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| An accident due to lack of visibility |
Description of Problem
An average of 40 accidents and five fatalities occur each year in the U.S. surface mining industry that can be attributed to the lack of visibility around large, off-highway mining equipment. These accidents account for 12% of all surface mine fatalities. They fall into two main categories: (1) collisions between mining equipment and smaller vehicles, workers on foot, structures, or other equipment and (2) driving or backing over the edge of an embankment, stock pile, dump point, or other change in terrain. The areas surrounding the equipment that an operator cannot see from the cab can be extensive and are a major contributing factor.
Research and Development Activities
In 1998, the Mine Safety and Health Administration (MSHA) proposed rules requiring some type of sensor-based proximity warning system and cameras to monitor blind areas around mining equipment. At that time, no sensor-based technology had been thoroughly tested on large, off-highway mining equipment. Cameras had been applied only to a limited extent. NIOSH proposed that a test program be initiated for off-the-shelf proximity warning systems to see how they performed on mining equipment before finalizing any rules. For the past few years, NIOSH and MSHA have been working together to evaluate proximity warning systems in order to understand their applications and limitations on mining equipment.
NIOSH developed a test protocol to evaluate various warning systems and studied available technology to assess which systems are most effective in preventing collisions in surface mining conditions. A combination of an off-the-shelf radar system and a camera has been thoroughly tested at a surface mine. Tests have also been done on innovative systems developed in cooperation with outside organizations. These include a GPS-based system and a stereovision system.
R&D Outputs and Transfer Activities
During 2001-2005, the results of this research were transferred to the mining industry through 13 technical publications and nine presentations. This research also assisted MSHA in publishing a Web page with information and training material on proximity warning systems.
Description of Intermediate Outcome
The NIOSH-originated procedures for testing and integrating protocols for use of proximity warning systems are being used by the mining industry, MSHA, and equipment manufacturers to make decisions about the most effective technologies to prevent accidents. NIOSH has provided input to MSHA regarding new regulations to improve the safety of operating surface mine haulage equipment. Some of the outcomes are as follows:
- NIOSH researchers were asked to act as subject matter experts and committee members during the development of the International Standards Organization (ISO) standard 16001 - Earth moving machinery - Hazard detection systems and visual aids - Performance requirements and tests. NIOSH Reports of Investigations (Ris) were referenced in the standard. Also, a NIOSH researcher wrote sections of the standard dealing with test procedures for radar (annex C) and tag-based proximity warning systems (annex F). This ISO standard can be accessed at: http://www.iso.org/
- The Canadian CIM Bulletin (Vol. 93, No. 1045) cited a NIOSH study that is evaluating proximity warning systems to monitor blind areas near mining equipment. The article is entitled "New Technology Makes Safety Easier."
- The United Kingdom's Health and Safety Executive (HSE) cited NIOSH test results on proximity warning systems in its report entitled "Improving the Safety of Workers in the Vicinity of Mobile Plant" (contract research report 358/2001). The NIOSH work was referred to as "arguably the most comprehensive comparative testing of vehicle and personnel detection systems."
- MSHA used NIOSH study results to publish a Web page describing available proximity warning systems for mining equipment. It is entitled "Accident Prevention through the use of New Technologies" and is available at http://www.msha.gov/.
- Caterpillar, Inc. and Phelps Dodge, Inc. are using NIOSH study results to make decisions about implementing proximity warning systems on mining equipment. A NIOSH researcher has been asked by Caterpillar to act as a subject matter expert on a work group that is designing a system for mining and construction equipment. Phelps Dodge has participated in NIOSH tests and is using NIOSH study results to select systems for large-scale tests.
- NIOSH worked closely with Preco Electronics, Boise, ID, to modify its existing radar-based proximity warning system so that it would work more effectively on large, off-highway equipment. NIOSH recommendations were incorporated in a radar system that uses multiple antennas to provide a wider obstacle detection area while monitoring both the front and rear of the equipment.