Of all the extreme environments that Ethernet devices are installed into — from subzero Arctic tundra to scorching hot deserts — underground mining sites may be the least hospitable toward electronic devices. Consequently, the mining sector has lagged general industry in its adoption of automation systems and process controls that rely heavily on Ethernet infrastructure. While mining companies recognize that Industry 4.0 technology holds great potential in improving their operational efficiency and productivity, concerns remain over the robustness of Ethernet devices, as well as their compatibility with non-standardized legacy equipment, and the ever-present threat of cyber-attacks.
In this blog Antaira discusses how these barriers are being gradually lifted thought the deployment of ruggedized industrial-grade Ethernet switches for mining activity. Although challenges remain, robust and adaptable Ethernet networks are now integral parts of most modern mining operations, including the difficult “last mile” of active mining or headings where connections and end-point devices are most at risk of damage. This blog takes the lid off of underground mines and looks inside at how industry leaders are benefiting by staying ahead of the communications curve and adding networking products to their mine planning equipment list.

Communication in Underground Mines

Highly reliable communication systems are critical in underground mining company operations. Without them, mine operators lose their ability:
• to monitor the movement of personnel
• to track mobile assets
• to coordinate teams above ground and those underground
• to safeguard against mining accidents including vehicle collisions, fires, cave-ins, or dangerous gases
• and to accurately measure and predict production and mineral extraction, among other managerial functions
In the past, mines relied on "leaky feeder” systems for person-to-person communication. Leaky feeders work by running a coax cable through the shafts of an underground mine, sending and receiving radio waves like an antenna along the length of the cable. One of the most glaring drawbacks of this approach is that the signal weakens considerably over long distances, therefore requiring line amplifiers. Also, leaky feeders operate at lower frequencies so transferring large data files is not possible. In addition, because mines are always changing and expanding, fixed location communication systems like a leaky feeder are often not practical.

Ethernet Underground

Modern Ethernet networks enable two-way transmission of voice, video and data throughout the mining operations, above and below ground, that keep decision makers informed and in control of the mining process. Ethernet provides a standardized, cost-efficient network protocol supported by hundreds of suppliers offering interoperable hardware, software and systems. Ethernet networks are scalable and easily redeployed to suit dynamic operating environments. A single site-wide network, based on Ethernet, can be used to support disparate legacy data systems and allow expandability for future services. Ethernet also has the flexibility of being run throughout a mine via a wireless mesh network using strategically placed Access Points (APs). Where the wireless signal range is limited by circular ramps and dips, stopes, and the structure of mine layout, Ethernet signals can be transmitted on ruggedized fiber-optic cables or over traditional copper cables.
At the center of underground mine networks are Ethernet switches. Equipped with multiple RJ45 and fiber ports, Ethernet switches seamlessly connect a mine’s networks, sub-nets and IoT devices. Ethernet switches make it possible for SCADA systems to keep track of the mine’s conveyors, pump stations, environmental monitoring systems, PLCs and various other connected machines. Faced with an array of older RS-485 serial protocol devices, a mine operator can simply employ a serial-to-Ethernet converter between the device and an Ethernet switch to add it to the network, saving the cost of replacing the legacy devices.
Another advantage of Ethernet switches is their support of various network topologies — ring, star, tree, point-to-point, etcetera. This builds stronger, more flexible network infrastructures, improving the efficiency of data transmission throughout the mining value chain, from pit to port.

Enhanced Capabilities Underground

To say that Ethernet communications has transformed underground mining would be a vast understatement. Large and small scale miners, mines on federal lands and in developing countries are leveraging Ethernet networks to significantly increase worker health and safety, cut costs, lower environmental impact, and boost productivity in mining activities. Below are a few examples: 
• Interconnecting excavators, conveyor belts, crushers, and other essential mining equipment and machinery enable real-time transmission of production data to the control room and provides more accurate information support for decision-making.
• Worker safety is improved by sensor networks monitoring levels of methane, carbon monoxide and other dangerous gases. Besides air quality, sensors will monitor temperatures and humidity, and detect the presence of smoke. These technologies are welcomed in many developing nations.
• Location tracking underground is made possible through the placement of RFID tags on miners’ hardhats and vehicles. In the event of an accident or a blasting operation hazard, miners can be immediately located and alerted to the danger. Mining companies appreciate that vehicles can be tracked with RFID for use in collision avoidance systems.
• Automation of equipment in hazardous locations of the mine eliminates the need for a person to be exposed to dangers. Also, the use of mining methods including driverless trucks and trains can be remotely operated from the control station, lowering the risks of driver error and improving production efficiency.
• IP cameras give above ground managers visual confirmation of drilling progress deep in the mine. Cameras and sensors also are used to monitor remote machinery to alert the mining companies technicians of the need for maintenance, preventing failures that result in costly production downtime.
• Data analysis of the use of natural resources, and accurately tracking the disposal of toxic waste, lessons the mine’s impact on the environment and lessens the possibility of mine closure. Energy consumption is greatly reduced by energy management systems now included in mining methods, such as the integration of ventilation-on-demand technology that only operates fans when miners are present in the area rather than running 24/7.
• Overall quality and speed of decision making is enhanced when miners, supervisors and experts, both on-site and offsite, can collaborate by way of connected networks across multiple field sites including the networks used in developing countries.
Artificial Intelligence is also making its way into mine development. AI gives mine operators greater agility to respond to commodity pricing fluctuations and changes in market demand. AI is ideal for identifying opportunities for process improvements and cost savings, scheduling equipment maintenance, and optimizing fleet management and shift allocations.

Antaira Ethernet Switches for Mining

Designed specifically for industrial environments, Antaira managed and unmanaged industrial Ethernet switches offer robust engineering to thrive in mines. The Antaira LMP-1802G-M12-10G-SFP-67-24-T managed M12 IP67 water resistant Gigabit switch, for instance, features 18 total ports to provide ample connectivity for IoT devices like robots, cameras, wireless access points, sensors, and actuators. Two ports are 10G SFP fiber slots while the other sixteen RJ45 ports support IEEE 802.3at/af PoE+, meaning you can supply 30W of power per port to all your connected Powered Devices (PDs). This switch also supports a wide operating temperature range of -40C to 75C (-40F to 167F).

Antaira recognizes that threats in the mining sector extend beyond the environment. Cyber-attacks are a real danger. Antaira Ethernet switches ensure the security of your confidential data through a combination of advanced encryption, identity authentication, port monitoring, end point verification, and other state-of-the-art means.

Conclusion

Rapid development of digital technology affects nearly every facet of the mining process today and is helping stakeholders gain the associated productivity and financial benefits tied to economic growth. In embracing this transformative change, the modern mining industry has moved towards a single, standardized consolidated protocol, Ethernet, as a replacement for older networks that were based on a series of vendor’s proprietary solutions. Ethernet allows multiple services to be run over a single backbone, thereby improving management while lowering deployment costs.
Antaira is uniquely qualified to supply mining companies with superior Ethernet solutions, coupled with the knowledge and experience to assist them in mine planning, deploying and maintaining a communications system that will achieve key operational goals. Contact Antaira at sales@antaira.com.