Acrobat is a registered trademark of Adobe Corporation in the USA. Microsoft Windows and Microsoft SQL Server are trademarks of Microsoft Corporation in the USA and / or other countries. Crystal Reports is a trademark or registered trademark of business Objects. This document is intended for those responsible for installing and configuring the Wenco system programs.
Acrobat is a registered trademark of Adobe Corporation in the USA. Microsoft Windows and Microsoft SQL Server are trademarks of Microsoft Corporation in the USA and / or other countries. Crystal Reports is a trademark or registered trademark of business Objects. This document is intended for those responsible for installing and configuring the Wenco system programs.
Acrobat is a registered trademark of Adobe Corporation in the USA. Microsoft Windows and Microsoft SQL Server are trademarks of Microsoft Corporation in the USA and / or other countries. Crystal Reports is a trademark or registered trademark of business Objects. This document is intended for those responsible for installing and configuring the Wenco system programs.
Wenco International Mining Systems Ltd. 2014 Wenco International Mining Systems Ltd. All rights reserved. 100 - 10271 Shellbridge Way, Richmond, B.C. V6X 2W8 Canada email: documentation@wencomine.com Acrobat is a registered trademark of Adobe Corporation in the USA. Microsoft Windows and Microsoft SQL Server are trademarks or registered trademarks of Microsoft Corporation in the USA and/or other countries. Crystal Reports is a trademark or registered trademark of Business Objects All other products or company names are used for identification purposes only, and may be trademarks of their respective owners. 2/25/2014 What's in this Manual This document contains information on installing and configuring BenchManager. Intended Audience This document is intended for those responsible for installing and configuring the Wenco system programs. This includes Wenco Technical Services personnel and may include mine site system administrators. BenchManager 2014 Wenco International Mining Systems Ltd. i Table of Contents ....................................................................................................................... 1 Chapter 1: Overview .............................................................................................................................. 1 About BenchManager .............................................................................................................................. 2 System Requirements ....................................................................................................................... 3 Chapter 2: Installing BenchManager .............................................................................................................................. 3 Install BenchManager on the MDT ....................................................................................................................... 4 Chapter 3: Configuring BenchManager .............................................................................................................................. 4 Step 1: Configure the Bench.ini and AGSConfig.ini Files .............................................................................................................................. 12 Step 2: Configure Registry Keys and WLAN Communications .............................................................................................................................. 14 Step 3: Start Wenco MDT and BenchManager Software .............................................................................................................................. 14 Step 4: (Only ALIGN-installed Shovels/Backhoes) Calibrate ALIGN Feature .............................................................................................................................. 15 Step 5: (If Using MDT5) Make Sure MDT3\Dispatch Buttons is Removed .............................................................................................................................. 15 Step 6: (If Using Fleet Awareness) Set Up Proximate Equipment Display ....................................................................................................................... 17 Chapter 4: Upgrading BenchManager .............................................................................................................................. 17 Step 1: Back Up the Bench.ini and AGSConfig.ini Files .............................................................................................................................. 17 Step 2: Install and Configure Upgrade .............................................................................................................................. 19 Step 3: Update Wenco Parameters ....................................................................................................................... 20 Appendices .............................................................................................................................. 20 Appendix 1: BenchManager Registry Keys .............................................................................................................................. 21 Appendix 2: AGS Installation for Shovels and Backhoes .............................................................................................................................. 