Mining automation projects are easier to estimate, design, and validate when the operating requirements are defined before hardware is selected. A useful project brief does not need to contain a finished engineering specification, but it should explain the process, equipment, environment, production target, interfaces, and acceptance criteria.

This guide outlines the information manufacturers, rebuild shops, and mine-site maintenance teams should assemble when planning a custom automation project. For an overview of available applications, visit BP Automation’s mining equipment automation page.

1. Define the problem before defining the machine

Start with the operational problem rather than a preferred robot, sensor, or controls platform. The project objective should be specific enough that engineering decisions can be evaluated against it.

Examples of useful objectives include:

  • Reduce repetitive manual handling of a defined component.
  • Improve consistency in a welding or hardfacing process.
  • Increase production capacity for a known family of parts.
  • Replace obsolete controls on existing fabrication equipment.
  • Capture production or quality data that is not currently available.
  • Improve access, guarding, or operator interaction around a process.

Document the current method, its constraints, and the result the new system must achieve. If several objectives exist, rank them. This prevents secondary features from obscuring the main business and technical requirement.

2. Document the parts, materials, and process

Mining equipment and wear components vary significantly in size, mass, geometry, material, and condition. A machine designed for clean new parts may require a different approach from one handling worn, repaired, or irregular components.

Provide the engineering team with:

  • Part drawings, three-dimensional models, photographs, or representative samples.
  • Minimum and maximum dimensions and weights.
  • Material grades, coatings, surface conditions, and expected contamination.
  • Permitted part variation, distortion, and wear.
  • Required welding, cladding, cutting, measurement, or handling process.
  • Existing process parameters and approved consumables where applicable.
  • Features that must not be contacted, heated, marked, or obstructed.

For a family of parts, identify which features are common and which require changeover. This affects fixture design, robot reach, motion requirements, recipe management, and operator setup.

3. Establish production requirements

Cycle time should be based on the complete operating sequence, not only the active process. Loading, identification, clamping, inspection, unloading, consumable changes, cleaning, and operator confirmation can all affect throughput.

Useful production data includes:

  • Required parts per hour, shift, or week.
  • Number and length of operating shifts.
  • Current cycle time and the desired future cycle time.
  • Expected product mix and batch size.
  • Planned changeover frequency.
  • Allowable planned and unplanned downtime.
  • Upstream and downstream process constraints.

Where production volume changes seasonally or by project, provide a realistic range rather than a single peak number. The design can then balance capacity, complexity, and cost.

4. Describe the operating environment

Mining and heavy-industrial environments can expose equipment to dust, vibration, moisture, temperature variation, impact, abrasive material, and electrical noise. These conditions influence component selection, enclosure design, sensing methods, cable routing, cooling, and maintenance access.

The project brief should identify:

  • Indoor or outdoor installation.
  • Normal and extreme ambient temperatures.
  • Dust, water, washdown, fumes, or abrasive contamination.
  • Floor condition, available footprint, ceiling height, and access routes.
  • Nearby vibration, mobile equipment, cranes, or material traffic.
  • Hazardous-area classification, if one has been established for the installation.
  • Available electrical power, compressed air, ventilation, and process utilities.

Site photographs and a dimensioned layout are valuable. For retrofit projects, electrical drawings, PLC backups, network information, and equipment manuals should also be collected where available.

5. Identify safety and operational responsibilities

Safety requirements must be developed around the actual machine, task, access points, and site procedures. The owner, operators, maintenance personnel, engineering team, and other stakeholders should agree on how people will load, operate, clean, troubleshoot, and maintain the system.

Discuss the following early:

  • Required operator access and normal interaction with the equipment.
  • Expected maintenance and recovery tasks.
  • Material loading methods and lifting equipment.
  • Guarding, gates, interlocks, emergency stops, and safe stopping behaviour.
  • Lockout and isolation points.
  • Site standards and applicable owner requirements.
  • Who will complete the required hazard assessment and approvals.

Late safety changes can affect the footprint, controls architecture, cycle time, and cost. Safety planning should therefore be part of the concept, not an add-on after mechanical design.

6. Define controls, HMI, and data interfaces

A custom machine may need to operate as a standalone system or communicate with existing plant equipment. Define preferred controls standards and required interfaces before software development begins.

