FIELD

[0001] The present invention relates to monitoring of rock processing activities, and in particular to identifying differences between a target tunnel profile and a realized tunnel profile after an excavation work.

BACKGROUND

[0002] Mobile rock processing machines, such as rock drilling rigs and mechanical cutting machines are used in underground construction and mining sites. In drilling- blasting based methods rock is excavated in rounds. Several successive rounds produce a tunnel having a tunnel face. At first drill holes are drilled to the tunnel face, where after the drilled holes are charged and blasted. Rock material of the amount of one round is detached at one blasting time. The detached rock material is transported away from the tunnel for further processing. [0003] For excavating rock, a mine excavation plan, which may comprise at least one drilling pattern, or drill hole pattern, is made in advance and information on the rock type, for example, is determined. In general, also various quality requirements may be set for the excavation process. Typically, the drilling pattern is designed as office work for each round. The pattern is provided for the rock drilling rig to drill holes in the rock in such a way that a desired round and tunnel profile can be achieved.

[0004] Particularly in construction tunneling sites accurate following of the excavation plan and the tunnel profile defined therein is essential. If too much rock is removed, which is hereby also referred to as overbreaking, need for expensive concrete spraying increases. If not enough rock has been removed, which is hereby referred also to as underbreaking, removal of excessive remaining rock is cumbersome and time- consuming, and may lead to removing too much rock, i.e. overbreaking. Excessive rock may be removed by cutting or drilling. The tunnel quality requirements may require removal of underbreaking exceeding the tunnel profile even by only 5 cm or more. Such underbreaking areas required to be removed may be small. [0005] Patent publication US-A1-2003/145658 and conference papers Warneke et al., "Use of a 3-D scanning laser to quantify drift geometry and overbreak due to blast damage in underground manned entries", Proceedings of the 1 ^st Canada-US Rock Mechanics Symposium - Rock Mechanics Meeting Society's Challenges and Demands 2007, pp. 93-100, and Edhammer et al., "Benefits of advanced technology in underground mining", Proceedings - 11 ^th AusIMM Underground Operator's Conference 2011, pp. 283- 291 disclose known apparatuses and methods for surveying the geometry of a realized tunnel.

SUMMARY [0006] The invention is defined by the features of the independent claims. Some specific embodiments are defined in the dependent claims.

[0007] According to a first aspect of the present invention, there is provided an apparatus, comprising: means for storing tunnel model data defining target tunnel profile for rock processing by a mobile rock processing machine, means for receiving operational tunnel profile data generated on the basis of scanning of surroundings of the rock processing machine and defining a realized tunnel profile, means for detecting current position of a tool of the rock processing machine, means for defining difference between the target tunnel profile and the realized tunnel profile on the basis of the position of the tool and on the basis of the tunnel model data and the realized tunnel profile data, and means for indicating the difference between the target tunnel profile and the realized tunnel profile on the basis of the position of the tool, wherein the difference is indicated in a 2D or 3D view displaying the target tunnel profile and the realized tunnel profile at least at the position of tool and indicating the position of the tool. The allowed tolerance for deviating from the target tunnel profile is defined, and either the allowed tolerance is indicated in the displayed realized tunnel profile, or at least excess rock areas exceeding the allowed tolerance in the realized tunnel profile are defined and indicated in the displayed realized tunnel profile.

[0008] According to a second aspect of the present invention, there is provided a method for rock processing monitoring, comprising: storing tunnel model data defining target tunnel profile for rock processing by a mobile rock processing machine, receiving operational tunnel profile data generated on the basis of scanning of surroundings of the rock processing machine and defining a realized tunnel profile, detecting current position of a tool of the rock processing machine, defining difference between the target tunnel profile and the realized tunnel profile on the basis of the position of the tool and on the basis of the tunnel model data and the realized tunnel profile data, and indicating the difference between the target tunnel profile and the realized tunnel profile on the basis of the position of the tool in a 2D or 3D view displaying the target tunnel profile and the realized tunnel profile at least at the position of tool and indicating the position of the tool, defining allowed tolerance for deviating from the target tunnel profile, and indicating the allowed tolerance in the displayed realized tunnel profile, or determining at least excess rock areas exceeding the allowed tolerance in the realized tunnel profile and indicating at least the excess rock areas in the displayed realized tunnel profile.