33 Appendix 3: BenchManager Offset Measurements BenchManager 2014 Wenco International Mining Systems Ltd. 1 Chapter 1: Overview Chapter 1: Overview About BenchManager BenchManager is a high-precision GNSS equipment-tracking system that provides bench elevation monitoring and ore quality control for loading and grading units. BenchManager uses onboard graphical real-time displays that show equipment orientation over the mine plan. Dig block coordinates, ore quality information, and digital terrain model files (DTM) are sent to BenchManager from the host computer system, and work performance data is returned from BenchManager. Use BenchManager to: load designs and maps that are transferred to the BenchManager unit from the dispatcher office. display a visual map so that the equipment unit operator can see a realtime display of the current ramp, dump, blast perimeters, hazardous areas, real-time floor, and face positions. transmit information about the working area back to the dispatch office for surveyors and engineers to use. BenchManager 2014 Wenco International Mining Systems Ltd. 2 Chapter 1: Overview System Requirements The mine system must have the following installed in order to use BenchManager: a configured Wenco Server (see the Wenco Server Installation Guide for information on the Wenco applications and services required on a Wenco Server). any RTK-compatible GPS Base Station. a Mesh radio network for transmitting GPS corrections and maps, and for receiving back the current floor and face positions. Wenco's BenchView software (see the BenchView Installation Guide for information on installing and configuring BenchView and the FTP Server for BenchView/BenchManager communications). In addition, installation on the equipment unit requires: a GPS enclosure to house the Novatel dual frequency GPS receiver and power supply. a GPS Antenna to receive positioning messages from satellites. a Mesh Antenna/WLAN AntennaAntennex 3dB gain antenna for communication with the radio network. a Mobile Data Terminal (MDT) touchscreen computer and display with Wenco MDT software and Wenco BenchManager software installed to store data and run BenchManager. (only if you are using MOBA or Novatron pitch and roll sensors) one of either: a PEAK PC104+ board installed in the Octagon C2, or a ruggedized PEAK dongle cable connected to a USB port on the Octagon C2. BenchManager 2014 Wenco International Mining Systems Ltd. 3 Chapter 2: Installing BenchManager Chapter 2: Installing BenchManager Install BenchManager on the MDT The BenchManager software is installed after the MDT software has been installed. Exit from the MDT software before running the BenchManager installation. To install the BenchManager software: 1. Browse to the BenchManager folder on the network or USB drive and double-click setup.exe. 2. Click Next at the Welcome screen. 3. Choose Accept on the License Agreement screen, and click Next. 4. Click Install. 5. Click Finish. BenchManager 2014 Wenco International Mining Systems Ltd. 4 Chapter 3: Configuring BenchManager Chapter 3: Configuring BenchManager Step 1: Configure the Bench.ini and AGSConfig.ini Files For each machine with BenchManager software installed, the configuration file should be completed before the hardware is installed on the equipment. 1. Use Windows Explorer to open the Bench.ini file (located in the C:\Program Files\Wenco\BenchManager\Config folder). 2. Refer to the BenchManager Parameters.xls document to configure the Bench.ini parameters. Below are the CRITICAL Bench.ini parameters that must be modified. (Parameters not listed here have default values that work for most situations.) Note: Units of Measure (UOM) are defined by the transformation settings under [local_grid]. All offset measurements must be measured in the UOM used by the site. Parameters Common to All Equipment Types Section Parameter Parameter Options Comments [App] elevation_unit= feet, meter [Vehicle] gps_height_offset= float value Difference between the local datum and the MSL (Mean Sea Level) datum. [Vehicle] antenna_height_offset= negative float value Vertical offset from the GPS antenna to the ground. [Vehicle] toe_radius= positive float value (Defined as dig_radius in the BenchView Equipment Editor.) Used to display the mined out area, it is the distance to the toe of the slope. The toe radius will vary from machine to machine, based on the equipment size. BenchManager 2014 Wenco International Mining Systems Ltd. 5 Chapter 3: Configuring BenchManager [Vehicle] crest_radius= positive float value (Defined as crest_buffer in Wenco Configuration Manager.) Distance to the crest of the slope with respect to the center of the machine. [Tilt] type= blank: Select this if you are not using a pitch and roll sensor. GPS: On a loader or dozer, this uses the change in elevation to measure the pitch. On a shovel, this uses the rotation of the shovel to measure pitch and roll. MOBA: This uses the pitch and roll sensor by MOBA. It must be must be aligned with the direction of travel and installed on a flat surface. Note: There are additional INI parameters to set for MOBA that are listed in the [MOBA] section of the BenchManager Parameters.xls file. See the BenchManager Parameters.xls file for details and options. Novatron: These are the same BenchManager 2014 Wenco International Mining Systems Ltd. 6 Chapter 3: Configuring BenchManager sensors used for the Arm Geometry system. See Appendix 2: AGS Installation for Shovels and Backhoes of the BenchManager Installation Guide for installation instructions in or on the cab. Note: There are additional INI parameters to