Controls information may include:

  • Preferred PLC, HMI, robot, drive, and network platforms.
  • Required operator roles, recipes, alarms, and production screens.
  • Communication with conveyors, welding equipment, inspection stations, or supervisory systems.
  • Required production counts, measurements, fault history, or traceability records.
  • Remote-support and cybersecurity requirements.
  • Backup, version-control, and change-management expectations.

BP Automation’s PLC automation systems and custom machine work can integrate controls with mechanical equipment, robotics, sensing, and operator interfaces.

7. Decide between a retrofit and a new system

Existing equipment may be a good retrofit candidate when its mechanical structure remains suitable and the main limitations are obsolete controls, unavailable components, weak diagnostics, or an outdated operating sequence. A new machine may be more appropriate when the existing structure, process capability, safety concept, or maintainability cannot support the required outcome.

For a retrofit assessment, document:

  • Equipment age, condition, and maintenance history.
  • Available electrical and mechanical drawings.
  • PLC, HMI, drive, and motion platforms currently installed.
  • Parts that are obsolete or difficult to source.
  • Known reliability, accuracy, and safety limitations.
  • Available shutdown window for installation and commissioning.

Review BP Automation’s industrial automation retrofit services for additional planning considerations.

8. Plan fixtures, material handling, and changeover

The core process cannot be separated from how the component reaches and leaves the work area. Heavy or irregular parts may require cranes, manipulators, conveyors, positioners, pallets, or purpose-built fixtures.

Define who is responsible for presenting the part, confirming orientation, securing it, and removing it after processing. If the system handles multiple products, document the desired changeover method and acceptable setup time.

Related capabilities may include automated material handling, robotic welding systems, or hard surface overlay machines. The correct combination depends on the process and part requirements.

9. Define testing and acceptance criteria

Acceptance criteria should describe how the completed system will be judged. Avoid relying only on general statements such as “works correctly” or “meets production.” Use measurable conditions wherever possible.

A project may need criteria for:

  • Cycle time and production rate.
  • Part range and changeover.
  • Weld, overlay, cut, measurement, or handling result.
  • Repeatability and process tolerances.
  • Alarm, interlock, and fault-recovery behaviour.
  • Data capture and communication.
  • Operator and maintenance documentation.
  • Factory acceptance testing and site acceptance testing.

Specify the samples, test conditions, consumables, operators, and inspection method that will be used during acceptance. This aligns expectations before fabrication and programming are complete.

10. Provide the information needed for an initial review

An early project inquiry is most useful when it includes:

  • A short description of the current process and desired result.
  • Part information, photographs, drawings, and production volumes.
  • Site layout and environmental conditions.
  • Existing equipment and controls information.
  • Required interfaces, owner standards, and acceptance criteria.
  • Target schedule and known installation constraints.
  • A contact who can answer process and maintenance questions.

You do not need a completed specification to begin. Unknowns can be recorded as open items and addressed during concept development or feasibility work.

Mining automation support in Alberta and Western Canada

BP Automation is based in Edmonton and supports automation projects across Alberta and Western Canada. The company develops custom machines and automation for fabrication, welding, hardfacing, material handling, controls, inspection, and equipment retrofits. Related planning resources include custom machine design and build and oil sands and SAGD automation.

A well-prepared project brief helps identify technical risks early and creates a clearer basis for concept development, estimating, design, and acceptance.

Frequently asked questions

Do we need a finished specification before contacting an automation company?

No. A concise problem statement, representative part information, production requirements, site conditions, and known constraints are enough to begin an initial discussion. Remaining requirements can be developed during scoping.

What is the most important information for an early estimate?

The current process, desired outcome, part size and weight, production rate, required automation functions, installation environment, existing interfaces, and acceptance criteria have the greatest influence on the initial concept.

Can one system handle several mining components?

Potentially. Feasibility depends on the variation in geometry, weight, process requirements, tooling, robot or machine reach, and acceptable changeover time. Define the complete part family at the start of the project.

How should retrofit downtime be planned?

Document the available shutdown window and identify work that can be completed before installation. Controls simulation, panel construction, mechanical preparation, backups, and staged testing can help structure the implementation plan, but the appropriate sequence depends on the equipment and site.

What should be included in factory acceptance testing?

Testing should use agreed parts or samples and verify the measurable acceptance criteria defined for the project. This may include sequence operation, safety functions, cycle time, process output, changeover, alarms, data handling, and documentation.

Planning a mining equipment automation project? Contact BP Automation or call (780) 448-9338 to discuss the application.