Why Interrupt Production Just to Measure Payload?

How automatic payload estimation can turn every machine cycle into production insight

In underground mining, payload is one of the most important measures of production performance. Tonnage per cycle, tonnage per shift and payload performance help operators understand how effectively machines and production areas are performing.

But measuring payload can come at a cost: interrupting the cycle.

The problem with conventional payload measurement

Conventional payload measurement on machines like LHDs requires the machine to remain stationary for several seconds with a loaded bucket.

During measurement, hydraulic pressure increases and the bucket oscillates before reaching a stable pressure level. This value is then used to determine the tonnage in the bucket. The process creates a short interruption in the tramming cycle and requires the operator to perform the measurement.

This creates two challenges. The machine has to stop to measure, and the availability of payload information depends on the measurement being performed.

What if payload could be estimated automatically?

One of our projects explored a different approach.

Instead of introducing a separate weighing step, existing machine signals can be used to estimate payload during the normal LHD cycle.

The approach compares hydraulic pressure during loaded travel with the corresponding pressure during empty travel. The pressure difference provides the basis for estimating the tonnage carried in the bucket.

The goal is simple: move from individual operator-initiated measurements towards automatic payload estimation for every production cycle.

From payload measurement to production visibility

Automatic cycle-level payload estimation changes the role of PLM.

It can remove the need for a dedicated measurement stop and reduce dependence on operator interaction. More importantly, payload information can become part of the regular production cycle.

This creates the basis for continuous visibility into tonnage per cycle, shift and production area. It also allows payload information to be viewed alongside other production KPIs such as cycle duration and machine utilization.

For underground operations, the value is not simply a different way to weigh a bucket. It is the opportunity to measure production without interrupting it.

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