set for Novatron that are listed in the [Novatron] section of the BenchManager Parameters.xls file. See the BenchManager Parameters.xls file for details and options. [Local Grid] cmeridian= positive or negative integer UTM central meridian. [Local Grid] k1= float value Local coordinate transformation scale factor. [Local Grid] k2= float value Local coordinate transformation scale factor. [Local Grid] shiftx= float value Local coordinate transformation shift in easting. [Local Grid] k3= float value Local coordinate transformation scale factor. [Local Grid] k4= float value Local coordinate transformation scale factor. [Local Grid] shifty= float value Local coordinate BenchManager 2014 Wenco International Mining Systems Ltd. 7 Chapter 3: Configuring BenchManager transformation shift in northing. [Local Grid] map_orgx= float value Easting coordinate that defines the origin of the cut/fill grid. [Local Grid] map_orgy= float value Northing coordinate that defines the origin of the cut/fill grid. Parameters Specific to Shovels/Backhoes Section Parameter Parameter Options Comments [Vehicle] type= shovel backhoe [Vehicle] machine_width= positive float value Used to calculate the four corners' position of the vehicle. It defines the width of the rectangle from the center of the machine. This is required for exclusion zone detection. [Vehicle] rear_length= positive float value Used to calculate the four corners' position of the vehicle. It defines the rear length of the rectangle from the center of the machine. This is required for exclusion zone detection. [Vehicle] boom_length= float value Scraper: negative float value Other types: Measured from the center of rotation/ center of the machine to the bucket center. It is also used to define the proximity BenchManager 2014 Wenco International Mining Systems Ltd. 8 Chapter 3: Configuring BenchManager positive float value rectangle around the center of the machine. [Vehicle] dx= float value Offset from the GPS antenna to the center of the machine. [Vehicle] dy= float value Offset from the GPS antenna to the center of the machine. [Vehicle] dxr= float value (Used in NovAtel ALIGN GPS only.) Offset from the remote GPS antenna to the center of rotation. (Shovels and backhoes use hdg_corr instead.) [Vehicle] dyr= float value (Used in NovAtel ALIGN GPS only.) Offset from the remote GPS antenna to the center of rotation. (Shovels and backhoes use hdg_corr instead.) Parameters Specific to Loaders/Dozers Section Parameter Parameter Options Comments [Vehicle] type= dozer loader [Vehicle] machine_width= positive float value Used to calculate the four corners' position of the vehicle. It defines the width of the rectangle from the center of the machine. BenchManager 2014 Wenco International Mining Systems Ltd. 9 Chapter 3: Configuring BenchManager [Vehicle] rear_length= positive float value Used to calculate the four corners' position of the vehicle. It defines the rear length of the rectangle from the center of the machine. [Vehicle] wheel_width_offset= positive float value Offset from the center of the machine to the center of the track or wheel. [Vehicle] wheel_length_offset= positive float value Distance from the center of the machine forward to the front of the wheels or track. [Vehicle] dx= float value Offset from the GPS antenna to the center of the machine. [Vehicle] dy= float value Offset from the GPS antenna to the center of the machine. [Vehicle] dxr= float value (Used in NovAtel ALIGN GPS only.) Offset from the remote GPS antenna to the center of rotation. (Shovels and backhoes use hdg_corr instead.) [Vehicle] dyr= float value (Used in NovAtel ALIGN GPS only.) Offset from the remote GPS antenna to the center of rotation. (Shovels and backhoes use hdg_corr instead.) BenchManager 2014 Wenco International Mining Systems Ltd. 10 Chapter 3: Configuring BenchManager AGS Parameters Section Parameter Parameter Options Comments [Vehicle] AGSInstalled= 1 - the vehicle has AGS installed Indicates whether or not the vehicle has AGS installed. [Vehicle] joint_offset_hori= positive float value Horizontal distance from the vehicle center to the boom joint. [Vehicle] joint_offset_vert= positive float value Vertical distance from the ground to the boom joint. 3. Refer to the BenchManager Parameters.xls document to configure the AGSConfig.ini parameters. Below are the CRITICAL AGSConfig.ini parameters that must be modified. (Parameters not listed here have default values that work for most situations.) Notes: Measurements will be provided by the site surveyors. For the MachineName parameters, all options are listed in the .ini file. These are your only options. Parameters Specific to Backhoes with AGS (Be sure to modify the parameters associated with the correct model type.) Section Parameter Parameter Comments BenchManager 2014 Wenco International Mining Systems Ltd. 11 Chapter 3: Configuring BenchManager Options [<MachineName>] BoomLength= float value Measured on the boom from the cab pin to the arm pin. [<MachineName>] ArmLength= float value Measured on the arm from the boom pin to the bucket pin. [<MachineName>] BucketLength= float value Measured on the bucket from the arm pin to the bucket teeth. [<MachineName>] BucketSensorDirectMount= F - mounted on linkarm Indicates whether the bucket sensor is mounted directly on the bucket or on the linkage arm. [<MachineName>] BaseLength= float value Distance from arm_bucket_pivot to arm_linkage_pivot. [<MachineName>] LinkageLength= float value Distance from arm_linkage_pivot to