[0009] According to a third aspect, there is provided an apparatus comprising at least one processing core, at least one memory including computer program code, the at least one memory and the computer program code being configured to, with the at least one processing core, cause the apparatus at least to: store tunnel model data defining target tunnel profile for rock processing by a mobile rock processing machine, receive operational tunnel profile data generated on the basis of scanning of surroundings of the rock processing machine and defining a realized tunnel profile, detect current position of a tool of the rock processing machine, define difference between the target tunnel profile and the realized tunnel profile on the basis of the position of the tool and on the basis of the tunnel model data and the realized tunnel profile data, and indicate the difference between the target tunnel profile and the realized tunnel profile on the basis of the position of the tool.

[0010] According to a fourth aspect, there is provided a mobile rock processing machine, comprising a carrier, at least one boom, and at least one scanning device for scanning surroundings of the machine, wherein the machine comprises the above- specified apparatus, and the tool is a mechanical cutting device or operable by a rock drill attached to a feed beam connected to the boom.

[0011] According to an embodiment, the view is updated in response to the movement of the tool. [0012] According to an embodiment, a front view indicating the target tunnel profile and the realized tunnel profile at the position of tool is displayed. [0013] According to an embodiment, a quality indicator is calculated on the basis of differences between the target tunnel profile and the realized tunnel profile for a round or advance since previous scanning.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIGURE 1 illustrates an example of a mobile rock processing machine in accordance with at least some embodiments of the present invention;

[0015] FIGURE 2 illustrates a top view of tunnel excavation; [0016] FIGURE 3 illustrates a method according to at least some embodiments of the present invention;

[0017] FIGURE 4 illustrates an example of scanned tunnel profile;

[0018] FIGURES 5 to 8b illustrate example display views in accordance with at least some embodiments of the present invention, and [0019] FIGURE 9 illustrates an example apparatus capable of supporting at least some embodiments of the present invention.

EMBODIMENTS

[0020] As an example of a rock processing device in which at least some of the embodiments may be illustrated, Figure 1 illustrates a rock drilling rig 1 comprising a carrier 2, one or more drilling booms 3 and drilling units 4 arranged in the drilling booms 3. The drilling unit 4 comprises a feed beam 5 on which a rock drilling machine 6 can be moved by means of a feed device. Further, the drilling unit 4 comprises a tool 7 with which the impact pulses given by the percussion device of the rock drilling machine are transmitted to the rock to be drilled.

[0021] The rock drilling rig 1 further comprises at least one control unit 8 arranged to control actuators of the rock drilling rig 1, for example. The control unit 8 may comprise one or more processors executing computer program code stored in a memory, and it may comprise or be connected to a user interface with a display device 9 as well as operator input interface for receiving operator commands and information to the control unit 8. In some embodiments, the control unit 8 is controlling information to be displayed, and there may be another control unit in the rig for controlling machine operations.

[0022] Figure 1 further discloses that one or more sensors 10 may be arranged for determining current position and direction of the tool 7. Such sensors 10 may locate in connection with the boom 3, or alternatively the sensing may be executed remotely from the carrier of even elsewhere. The sensing data is provided to the control unit 8, which may execute appropriate calculations.

[0023] The drilling rig 1 may comprise at least one scanner unit 11 for scanning tunnel profile. In some embodiments, the scanning results are applied to detect position and direction of the rig 1 and one or more further elements thereof, such as the tool 7. This may enable to avoid or reduce number of specific sensors 10 for determining the position and direction of the rig elements.

[0024] In some embodiments, the rig 1 or the control unit 8 thereof may execute a point cloud matching program for matching operational tunnel profile cloud data to tunnel model cloud data. Position and direction of the scanning device and/or another interest point of the machine 1, such as the (leading edge of the) tool 7, may be determined in the mine coordinate system on the basis of the detected matching between the operational point cloud data and the reference cloud data. Such scanning and point cloud matching based positioning may be used instead or in addition to other positioning means in the machine, such as positioning based on (position) sensors and tachymetry.

