Automated Flange Bolting Robot with Camera Vision for Mining and Minerals Processing Infrastructure

The Challenge 

Industrial bolted flanges are extensively utilised across mining and minerals infrastructure including heat exchangers, piping, tanks, pressure vessels and process equipment. Currently, there is no automated solution for necessary and regular bolting activities that occur on this infrastructure.  

Manual bolting utilises heavy equipment, at height, in dangerous and stressful conditions. HSEQ incidents regularly include physical injuries, falls from heights, chemical burns, heat stroke and exhaustion. Workforce costs associated with injuries and long-term compensation are very high. Productivity costs associated with these manual processes are also very high with plant down-time representing the highest total cost. 

This is a large-scale problem, with over 20,000 mines, refineries, process mills, power plants and industrial plants globally that all use very similar large-bolted flanges.  

For example, Project Sponsor Alcoa of Australia have seven sites in WA with approximately 300 large diameter (1000-2000mm) bolted flanges and another 10 facilities internationally that utilise bolted flanges in some form. 

TMT’s proposed bolting robot will deliver a universal, automated, high speed bolting machine that can be operated safely by a diverse workforce, to dramatically improve productivity, HSEQ and workforce challenges experienced by operators and producers both locally and internationally. 

Proposed Solution 

TMT propose that an Automated Bolting Robot is able to provide a safer, faster and more productive technology solution to the market need in the mineral and mining sector for improvements in flange bolting operations. 

The project proposes that R&D can deliver key technological outcomes that facilitate the assembly of a bolting robot that can automatically execute bolting and unbolting processes whilst managing misalignment, obstructions, stuck bolts, multi-staged torquing and star pattern bolting procedures.  

These technologies include; 

• Specialised mechanical, electrical, pneumatic and hydraulic components for the engagement, manipulation and handling of bolts and nuts, 

• Automation control software and electronics,  

• Sensors, camera and electronic components for the accurate operation of the robot with consideration to alignment and force limits, and 

• Development of safety protocols and H.M.I. to allow the system to operate unmanned. 

Critically, an automated bolting robot will also assist the mining and mineral sector to address 

rapidly evolving, employee diversity regulatory requirements. 

Proposed Benefits to WA

The proposed Automated Robotic Bolting System will address the industry need to replace manual flange bolting processes on Mining/Minerals worksites directly. 

The outcomes to this project will include; 

• Provision of equipment that aligns with the requirements for the Workforce of the future, addressing a wide range of physical, psychological and technical competence capabilities. The robot removes all heavy lifting activities and dramatically improves the quality of the working environment. 

• Vastly improving HSEQ outcomes for bolting operations in alignment with Safety, Social and Environmental Sustainability requirements onsite. The physical removal of the operator from highly physical, dangerous, and stressful activities will directly resolve HSEQ limitations to site activities reduce costly safety processes that are needed to mitigate risk. 

• Development of technologies which will be applicable to future equipment technologies on WA mining and minerals site. Other automated equipment that requires sensor, camera, actuator, machine vision and control technologies will benefit.