linkage_transmit_pivot. [<MachineName>] TransmitArmLength= float value Distance from linkage_transmit_pivot to transmit_coupler_pivot. [<MachineName>] CouplerLength= float value Distance from transmit_coupler_pivot to arm_bucket_pivot. [<MachineName>] BaseAngle= float value Angle from boom_arm_pivot to arm_bucket_pivot to arm_linkage_pivot. [<MachineName>] Bucket_CouplerAngle= float value Angle from bucket_teeth to arm_bucket_pivot to transmit_coupler_pivot. BenchManager 2014 Wenco International Mining Systems Ltd. 12 Chapter 3: Configuring BenchManager Parameters Specific to Shovels with AGS (Be sure to modify the parameters associated with the correct model type.) Section Parameter Parameter Options Comments [<MachineName>] BoomLength= float value Measured on the boom from the cab pin to the arm pin. [<MachineName>] ArmLength= float value Measured on the arm from the boom pin to the bucket pin. [<MachineName>] BucketLength= float value Measured on the bucket from the arm pin to the bucket teeth. [<MachineName>] BucketSensorDirectMount= T - mounted on bucket Indicates whether the bucket sensor is mounted directly on the bucket or on the linkage arm. Step 2: Configure Registry Keys and WLAN Communications Use the registry to configure the BenchManager Server WLAN address: 1. Start regedit. 2. Go to the registry key: HKEY_LOCAL_MACHINE\Software\Wenco\BenchMan ager. MDT4: You need to enter the Server A WLAN IP Address, Server B WLAN IP Address, and WLAN Subnet Mask registry entries manually. Configure the BenchManager Registry Keys . 20 BenchManager 2014 Wenco International Mining Systems Ltd. 13 Chapter 3: Configuring BenchManager MDT5: The Server A WLAN IP Address, Server B WLAN IP Address, and WLAN Subnet Mask registry entries are automatically set when the MDT5 resynchronizes. Check that the BenchManager Registry Key values are correct. 3. Go to the WLAN subkey: HKEY_LOCAL_MACHINE\Software\Wenco\BenchMan ager\WLAN. Make sure that the values under this registry key are set correctly. Note for MDT4: For MDT4 installations, this setting can be updated using the Field Configuration Editor (an icon for the Field Configuration Editor is installed onto the desktop). Start the Field Configuration Editor, click the BenchManager WLAN tab, and add a checkmark to the Active checkbox. Then enter the IP Address where the BenchView Service is located. For more configuration information, see here . 20 20 BenchManager 2014 Wenco International Mining Systems Ltd. 14 Chapter 3: Configuring BenchManager Step 3: Start Wenco MDT and BenchManager Software To start the MDT and BenchManager software: 1. Start the MDT software. The Badge In screen displays briefly. 2. The BenchManager screen displays for a few seconds. Note: Do not interfere during the startup process. Wait until the BenchManager screen displays. 3. The display switches back to the MDT Badge In screen. Badge in to the MDT. Press the button on the MDT screen to switch to the BenchManager screen. Press the button on the BenchManager screen to switch to the MDT screen. Step 4: (Only ALIGN-installed Shovels/Backhoes) Calibrate ALIGN Feature Notes: This procedure is only for shovels and backhoes with ALIGN GPS installed. The operator must be granted the ALIGN Calibration privilege before performing the calibration. To perform manual calibration: 1. On the GPS tab of the Position Data menu, uncheck the Use ALIGN checkbox. 2. Have the operator rotate the shovel until the center of rotation (COR) is calculated. The appearance of the shovel graphic on the BenchManager screen indicates that the COR is calculated. 3. Stop rotation and shovel movement. Keep the shovel stationary for about 10 seconds to ensure that the ALIGN data is stable. 4. On the GPS tab of the Position Data menu, press the Calibrate ALIGN button. 5. If the calibration procedure is successful, the Calibrate ALIGN button turns green. To use ALIGN, check the BenchManager 2014 Wenco International Mining Systems Ltd. 15 Chapter 3: Configuring BenchManager Use ALIGN checkbox. Automatic calibration: BenchManager automatically calibrates ALIGN if all of the following conditions are met: INI::align_auto_calibration = 1, and the shovel has rotated wide enough to find the center of rotation and then stopped, and either: the ALIGN has not already been calibrated, or the previous calibration failed (i.e., INI::hdg_corr does not exist, or is equal to -9999.9). You can do manual calibration regardless of the INI:: align_auto_calibration setting. However, automatic calibration can only occur when INI:: align_auto_calibration = 1. Step 5: (If Using MDT5) Make Sure MDT3\Dispatch Buttons is Removed If BenchManager is working with MDT5, make sure that the registry key HKEY_LOCAL_MACHINE\Software\Wenco\MDT3\Dispatch Buttons is removed. This key contains pre-defined dump/material dispatches, which are supported in MDT4 but not MDT5. With this key, BenchManager displays a Next button that brings up a set of dump/material dispatch buttons. Step 6: (If Using Fleet Awareness) Set Up Proximate Equipment Display You can configure the Wenco system to display proximate equipment in BenchManager. To configure BenchManager to display proximate equipment: 1. Configure PitNav, by completing all steps of the PitNav Installation and Configuration Guide. Pay special attention to: Chapter 3: Obtain a Fleet Awareness for PitNav license for your mine site. The Proximate Awareness BenchManager 2014 Wenco International Mining Systems Ltd. 16 Chapter 3: Configuring BenchManager feature is not available with a simple PitNav license. 