting 


324562.4326 ft, and altitude 
 5580.008 ft. The file consisted of 603

blocks of data. The RT and the INS position data plot is shown in

figure 14. The RT and the INS altitude data plot is shown in figure 15.

Ascatter plot of the RT and the INS northing and easting differences is

shown in figure 16.

File 09131309.pcu

The RT was placed on the MID CP, and the target was placed on

the WEST CP. The RT data were HA 
 0.0003(,
15

Figure 16.—RT and INS northing and easting difference file 09130927.pcu.

Figure 17.—RT and INS position file 09131309.pcu.

The calculated SF was 0.9997982135. With the RT on MID and altitude 
 5571.642 ft. The file consisted of 735 blocks of data.

the target on the CM, the RT data were HA 
 292.114(, VA 
 The RT and the INS position data plot is shown in fig-ure 20.

89.2055(, and SD 
 298.133 ft. The calculated coordinates of The RT and the INS altitude data plot is shown in figure 21. A

the starting point of the CM were northing scatter plot of the RT and the INS northing and easting


 860979.936 ft, easting 
 324662.342 ft, and altitude differences is shown in figure 22.


 5571.642 ft. The file consisted of 977 blocks of data. The RT

and the INS position data plot is shown in figure 17. The RT

and the INS altitudedata plot is shown in figure 18. A scatter plot

of RT and the INS northing and easting differences is shown in

figure 19.

File 09131522.pcu

The RT was placed on the MID CP, and the target was 88.1948(, and SD 
 403.588 ft. The calculated coordinates of

placed on the WEST CP. The RT data were HA 
 0.0003(, VA the starting point of the CM were northing


 89.2304(, SD 
 538.325 ft, HI 
 0.935 ft, and HR 
 0.3 ft. 
 861013.611 ft, easting 
 324562.4326 ft, and altitude

The calculated SF was 0.9997982135. With the RT on MID and 
 5580.008 ft. The file consisted of 666 blocks of data. The RT

the target on the CM, the RT data were HA and the INS position data plot is shown in figure 23. The RT


 292.114(, VA 
 89.2055(, and SD 
 298.133 ft. The cal- and the INS altitude data plot is shown in figure 24. A scatter

culated coordinates of the starting point of the CM were northing plot of the RT and the INS northing and easting differences is


 860979.936 ft, easting 
 324662.342 ft, and shown in figure 25.

File 09130928.sgu

The RT was placed on the MID CP, and the target was

placed on the WEST CP. The RT data were HA 
 0.0(, VA 


89.2306(, SD 
 538.33 ft, HI 
 0.935 ft, and HR 
 0.3 ft. The

calculated SF was 0.99978825238. With the RT on MID and

the target on the CM, the RT data were HA 
 291.1544(, VA 

16

Figure 18.—RT and INS altitude file 09131309.pcu.
17

Figure 19.—RT and INS northing and easting difference file 09131309.pcu.

Figure 20.—RT and INS position file 09131522.pcu.
18

Figure 22.—RT and INS northing and easting difference file 09131522.pcu.

Figure 21.—RT and INS altitude file 09131522.pcu.
19

Figure 23.—RT and INS position file 09130928.sgu.

Figure 24.—RT and INS altitude file 09130928.sgu.
20

Figure 25.—RT and INS northing and easting difference file 09130928.sgu.