[0025] It is to be noted that in some alternative embodiments the rock processing machine in which embodiments of the invention are applied is unmanned. Thus, the user interface may be remote from the machine and the machine may be remotely controlled by an operator in the tunnel, or in a control room at the mine area or even long distance away from the mine via communications network(s).

[0026] A drilling pattern or plan or other type of excavation plan may be designed offline and off-site, for example in an office. Such a plan is loaded to a memory of the rock drilling rig 1 and may be at least displayed for the operator of the drilling rig. The control unit 8 may also control drilling work cycle actions on the basis of the drilling plan. The drilling plan may be sent via wired or wireless connection to the control unit 8 or it may be retrieved from one or more memory devices by the control unit 8. The operator 12 of the rock drilling rig 1 controls the drilling interactively with the control unit 8. [0027] With reference to Figure 2, illustrating a top view of a tunnel and drilling rig

1, the drilling plan defines positions of holes 21a, 21b to be drilled which may be arranged in several drill hole rows. Figure 2 also illustrates a target tunnel profile 20 and a realized tunnel profile 24 detected on the basis of scanning the walls after a round excavation. The tunnel profiles may also be referred to as tunnel cross-section profiles. In the realized tunnel profile 24, there are areas of overbreaking 22 and underbreaking 23.

[0028] Figure 3 illustrates a method according to some embodiments. The method may be carried out in a mobile rock processing machine, such as the drilling rig 1 and by the control unit 8 thereof.

[0029] Tunnel model data directly or indirectly defining a target tunnel profile for a mobile rock processing machine, such as the drilling rig 1, is received and/or stored 300. The tunnel model data may be received from a memory of or connected to the control unit 8, or from a remote device, such as a computer comprising software for remote control and/or mine design.

[0030] Operational tunnel profile data generated on the basis of scanning of surroundings of the rock processing machine and defining a realized tunnel profile is received 310.

[0031] The reception of the operational tunnel profile data is to be understood broadly: The operational tunnel profile data may be received by the control unit 8 from another unit, such as the scanner unit 11, which prepares the data based on scanning data, or the control unit may prepare the operational tunnel profile data based on received scanning data. In a further example embodiment, another machine with scanner, such as another drill rig or a separate scanning unit generates the operational tunnel profile data which is copied to the apparatus carrying out the method of Figure 3.

[0032] The control unit 8 may request realized profile from the scanner unit 11 at desirable area, such as the newly excavate round or a more limited area around the current position of the tool 7. [0033] Current position of a tool of the rock processing machine in the mine is detected 320. The tool may be a mechanical cutting device or a tool attached to a rock drill attached to a feed beam. In case of a rock drilling rig, position of a drill bit attached to a drill string may be defined. [0034] Difference between the target tunnel profile and the realized tunnel profile is defined 330 on the basis of the position of the tool and on the basis of the tunnel model data and the realized tunnel profile data. The difference may be defined at and/or around the position of the tool by comparing respective point cloud data. The difference between the target tunnel profile and the realized tunnel profile on the basis of the position of the tool is indicated 340.

[0035] The difference may be indicated 340 in a view in a display device 9 for a local or remote operator of the machine. It is to be appreciated that deviations at other positions from the target tunnel profile, as well as further assistive information may be indicated at the same time with block 340. [0036] The difference may be indicated 340 in a 2D or 3D view displaying the target tunnel profile and the realized tunnel profile at least at the position of tool and indicating the position of the tool. Such deviation view is updated in response to the movement of the tool, i.e. the method may return from 340 to block 320. The view may be updated at desirable or adjustable resolution, for example selected in the range between 0.01 to 0.2 meters. In response to scanning further newly excavated mine surfaces after an executed round, the method may return to block 300.

[0037] The control unit 8 may define 330 area(s) of excess rock resulted after excavation round execution on the basis of comparison of the tunnel model data and the operational tunnel profile data associated with the executed round. [0038] It may be very difficult for the operator to conventionally detect (underbreak) areas with excessive rock in the challenging tunnel conditions, e.g. due to limited visibility and distance to such areas, particularly since such areas may be very small, even less than ten cm ² . Presently disclosed features substantially facilitate detection and positioning of such areas with excessive rock that needs to be removed. The updating of the indication enables to substantially ease and thus accelerate the positioning of the tool 7 to remove the excess rock. The binding between the leading edge connected to the boom, such as the drilling bit attached to the drill rod, can be achieved 'naturally', and separate indicating devices, such as lasers are not required.

