Pioneering Autonomous Operations in Aus with J2A: Transforming Coal Mining with Ultra-Class Machines

Background & summary

A leading global mining operator embarked on a pioneering initiative to transition two of its coal operations to fully autonomous fleets. This transition marked a significant milestone in the mining industry, as the client became the first to deploy autonomous haulage systems (AHS) in a coal mine, incorporating ultra-class machines into its fleet.

FTP’s extensive experience in deploying Caterpillar autonomous haulage systems was a key factor in the client’s decision to partner with us for this transition. Our proven track record in the mining sector, combined with our technical expertise, positions us as the ideal partner to navigate the challenges and successfully deliver this cutting-edge solution.

The Challenge

This coal operation had never previously deployed autonomous technology, and certified solutions were nearing the end of their lifecycle. With limited spectrum availability and technology offerings, the client faced several challenges in bringing this ambitious project to life. These included:

– The lack of experience in deploying autonomous systems within the coal mining sector.
– Limited access to the necessary spectrum and available technology solutions to support the integration of AHS.
– Addressing critical issues related to safety, efficiency, and skills shortages.
– The need for a trusted partner with proven expertise in autonomous technology deployment.

Design

During the study phase FTP Embedded Network Engineers who played a pivotal role in guiding the client through technology selection and roadmap development. They collaborated closely with the OEM, site stakeholders, service owners, and security teams to ensure alignment with project goals. This collaboration resulted in a comprehensive OT Wireless Network Design tailored to the client’s needs. FTP’s Network Engineers completed both High and Low-Level OT Network Designs, encompassing all technical design elements, including:
– Technical design drawings
– Cable schedules
– Feeder and tower diagrams
– Rack layouts
– Fibre designs

Implement

FTP’s embedded resources processed, factory acceptance tested, configured, labeled, and tracked over 3,000 unique network devices, preparing them for shipment to the site. These devices were destined for installation on towers, trailers, and server rooms. FTP Network Engineers were responsible for acquiring, testing, configuring, labeling, and staging all hardware (over 3,000 IP devices), ensuring they were ready for installation by third-party installers. Following the hardware preparation, FTP conducted site acceptance, integration, and readiness testing in close collaboration with site stakeholders, engineers, and our OTSC team to ensure a seamless transition to operational status.

Support

Following the initial network deployment, FTP personnel provided dedicated network support, ensuring all machines were configured, commissioned, and integrated into the new Operational Technology (OT) network over a six-month period. In addition to on-site resources, the Operational Technology Support Centre (OTSC) played a crucial role in the initial deployment and ongoing operations by: Conducting extensive drive testing and compiling comprehensive reports to verify that new operational areas met the requirements for autonomous machine deployment. Providing SME escalation support to assist site-based FTP resources with troubleshooting and optimisation. Delivering daily, weekly, and monthly performance reports, including root cause analysis for both network and Fleet Management System (FMS) issues. This structured approach ensured seamless integration, optimised performance, and continuous support for the new OT network.

FTP's Benefits

The successful implementation of fully autonomous operations at coal mines through J2A introduced the world’s first autonomous fleet using Ultra-Class machines, setting a new industry standard.
This transition enhanced safety by removing human involvement in hazardous areas, boosted operational efficiency, and reduced costs.

To ensure a seamless transition, our IMS platform was installed at the beginning of the new technology rollout. This proactive approach guaranteed that as new technologies were commissioned onto the network, the existing OT network remained stable without any degradation. It also enabled complete network commissioning, along with thorough drive testing and performance analysis in all autonomous zones before machinery operation commenced.

More than 3,000 network devices and autonomous systems were seamlessly integrated, with extensive testing, configuration, and coordination alongside third-party installers.

ready to learn more?

At FTP, we specialise in creating innovative, tailored solutions that help businesses like yours tackle complex challenges. With a proven track record in designing and implementing cutting-edge technologies, our team works closely with you to achieve measurable outcomes—whether it’s enhancing safety, boosting productivity, or optimising operations.

Partner with us to transform your vision into reality. Get in touch today to see how we can support your next big project.