2. Start BenchManager from each MDT5. 3. In BenchManager's Tools menu, add a checkmark to Show Proximate Vehicles. BenchManager 2014 Wenco International Mining Systems Ltd. 17 Chapter 4: Upgrading BenchManager Chapter 4: Upgrading BenchManager Step 1: Back Up the Bench.ini and AGSConfig.ini Files Before upgrading BenchManager, it is a good idea to create a backup of the Bench.ini file for the equipment unit. To create a copy of the Bench.ini file: 1. Browse to the c:\program files\Wenco\BenchManager\Config folder. 2. Copy the Bench.in file to a new location. Step 2: Install and Configure Upgrade To upgrade BenchManager: 1. Install the new software by following the instructions in Chapter 2 of this document. Note: It is no longer necessary to uninstall the previous version of the application before running the updated installation kit. 2. Open the c:\program files\Wenco\BenchManager\Config\bench.ini file to confirm that the file contains the same information as before the upgrade. 3. Check the WLAN settings by following the instructions in Chapter 3. 4. Check the readme file in the installation folder to see if new configuration items have been added to the bench. ini file since the last installation. If there are new items you will need update the installed version. To update the bench.ini file: a) Open the updated default version of the bench.ini file from the \program files\Wenco\BenchManager\ ConfigDefault folder. b) Open the configured version of the bench.ini file from the \program files\Wenco\BenchManager\ Config folder. c) Compare the entries in the two versions of the file. d) Copy any new configuration items from the updated default version to the configured version. [FTP] section: For bv_repository_path, enter the folder where the BenchView repository files are saved. Enter the folder that is configured in the Wenco Configuration Manager parameter: Repository BenchManager 2014 Wenco International Mining Systems Ltd. 18 Chapter 4: Upgrading BenchManager Directory. Example: If the Wenco Configuration Manager Repository Directory parameter setting is: \Wenco FTP Site\BenchView\Repository Then in the bench.ini file, the bv_repository_path=\BenchView\Repository BenchManager 2014 Wenco International Mining Systems Ltd. 19 Chapter 4: Upgrading BenchManager Step 3: Update Wenco Parameters If you are upgrading the BenchManager software, there may be an update of Wenco Parameters that needs to be installed on your system. Wenco Parameters are configuration settings that are used with Wenco applications. Each time there is new Wenco Parameters release that is relevant for your mine, Wenco Technical Services will send you a file containing the Wenco Parameters update. Note: The WencoDB Home editor Software Version History displays the version and installation date of WP updates. To update the Wenco system using the latest Wenco Parameters: 1. Copy all of the files from the Wenco Parameters installation kit or zipped file to the <system partition>:\WencoWP folder on your Wenco server. In the Two Server Model, copy the files onto the Operational Server. In the Four Server Model, copy the files onto the Operational Services Server. 2. Double click on WencoParameters.exe in the <system partition>:\WencoWP folder to start the Wenco Parameters Installer. Notes: Refer to the Wenco Parameters Installer Guide document for information about using the Wenco Parameters Installer. A readme file with release notes is included with each Wenco Parameters release. BenchManager 2014 Wenco International Mining Systems Ltd. 20 Appendices Appendices Appendix 1: BenchManager Registry Keys The BenchManager registry keys are located in the registry under: HKEY_LOCAL_MACHINE\Software\Wenco\BenchManager Name Default Description Interface WLAN Defines the radio modem configuration used by the BenchManager system. Server A WLAN IP Address These registry entries are set by the MDT5 when it resynchronizes to the database. The value is the same as the value in the Wenco Configuration Manager > System parameter with the same name. Server B WLAN IP Address WLAN Subnet Mask BenchManager\WLAN Subkey Name Default Description Host Address IP Address of the BenchView Service computer. BenchManager will automatically upate the host address when it detects a server switch. Refresh Interval 120000 If the MDT unit has not seen any traffic for the defined time (in milliseconds), then the unit invokes a ping cycle in order to establish that the Host is still functioning and is aware of the units location. BenchManager 2014 Wenco International Mining Systems Ltd. 21 Appendices Name Default Description UDP Port 40003 Identifies the port on which the BenchManager sends and receives WLAN Messages. This should be the same as the port used for the BenchView Service. Ack Timeout 1500 For every transmitted message, Ack Timeout specifies the duration (in milliseconds) that BenchManager waits for an Ack message to arrive. The Ack message confirms that the outgoing message has been received by the target application. Maximum Retries 3 For every transmitted message, if BenchManager does not receive an Ack message within the Ack Timeout duration, BenchManager retransmits its message. Maximum Retries defines the maximum number of times BenchManager will try to retransmit it. Appendix 2: AGS Installation for Shovels and Backhoes AGS Hardware Installation There are five stages for installing hardware for the Wenco Arm Geometry System (AGS): 1. Survey the Shovel or Backhoe 2. Lay Out the Boom and Arm Sensors 3. Weld the Brackets 4. Run the Cables 5. Install and Terminate the Cables Step 1: Survey the Shovel or Backhoe Having accurate dimensions of the shovel/backhoe is essential for BenchManager to precisely position the shovel bucket. Below is a description of survey measurements required to configure a Wenco AGS shovel/backhoe system. 