File 09131307.sgu

The RT was placed on the MID CP, and the target was

placed on the WEST CP. The RT data were HA 
 0.0003(, VA


 89.2304(, SD 
 538.325 ft, HI 
 0.935 ft, and HR


 0.3 ft. The calculated SF was 0.9997982135. With the RT on

MID and the target on the CM, the RT data were HA


 292.114(, VA 
 89.2055(, and SD 
 298.133 ft. The calculated coordinates of the starting point of the CM were northing 


860979.936 ft, easting 
 324662.342 ft, and altitude The RT data were HA 
 0.0003(, VA 
 89.2304(, SD


 5571.642 ft. The file consisted of 539 blocks of data. The RT 
 538.325 ft, HI 
 0.935 ft, and HR 
 0.3 ft. The calculated SF

and the INS position data plot is shown in figure 26. The RT was 0.9997982135. With the RT on MID and the target on the

and the INS altitude data plot is shown in figure 27. A scatter CM, the RT data were HA 
 292.114(, VA 
 89.2055(, and SD

plot of the RT and the INS northing and easting differences is 
 298.133 ft. The calculated coordinates of the starting point of

shown in figure 28. the CM were northing 
 860979.936 ft, easting

File 09131450.sgu

The RT was placed on the MID CP, and the target was

placed on the WEST CP. The RT data were HA 
 0.0003(, VA


 89.2304(, SD 
 538.325 ft, HI 
 0.935 ft, and HR 
 0.3 ft.

The calculated SF was 0.9997982135. With the RT on MID and

the target on the CM, the RT data were HA


 292.114(, VA 
 89.2055(, and SD 
 298.133 ft. The

calculated coordinates of the starting point of the CM were

northing 
 860979.936 ft, easting 
 324662.342 ft, and altitude


 5571.642 ft. The file consisted of 413 blocks of data. The RT

and the INS position data plot is shown in fig-ure 29. The RT

and the INS altitude data plot is shown in figure 30. A scatter

plot of the INS northing and easting differences is shown in

figure 31.

File 09131525.sgu


 324662.342 ft, and altitude 
 5571.642 ft. The file consisted

of 817 blocks of data. The RT and the INS position data plot is

shown in figure 32. The RT and the INS altitude data plot is

shown in figure 33. A scatter plot of the RT and the INS

northing and easting differences is shown in figure 34.
21

Figure 26.—RT and INS position file 09131307.sgu.

Figure 27.—RT and INS altitude file 09131307.sgu.
22

Figure 28.—RT and INS northing and easting difference file 09131307.sgu.

Figure 29.—RT and INS position file 09131450.sgu.
23

Figure 30.—RT and INS altitude file 09131450.sgu.

Figure 31.—RT and INS northing and easting difference file 09131450.sgu.
24

Figure 32.—RT and INS position file 09131525.sgu.

Figure 33.—RT and INS altitude file 09131525.sgu.
25

Figure 34.—RT amd INS northing and easting difference file 09131525.sgu.

File 09131600.sgu

The RT was placed on the MID CP, and the target was

placed on the WEST CP. The RT data were HA 
 0.0003(, VA


 89.2304(, SD 
 538.325 ft, HI 
 0.935 ft, and HR 
 0.3 ft.

The calculated SF was 0.9997982135. With the RT on MID and

the target on the CM, the RT data were HA


 292.114(, VA 
 89.2055(, and SD 
 298.133 ft. The calculated coordinates of the starting point of the CM were northing


 860979.936 ft, easting 
 324662.342 ft, and altitude 


5571.642 ft. The file consisted of 816 blocks of data. The RT

and the INS position data plot is shown in fig-ure 35. The RT

and the INS altitude data plot is shown in figure 36. A scatter

plot of the RT and the INS northing and easting difference is

shown in figure 37.

File 09140933.pcu

The RT was placed on the MID CP, and the target was

placed on the EAST CP. The RT data were HA 
 0.0006(, VA


 90.5814(, SD 
 609.585 ft, HI 
 0.935 ft, and HR 
 0.3 ft.

The calculated SF was 0.999729317206. With the RT on MID

and the target on the CM, the RT data were HA


 294.3028(, VA 
 88.3522(, and SD 
 403.667 ft. The calculated coordinates of the starting point of the CM were northing


 861034.698 ft, easting 
 324571.217 ft, and altitude 


5578.185 ft. The file consisted of 3,170 blocks of data. The RT

and the INS position data plot is shown in fig-ure 38. The RT

and the INS altitude data plot is shown in figure 39. A scatter plot of the RT and the INS northing and easting

differences is shown in figure 40.