[0039] Information on allowed tolerance for deviating from the target tunnel profile may be stored in the drilling plan or another file storing the tunnel model data. The allowed tolerance may be indicated in the displayed realized tunnel profile. At least excess rock areas in the realized tunnel profile exceeding the allowed tolerance may be defined and indicated in the displayed view. In connection with (or after) the block 330, the control unit may compare the detected differences to tolerance values to detect areas exceeding the tolerance values and requiring further action by the operator. For example, such tolerance- exceeding areas may emphasized or highlighted in the view by specific colour or other highlighting means. Alternatively, only the tolerance-exceeding areas may be indicated to the operator.

[0040] Figure 4 illustrates an example 3D view of a tunnel scanned tunnel profile.

Example excess rock area 40 mainly in the roof section of the tunnel is indicated in the view which may in an embodiment be displayed for the operator. The target tunnel profile may be indicated 41 in the view.

[0041] According to some embodiments, a top view indicating the area of excess rock from top of the machine and tunnel is displayed after round execution. Some examples of such a view are provided in Figures 5, 6a, 7a, and 8 a. [0042] Figure 5 illustrates an example view of tunnel profile similar to that of Figure

4, comprising an excess rock area 40 to be removed. In some embodiments, the view is updated to indicate the current position of the tool(s) 7a and the drilling rig 1. Line 51 illustrates the outermost drill hole of the executed round. Line 53 illustrates predefined tunnel line to which the drilling plan coordinates are attached. A scale indicator 52 may also be displayed to assist the operator to perceive distances in the view.

[0043] According to some embodiments, a front view indicating the target tunnel profile and the realized tunnel profile at the position of tool is displayed. The top view and/or front view may be displayed in connection or together with a drilling plan view. In the example of Figure 5, the rig 1 needs to be reversed to process the excess rock 40. The top view may be displayed during the reverse drive and tool positioning assisting the operator to find an appropriate position to start to process (the edge section of) the excessive rock area.

[0044] With reference to example views of Figures 6a and 6b, the rig 1 has been reversed and navigated as indicated in the top view of Figure 6a. The control unit 8 may automatically or in response to operator input display a front view illustrated in Figure 6b indicating the target tunnel profile 62 and the realized tunnel profile 63 at the depth position 61 of the tool 7a towards the tunnel head (X direction). Such front view may be displayed in addition or instead of the top view of Figure 6a e.g. in response to starting fine-positioning of the tool 7a indicated by circle 64. The positions of other tools 7b and 7c may also be indicated 65, 66 in the Z-Y direction.

[0045] An indication 67 of the thickness of the excess rock at the position of tool may be determined and displayed in the front view, for example.

[0046] Figures 7a and 7b illustrate example top and front views, respectively, after positioning of the tool 7a at the proximity of the starting edge of the excess rock area 40 as indicated by line 61. In accordance with the current position and direction of the feed beam/tool, resulting hole may be indicated 71.

[0047] The control unit 8 may be configured to define a required rock processing action required to remove the excess rock, such as depth of a hole to be drilled. In an embodiment, length of the required hole 71 is thus estimated. The estimated length of the hole required to remove the excess rock may be indicated 72 in the top view, front view, and/or in another view or window. In an embodiment, such indicator 72 (or 71) is updated in real-time along with advance of the drilling action, i.e. progress of the drill bit. This further helps the operator to detect appropriate point to end the drilling.

[0048] With reference to Figures 8a and 8b, the control unit 8 may be configured to receive an input from the operator indicating a point of interest 81 in the displayed view. Such input may be received on the basis of input to a slide controller, for example. Difference between the target tunnel profile and the realized tunnel profile at the point of interest is defined. A view, such as illustrated in Figure 8b, may be displayed indicating the difference 84 between the target tunnel profile 62 and the realized tunnel profile 82 at the point of interest 81. The tunnel profile at the point of interest may also be indicated 82. The indications at the point of interest may be displayed in the same or separate view than those 63, 40 of the current position 61, 64 of the tool. This functionality may be useful for the operator to estimate the required processing action to remove the excessive rock, such as estimating end point of the hole to be drilled.