21 23 26 26 27 BenchManager 2014 Wenco International Mining Systems Ltd. 22 Appendices Shot Location Comment Four or more shots on the circular ring on the undercarriage Use to determine the center of rotation. One shot on the center line of the bucket Use this point and the center of rotation point from above to determine the center-line of the machine. One shot on top of each GPS antenna One shot on the boom joint Use to determine the boom joint height above ground. One shot on each pivot point on the arm Use to measure components of the arm. Take shots for each of the pivot points (P1 to P5) as illustrated in the image below and the backhoe bucket image on page 9. Survey shots on arm: Survey shot locations: One or two shots at the track level below the boom joint Used to determine the elevation difference between the GPS antenna and the ground. A shot on both sides of the machine near the center of rotation is best. BenchManager 2014 Wenco International Mining Systems Ltd. 23 Appendices Step 2: Lay Out the Boom and Arm Sensors Once the surveyor has taken the above measurements, the surveyor has enough information to mark reference points on the boom and arm. Use a felt or grease pen to mark these reference lines. Notes: When mounting the sensor on the linkage (see sensor ID 101 picture below), the terminated end of the sensor MUST be pointing parallel along the line from P4 to P3 (i.e., towards the piston coupler). The sensors must be mounted on the left side of the machine. Boom layout (sensor ID 103): Lay out two points just in front of the cab along the line between the boom-joint and the joint connecting the boom to the arm (P5). The welders will use this line as a reference to place the AGS sensor base plate. The base plate must be parallel to this line, and as close to the boom joint as is practical (which is just in front of the cab). Refer to the pictures below. BenchManager 2014 Wenco International Mining Systems Ltd. 24 Appendices Arm sensor layout (sensor ID 102): Lay out two points along the line from P5 to P1 that defines the arm length. The welders will use this as a reference line. The sensor mounting plate must be placed parallel to this reference line. Just above point P5 is the preferred location. Refer to the pictures below. BenchManager 2014 Wenco International Mining Systems Ltd. 25 Appendices Cab sensor (sensor ID 105): The cab sensor must be located on a flat surface somewhere on the body/cab of the shovel. Refer to the pictures below for a typical installation. Linkage Sensor (sensor ID 101): The bucket sensor will most commonly be placed on the linkage assembly near the bucket. It must be placed in a plane parallel to the plane of the boom and arm sensors. The boom and arm sensors are placed on the left side of the machine. The bucket sensor is placed on the inside of the right-hand linkage assembly. It is in the same orientation as if it were on the outside face of the linkage on the left side of the machine. It is not in the same plane as the other sensors but it is parallel to the plane of the boom and arm sensor. BenchManager 2014 Wenco International Mining Systems Ltd. 26 Appendices A good location for the linkage/bucket sensor is on the inside of the linkage assembly. Refer to the pictures below. Step 3: Weld the Brackets Have a welder weld the brackets in place as shown in the pictures above. Step 4: Run the Cables Cables are fastened with cable ties to existing hoses and cables as shown in the pictures above. Whenever possible, fasten the cable to rigid (stationary) hydraulic lines. Have a qualified person operate the machine and observe its movements prior to attaching the cable, to ensure proper routing. BenchManager 2014 Wenco International Mining Systems Ltd. 27 Appendices Step 5: Install and Terminate the Cables Install and terminate the cables, following the steps below. 1. Install cables as noted in Step 4: Run the Cables and cut to required length. 2. Slide on crimp sleeve (provided in the plastic bag attached to the cable). 3. Slide on heat shrink (provided in the plastic bag attached to the cable). 4. Remove approximately 2 inches of stainless steel outer braid. 5. Remove approximately 1.5 inches of cable jacket. 6. Use coax crimpers to crimp the sleeve over the outer braid. 7. Terminate the connector according to the manufacturer's instructions (located on the bag). Note: Sensor cables are coded by color to match the BenchManager 2014 Wenco International Mining Systems Ltd. 28 Appendices color-coded positions on the back of the M12 connectors. Wire Color M12 Connector Position Color RED RED BLACK BLACK BLUE BLUE WHITE WHITE GREEN GREY BROWN NOT USED BenchManager 2014 Wenco International Mining Systems Ltd. 29 Appendices AGS Software Installation Configuration parameters for the AGS are set in two configuration files: Bench.ini : parameters relevant to the vehicle. AGSConfig.ini : parameters relevant to the AGS. The parameters should be set from measurements gathered during the installation of the AGS sensor hardware (refer to the document BenchManager Parameters.xls). 