HIGHWALL RESULTS

The highwall tests required a new CP that was in line with

the hole, because the RT and target are a line-of-sight system.

Any obstructions stop the data flow. We only expected to obtain

a small amount of data from the test. The new CP was named

"SEC". With the RT on MID and the target on EAST, the RT

measured HA 
 359.5954(, VA 
 90.5813(, SD


 609.59 ft, HI 
 0.935 ft, and HR 
 0.3 ft. The calculated SF

was 0.999721. A tripod was placed at the intended SEC point,

and a target was mounted on it. With the RT on MID and the

target on SEC, the RT measured HA 
 106.3055(, VA


 90.5353(, and SD 
 188.53 ft. The SEC coordinates calculated from these values were northing 
 860813.7739 ft, easting


 325118.9844 ft, and altitude 
 5565.3 ft. The details of the

data file generated for the highwall test are described below.

File 09261449.pcu

The RT was placed on the SEC CP, and the target was

placed on the MID CP. The RT data were HA 
 0.0004(, VA


 89.2336(, SD 
 188.565 ft, HI 
 0.854 ft, and HR 
 0.3 ft.

The calculated SF was 0.999458489729. With the RT on SEC

and the target on the CM, the RT data were HA 
 18.4215(, VA


 90.0256(, and SD 
 77.487 ft. The calculated coordinates of

the starting point of the CM were northing


 860887.1288 ft, easting 
 325143.8196 ft, and altitude


 5566.0870 ft. The file consisted of 1,502 blocks of data. The

RT and the INS position data plot is shown in figure 41. The RT

and the INS altitude data plot is shown in figure 42.
26

Figure 35.—RT and INS position file 09131600.sgu.

Figure 36.—RT amd INS altitude for 09131600.sgu.
27

Figure 37.—RT and INS northing and easting difference file 09131600.sgu.

Figure 38.—RT and INS position file 09140933.pcu.
28

Figure 39.—RT and INS altitude file 09140933.pcu.

Figure 40.—RT and INS northing and easting difference file 09140933.pcu.
29

Figure 41.—RT and INS position file 09261449.pcu.

Figure 42.—RT and INS altitude file 09261449.pcu.

A scatter plot of the RT and the INS northing and easting

differences is shown in figure 43.

The CEP’s and SEP’s for all of the OP files are shown in

table 2. The CEP’s and SEP’s were calculated based on the

data contained in the table. The minutes shown are cumulative

from file to file. The last position update is shown in the first file

that it was performed. The CEP’s and SEP’s carry over from file

to file depending on the last position update performed.

Essentially, the data used to calculate the CEP’s and SEP’s were

extracted from all of the files associated with one position update

and were divided by the total amount of time that data were

recorded in order to calculate the CEP’s and SEP’s. The CEP’s

ranged from 3.62 cm/hr to 28.16 cm/hr; the SEP’s ranged from

10.18 cm/hr to 49.07 cm/hr over the entire series of tests. The

mean of the CEP’s was 13.1 cm/hr; the mean of the SEP’s was

22.44 cm/hr. More data should be obtained in order to improve

the confidence level of the results presented. The data in table 2

are shown in U.S. survey feet, but the results are presented in

metric in order to be consistent with other users of the INS who

do not use the NAD27 datum.
30

Figure 43.—RT and INS northing and easting difference file

09261449.pcu.

