One of North America’s leading producers of concentrated phosphate and potash introduced a new strategy to improve both mining operations and workforce safety. As part of that effort, the company deployed vision technology manufactured by Excelsense to support safer, more efficient mobile equipment operations at its phosphate mine in Florida.
The Opportunity
Mining environments demand equipment and systems that can perform reliably in harsh conditions. In this case, the company was looking for a way to improve visibility around mobile equipment while also reducing the need for workers to physically approach machines in active operating areas.
Excelsense specializes in optical vision systems for heavy industry, with a particular focus on mining. Its camera systems are designed to be highly durable, self-sufficient, and self-cleaning, eliminating the need for external hoses, nozzles, or air tanks that can become vulnerable in difficult mine conditions. This also improves safety by reducing the need for site personnel to directly inspect or maintain the camera units in the field.
The Solution
To support the mine’s operations, automation technology was deployed using Excelsense ToughEye™ 1700 self-cleaning cameras on one of the site’s Komatsu 155AX dozers. The system was used to assist with pushing raw material from beneath the stacker while allowing personnel to direct the machine from a safe remote location.
By using the Automation Centre, site personnel could access the full range of machine functions as though they were sitting inside the cab. Five ToughEye™ 1700 self-cleaning cameras were installed in key positions around the dozer to give operators clear, unobstructed views of the working area.
Built for Harsh Mining Conditions
The ToughEye™ 1700 cameras were specifically selected for their ability to operate in demanding mine environments. The units are designed to continue functioning in abrasive dust, mud, oil, grease, and water. They can self-clean for years without scheduled maintenance and do not require hoses, tanks, nozzles, or refill products such as detergents.
The site also configured the Automation Centre so personnel could activate the camera’s self-cleaning function with the press of a button. When activated, the lens rotates 360 degrees and the built-in cleaning system clears the lens to restore crystal-clear vision. The cameras could also be set to operate on a timed cleaning cycle.
The Results
Since the installation of the ToughEye™ 1700 cameras and the automation technology, site personnel reported strongly positive feedback. The self-cleaning capability gave the dozer operator a much clearer and more consistent view of the work area, which in turn significantly improved dozer utilization.
The rotating 360-degree cleaning action also meant operators no longer needed to approach the machine to manually clean the camera lens, reducing both risk and the potential for lens damage. Just as importantly, operators were able to manage camera functions and dozer functions remotely from the Automation Centre, creating a meaningful safety improvement for site personnel while also enabling more efficient operation.
Conclusion
This case study shows how rugged self-cleaning camera systems can support both safety and productivity in mobile mining equipment operations. By combining remote operation with reliable visibility and minimal maintenance requirements, the site was able to improve equipment utilization, reduce operator exposure to hazardous work areas, and create a more efficient operating environment overall.