30 31 BenchManager 2014 Wenco International Mining Systems Ltd. 30 Appendices Bench.ini Parameters Note: The information about the parameters below is added as of BenchManager version 3.5.2007. The measurements are in meters or feet, depending on the site. Bench.ini Vehicle AGS Parameters Parameter Comment AGSInstalled Set to 1 to indicate that the AGS is installed on the vehicle. joint_offset_hori Horizontal distance from the vehicle center to the boom joint. This will generally be the same for each model. joint_offset_vert Vertical distance from the ground to the boom joint. This will generally be the same for each model. under_scoop_offset Adjust the candidate bucket elevation by this amount. The following parameters define the Bucket Zone used to trigger bucket detection. They should be adjusted after the AGS accuracy has been confirmed. horizontal_dig_limit Do not calculate a bucket if the bucket is this distance away from the boom joint. min_forward_distance The bucket must move forward in the zone at least this distance. scoop_height The bucket must move upwards in the zone at least this distance. vertical_limit Do not calculate a bucket if the bucket is this distance above the boom joint. vertical_trigger Start calculating the bucket if the vertical distance from the boom joint exceeds this value. BenchManager 2014 Wenco International Mining Systems Ltd. 31 Appendices AGSConfig.ini Parameters Notes: The information about the parameters below is added as of BenchManager version 3.5.2007. The following parameters are only required if BucketSensorDirectMount=F: BaseLength, LinkageLength, TransmitArmLength, CouplerLength, BaseAngle, Bucket_CouplerAngle. The measurements are in meters or feet, depending on the site. AGSConfig.ini AGS Parameters Parameter Comment MachineName Set this value to one of the predefined configurations in the file (e.g., Hitachi_EX3600_Backhoe). BoomLength Measured length between the pins on the boom. ArmLength Measured length between the pins on the arm. BucketLength Measured value between the pin on the bucket and the tip of the teeth. BucketSensorDirectMount Set to T if the sensor is mounted on the bucket usually shovels. Set to F if the sensor is mounted on the linkage arm usually backhoes. BaseLength P1P4: Measured length between the bucket pin (P1) and the linkage pin on the arm (P4). LinkageLength P4P3: Measured length between the arm pin (P4) and the transmit pin (P3) on the linkage arm. TransmitArmLength P3P2: Measured between the linkage pin (P3) and the coupler pin (P2) on the transmit arm. CouplerLength P2P1: Measured length between the transmit pin (P2) and the bucket pin (P1) on the coupler. BaseAngle A2: Measured angle from the boom pin (P5) to the bucket pin (P1) to the linkage pin (P4) on the arm. Bucket_CouplerAngle A1: Measured angle from the bucket teeth to BenchManager 2014 Wenco International Mining Systems Ltd. 32 Appendices the bucket pin (P1) to the transmit pin (P2) on the coupler. BenchManager 2014 Wenco International Mining Systems Ltd. 33 Appendices Appendix 3: BenchManager Offset Measurements BenchManager Shovel Offset Measurements The following descriptions refer to the diagrams shown above and below. Record all measurements in meters. Convert to feet afterwards if required. Note: The recommended location of the GPS antennas is to the rear of the machine to minimize shadowing from the pit wall. The locations shown above are just for illustrative purposes. The following parameters are inserted into the Bench.ini configuration file. BenchManager 2014 Wenco International Mining Systems Ltd. 34 Appendices Measurement Description dx Distance from the center of the machine rotation to the center of the Master GPS antenna as shown above. Take note of whether the antenna is on the left (negative value) side or right (positive value) side of the machine. The GPS Master-GPS Remote diagram above shows the GPS antenna on the left side of the machine. dy Distance from the center of rotation to the center of the Master GPS antenna as shown above. Take note of whether the GPS antenna is forward (positive value) of the center of rotation or to the rear (negative value). The GPS Master-GPS Remote diagram above shows the GPS antenna to the rear of the machines center of rotation. dxr Distance from the center of rotation to the remote antenna. The GPS Master-GPS Remote diagram above shows the remote antenna on the right side of the machine. dyr Distance from the center of rotation to the remote antenna. The GPS Master-GPS Remote diagram above shows it forward of the center of rotation. antenna_height_offset (J) Distance from the phase center of the GPS antenna to the bottom of the tracks (ground level). The bottom of the GPS antenna shows the offset from the base of the antenna to the phase center of the antenna. Enter this as a negative (-) value. boom_length (D) Estimated distance from the center of rotation to the cutting edge of the shovel bucket. rear_length Distance from the center of rotation to whatever is sticking out the furthest at the back of the machine. toe_radius (B + C) Estimated distance from the center of rotation to the toe of the slope. This is usually the same value as the boom_length or a little longer. crest_radius Estimated distance from the center of rotation to the crest of the digging face. The distance from the toe of the slope to the crest can be calculated by knowing the slope of the pit wall and its height. For example: Slope = 1:3 Height = 15 meters Toe to Crest distance = 15 * 1/3 = 5 crest_radius = boom_length + 5 BenchManager 2014 Wenco International Mining Systems Ltd. 35 Appendices To measure dx, dy using a tape measure To determine the correct heading of the machine based on a center of rotation calculation, we need to know the location of the GPS antennas with respect to the center of rotation. Unfortunately, the center of rotation is not easily defined. What is more easily defined is the center-line of the shovel. 