Table 2.—Data file summaries

File name Time Delta east sq Delta north sq Delta alt sq Results

09120927.pcu 9:27 start 162.9925 sum 42.6932 sum 218.696 sum CEP 
 0.432 ft/hr

Last position update 9:27 10:26 end 692 blocks 692 blocks 692 blocks SEP 
 0.665

(59 min)

09131309.pcu 13:09 start 172.5297 sum 139.732 sum 715.761 sum

Last position update 13:09 15:22 end 976 blocks 976 blocks 976 blocks

(133 min)

09131522.pcu 15:22 start 758.6947 sum 153.9687 sum 10600.6 sum CEP 
 0.119 ft/hr

16:37 end 734 blocks 734 blocks 734 blocks SEP 
 0.334

(208 min)

09140933.pcu 9:33 start 33830.48 sum 6414.007 sum 62467.1 sum CEP 
 0.59 ft/hr

Last position update 9:33 14:14 end 3169 blocks 3169 blocks 3169 blocks SEP 
 0.999

(281 min)

09261449.pcu 14:49 start 519.4153 sum 13973.84 sum 20264.5 sum CEP 
 0.924 ft/hr

Last position update 14:49 17:08 end 1501 blocks 1501 blocks 1501 blocks SEP 
 1.61

(139 min)

09130928.sgu 9:26 start 119.0189 sum 31.26214 sum 11.1372 sum CEP 
 0.376 ft/hr

Last position update 9:27 10:28 end 665 blocks 665 blocks 665 blocks SEP 
 0.394

(62 min)

09131307.sgu 13:06 start 119.568 sum 25.99194 sum 89.39 sum

Last position update 13:09 13:55 end 538 blocks 538 blocks 538 blocks

(49 min)

09131450.sgu 14:49 start 357.0373 sum 186.7908 sum 577.26 sum

15:25 end 412 blocks 412 blocks 412 blocks

(85 min)

09131525.sgu 15:25 start 279.9923 sum 73.30422 sum 868.867 sum

15:46 end 220 blocks 220 blocks 220 blocks

(106 min)

09131600.sgu 15:58 start 759.8401 sum 80.34661 sum 16894.0 sum CEP 
 0.139 ft/hr

17:12 end 816 blocks 816 blocks 816 blocks SEP 
 0.416 

(180 min)
31

SUMMARY

The Pittsburgh Research Center under the former U.S. that it may provide adequate navigation of the CM while mining

Bureau of Mines developed technology that provides remote coal. However, additional testing using the same methods

control and navigation of continuous mining machines to en- presented here is required to minimize the anomalies and improve

hance the safety of U.S. underground coal mine workers. The the confidence level of the CEP presented 

control system was built in modular form so that it can be adapted (13.1 cm/hr) and the SEP presented (22.44 cm/hr). Final accurto most coal mining machine applications using only the modules acies for CEP and SEP in the same range as the presented acrequired for a particular mining scenario. The technology curacies would indicate that the HORTA is a viable candidate for

developed permits the operator to effectively work at distances up reasonably accurate CM navigation. This report has detailed the

to 150 m from the hazardous coal production area (the face). The entire system, as well as all of the performance results.

INS employed by the research team was tested in a variety of coal

mining conditions; results indicate

ACKNOWLEDGMENTS

The team members and the responsibility of each are in- Timothy J. Matty - CM systems and operation; Kenneth Perry -

cluded here to acknowledge their contributions to the success of mine development administrator, Interwest Mining Co.;

this project: Donna L. Anderson - data acquisition and display; William H. Schiffbauer - INS, RT, control system, data

John Elkin - Glenrock mine manager; Edward F. Fries - acquisition, data analysis; Michael J. Schmid - Honeywell INS

TRACKER software; Christopher C. Jobes, Ph.D. - RCS; Jon A. system representative; George H. Schnakenberg, Jr., Ph.D. -

Hummer (Spacemark, Inc. (SMI)) - CM systems and operation; project manager, data analysis, spread sheets; Raymond W.

William H. Lewis - video systems and control trailer; Timothy J. Vereneck (SMI) - CM systems and operation; and Jeffrey H.

Lutz - stacking conveyor and CM operation; Welsh - group supervisor.