1. Measure the perpendicular distance from the center of the antenna to the center-line of the shovel. This should be accurate to within a couple of centimeters if care is taken. This is the dx measurement. 2. Now measure the perpendicular distance from the antenna center to the center of rotation as best you can. This is not as obvious to locate. This is your dy measurement. You can refine this measurement later once BenchManager is running (see step 4 below). 3. Enter these values into BenchManagers ini file as dx and dy. 4. To refine the dy measurement: a) Run BenchManager in COR (center of rotation) mode. b) Go to the Tools page and look at the Radius label. This displays the calculated radius (R) from the COR to the antenna. Take note of this value and let it calculate two or three times. c) Take the average radius value and calculate dy using Pythagorass formula: dy = sqrt(R^2 - dx^2) BenchManager 2014 Wenco International Mining Systems Ltd. 36 Appendices BenchManager Loader Offset Measurements The following descriptions refer to the diagrams shown above. Record all measurements in the same units as the coordinate system. Note: Locations of the antennas shown above are for illustrative purposes only. Try to place the Master receiver near the center-line of the machine. Measurement Description dx Distance from the center of machine to the center of the GPS antenna as shown above. Take note of whether the antenna is on the left (negative) side or right (positive) side of the machine. The diagram above shows the Master GPS antenna on the left side of the cab. dy Distance from the center of the cab to the center of the GPS antenna as shown above. Take note of whether the GPS antenna is forward (positive) of the cab center or rear (negative) of the cab center. The diagram above shows the Master GPS antenna to the rear of the cab center. dxr Distance from the center of rotation to the remote antenna. dyr Distance from the center of rotation to the remote antenna. antenna_height_offset (C) Distance from the phase center of the GPS antenna to the bottom of the tracks (ground level). The bottom of the GPS antenna shows the offset from the base of the antenna to the phase center of the antenna. Enter this as a negative (-) value. boom_length Distance from the center of the cab to the cutting edge of the loader bucket. The cut/fill is calculated here. Wheel_width_offset is also used to determine where the cut/fill is calculated (see below). BenchManager 2014 Wenco International Mining Systems Ltd. 37 Appendices wheel_width_offset (B/2) Distance from the center of the loader to the center of the wheels, or, half of dimension B in the cross-sectional diagram shown above. Cut/fill values are calculated at two locations on each side of the machine based on these offsets. rear_length Distance from the center of the cab to whatever is sticking out the furthest at the back of the machine. In the diagram above, it is the fender. machine_width Width of the loader bucket as shown above. toe_radius Estimated distance from the center of the cab to the toe of the slope. This is usually the same value as the boom_length or a little longer. crest_radius Estimated distance from the center of the cab to the crest of the digging face. BenchManager 2014 Wenco International Mining Systems Ltd. 38 Appendices BenchManager Bulldozer Offset Measurements The following descriptions refer to the diagrams shown above. Record all measurements in metres. Convert to feet afterwards if required. Note: These measurements apply when there is only one antenna. Measurement Description dx Distance from the center of the machine to the center of the Master GPS antenna as shown above. Take note of whether the antenna is on the left side or right side of the machine. The diagram above shows the GPS antenna on the right side of the cab. dy Distance from the center of cab (the crease in the roof of the cab) to the center of the GPS antenna as shown above. Take note of whether the GPS antenna is forward of the cab center or rear of the cab center. The diagram above shows the GPS antenna to the rear of the cab center. antenna_height_offset (J) Distance from the phase center of the GPS antenna to the bottom of the tracks (ground level). The bottom of the GPS antenna shows the offset from the base of the antenna to the phase center of the antenna wheel_length_offset Distance from the center of the cab to the cutting edge of the dozer blade. The cut/fill is calculated here. Wheel_width_offset is also used to determine where the cut/fill is calculated (see below). wheel_width_offset (A/2) Distance from the center of the dozer to the center of tracks, or, half of dimension A in the cross-sectional diagram shown above. The cut/fill values are calculated at two locations on each side of the machine based on these offsets. rear_length Distance from the center of the cab to whatever is sticking out the furthest at the back of the machine. In the diagram above, it is the ripper. If the machine BenchManager 2014 Wenco International Mining Systems Ltd. 39 Appendices does not have a ripper, then just measure to the limit of the machine. machine_width (B) Width of the dozer blade as shown above.