REFERENCES

Buckner RB [1993]. State plane coordinates in modern surveying prac- Sammarco, JJ [1993]. Field evaluation of the modular azimuth and potice. Johnson City, TN. sitioning system (MAPS) for a continuous mining machine. Pittsburgh, PA:

Hamilton J [1996]. Survey recommendations continuous miner inertial U.S. Department of the Interior, Bureau of Mines, IC 9354.

system test and analysis. Prepared for the U.S. Department of the Interior, Savage PG [1991]. Introduction to strapdown inertial navigation systems.

Bureau of Mines, Pittsburgh Research Center, Pittsburgh, PA. Plymouth, MN: Strapdown Associates, Inc.
32

APPENDIX A.—IN-DEPTH DESCRIPTION OF THE REFERENCE COORDINATE SYSTEM

Coordinate systems are the means of referencing geographic referenced to determine the basic accuracy of the INS. The

information to locations on the Earth’s surface and are the NAD27 system was established in the late 1920's for use in the

reference to standard models of the Earth’s surface represented by United States and was based on the astronomic location of an

an oblate spheroid of revolution (a flattened sphere). The origin station called Meades Ranch located in Kansas. Meades

equatorial diameter (the major axis) of the Earth is approximately Ranch, along with an azimuth to a nearby station called Waldo,

27 miles greater than the polar diameter (minor axis). Generally, became the origin for geodetic coordinates in the United States.

the Earth is interchangeably referred to as a "spheroid" or an The datum was chosen to "best fit" the figure of the Earth in the

"ellipsoid." continental United States (as best as could be done at the time).

The shape of any Earth datum, such as "sea level," is not a This position was propagated throughout the network primarily

perfect spheroid due to variations in the strength and direction of by triangulation and later by trilateration. Triangulation consisted

gravity. This imperfect shape is called the geoid. The geoid is an of a series of triangles or quadrilaterals in which all angles were

equipotential surface, perpendicular to the direction of gravity at measured, and base lines (a surveyed line established with more

all points. The plumb line, or the vertical (defined by gravity), is than usual care to which surveys are referred for coordination and

affected by land masses and the density of crustal rock near the correlation) were measured at given intervals to provide scale

surface. This causes the surface of the geoid to undulate, with the control. In addition, astronomic observations were made at

physical effect of "bumps" certain stations (Laplace stations, which compensate for the

or waviness. The geoid is therefore not a mathematical surface difference between astronomic and geodetic azimuth) to control

like a spheroid. the tendency of the network to swing. Trilateration, which

The geoid shape has been determined by astrogeodetic and became feasible with the advent of EDMI's, consists of

gravimetric methods. The equipotential surface is determined by measurements of both angles and distances in a polygon, or often

a least squares fit of the observed data. Its position is unknown a chain of lines that formed a traverse (a method of surveying in

exactly because the data are not continuous. There can be local which lengths and directions of lines between points on the Earth

anomalies between observation stations causing deviations from are obtained by or from field measurements and used in

what the best fit indicates. determining the positions of the points). The inclusion of spaceFor all except geodetic-related work, the geoid and the spher- based methods of measurements (first using stellar cameras, then

oid have been considered to coincide and are simply called "sea Doppler, and later GPS), along with the possibility of directly

level" by most surveyors. The differences are not important for measuring lines tens to hundreds of kilometers long with EDMI's,

local surveys where high accuracy may be of little concern, but led to the discovery of distortions in the existing network, which

in high-accuracy surveys, the differences cannot be ignored. had been built up piecemeal over decades. This led NGS to

The position of a point on any spheroid used to describe the undertake a total readjustment of the interconnected network that

Earth is represented by latitude and longitude, which are angular covered North America and Central America as far south as

coordinates. Latitude is the angle from the equatorial plane to the Panama. The result was the development of a reference system

point measured along a meridian line. Latitudes can be either that best fit the world as a whole and that has its origin at the

north or south of the equator. Longitude of a point is the angle center of the Earth. This is the Geodetic Reference System of

measured east or west of a 0( reference meridian plane to a 1980 (GRS80), which is nearly identical to the satellite system,

meridian plane through the point. The reference meridian is World Geodetic System of 1984 (WGS84). The readjustment

called the "prime meridian" and passes through Greenwich, U.K. was completed in 1988. This new datum is known as the North

In surveying, geodetic positions vary according to which American Datum of 1983, 1986 adjustment (NAD83), and has

spheroid is being used at a particular place and point in time, and an absolute accuracy of about 1 m across the country, with

this must be considered when comparing values of spherical relative accuracies of about 3 ppm. Since then, high-precision

coordinates. GPS methods have been used to establish a network of accurate

There have been at least 14 different ellipsoids used to (0.1 to 1 ppm) stations known as HARN. These HARN stations

approximate the oblate spheroid best representing the size and result in a homogenous network with absolute accuracies of about

shape of the geoid called Earth. The Clarke Spheroid of 1866 0.1 m. The difference between NAD27 and NAD83 varies all

endured in the United States from 1866 to 1986. Honeywell over the country. In the area in Wyoming, where our test was

chose to use that model for the INS system discussed in this run, the difference is about 44 m. NAD27, NAD83, GRS80,

report. There are, however, more recent ellipsoids. The Clarke’s WGS84, and HARN have been discussed here because these

1866 spheroid datum for the United States is known as the North systems were used to set up the local CP's used at the Wyoming

American Datum of 1927 (NAD27). The dimensions of the site.

Clarke's 1866 spheroid for the United States is well defined, but Simply put, the SPCS NAD27 provides a means to use

that is not the case for the entire Earth. plane surveying methods on a spherical Earth. NAD27 provided

The INS used by us employs the State Plane Coordinate means, through mathematical projections, for precise conversion

System (SPCS) called NAD27 [Buckner 1993]. This was chosen of latitudes and longitudes into X and Y (cartesian) coordinates,

because most U.S. underground coal mine maps conform to referred to assigned origins in each State. Each State also has

NAD27. More accurate systems (e.g., WGS84), however, were enacted legal statutes adopting a mathematical definition and
zone. Some States have multiple zones. The zones for all States data and results in feet rather than meters for uniformity. For

are given four-digit codes for unique identification. The zones comparison purposes, there are 3.280833333 ft/m for the U.S.

are called projections, of which there are three types: Lambert, survey foot. There is also an International survey foot; it is

Transverse Mercator, and Oblique Mercator. The Lambert system 3.280839895 ft/m.

is usually used for states whose long dimension is east-west Until very recently, elevations were referenced to the

direction; the Transverse Mercator system is used for States that National Geodetic Vertical Datum of 1929 (NGVD29) which,

lie north-south. The only state using Oblique Mercator is Alaska. prior to 1973, was known as the Sea Level Datum of 1929. Its

The site of the OP experiments resides in Wyoming SPCS East origin is the observed heights of mean sea level at 26 tide gauges,

Zone 4901; it is based on a Transverse Mercator projection. 21 in the United States and 5 in Canada. Because mean sea level

NAD27 is specified in U.S. survey feet, not in meters. is not constant over time, the name for the datum was not correct.

Therefore, the author was forced to keep most of the analysis The datum is not mean sea level, the geoid, or any other

equipotential surface. As with the Horizontal Network, the

Vertical Network developed distortions over time and crustal

motion occurrences affected much of the networks. This led to

the decision to tune the network, and the North American Vertical

Datum of 1988 (NAVD88) came into being. For this datum, the

height of the primary tidal benchmark at Father Point/Rimouski,

Quebec, Canada, was held as the fixed constraint. The mark is

located at the mouth of the St. Lawrence River. The research

team used NGVD29 as its reference for the INS.
34

DHHS (NIOSH) Publication No. 98-101

November 1997