[0049] In some embodiments, one or more automated features for removing the excessive rock are controlled in accordance with the defined action. For example, the control unit may control automatic positioning and direction of the tool to remove the detected excess rock (which may require an input from the operator). Further, at least some of the rock processing actions may be at least partly automated. For example, the drilling may be stopped automatically in response to achieving the length of the hole defined by the control unit 8.

[0050] The control unit 8 may receive an input from the operator of the machine to change to another tool 7b, 7c. In response to such input, the control unit 8 may be configured to update displayed view to indicate the difference between the target tunnel profile and the realized tunnel profile at the position of the other tool. The operator may simply select the tool to track the tunnel profile.

[0051] In some embodiments, a quality indicator is calculated on the basis of differences between the target tunnel profile and the realized tunnel profile for a round or advance since previous scanning.

[0052] The quality indicator may be calculated by comparing the operational tunnel profile data and the tunnel model data, and directly on the basis of detected (and indicated) areas exceeding the tolerance for deviating from the target tunnel profile. The quality indicator may be calculated for each round, and may utilize information of realized hole positions.

[0053] The quality indicator may be specified in a form of a performance index, and may indicate the proportion of such tolerance- exceeding underbreaking and/or overbreaking. The quality indicator information may be stored into the memory and included in production reporting. The control unit may cause display of such quality indicator, e.g. in connection with one more of displays illustrated above. This further assists the operator and/or other mine personnel to monitor excavation performance. [0054] It is to be appreciated that various further features may be complement or differentiate at least some of the above-illustrated embodiments. For example, there may be further user interaction and/or automation functionality further facilitating the operator to detect the excess stone areas 40, select appropriate rock processing action and control the machine to remove the excess rock. For example, the user interface (UI) of the machine may enable the user to select areas in the displayed view, such as one or more of the views in Figures 5 to 8b. The UI may enable the operator select the excess stone area 40 and zoom-in and/or obtain additional information, for example.

[0055] An electronic device comprising electronic circuitries may be an apparatus for realizing at least some embodiments of the present invention, such as the main operations illustrated in connection with Figure 3. The apparatus may be comprised in at least one computing device connected to or integrated into a control system of the rock processing machine. Such control system may be an intelligent on-board control system controlling operation of various sub-systems of the rock processing machine, such as a hydraulic system, a motor, a rock drill, etc. Such control systems are often distributed and include many independent modules connected by a bus system of controller area network (CAN) nodes, for example. In some embodiments, the apparatus is an add-on instrumentation, such as an aiming tool for pre-designed drilling or excavation plan execution.

[0056] Figure 9 illustrates an example apparatus capable of supporting at least some embodiments of the present invention. Illustrated is a device 90, which may comprise the control unit 8 illustrated above. The device may be configured to carry out at least some of the embodiments relating to the rock processing machine tool position associated profile indication.

[0057] Comprised in the device 90 is a processor 91, which may comprise, for example, a single- or multi-core processor wherein a single-core processor comprises one processing core and a multi-core processor comprises more than one processing core. The processor 91 may comprise more than one processor. The processor may comprise at least one application-specific integrated circuit, ASIC. The processor may comprise at least one field-programmable gate array, FPGA. The processor may be means for performing method steps in the device. The processor may be configured, at least in part by computer instructions, to perform actions.

[0058] The device 90 may comprise memory 92. The memory may comprise random-access memory and/or permanent memory. The memory may be at least in part accessible to the processor 91. The memory may be at least in part comprised in the processor 91. The memory may be at least in part external to the device 90 but accessible to the device. The memory 92 may be means for storing information, such as drilling plan 94 and parameters affecting operations of the device. The memory may comprise computer program code 93 including computer instructions that the processor is configured to execute. When computer instructions configured to cause the processor to perform certain actions are stored in the memory, and the device in overall is configured to run under the direction of the processor using computer instructions from the memory, the processor and/or its at least one processing core may be considered to be configured to perform said certain actions.

[0059] The device 90 may comprise a communications unit 95 comprising a transmitter and/or a receiver. The transmitter and the receiver may be configured to transmit and receive, respectively, information in accordance with at least one cellular or non-cellular standard. The transmitter and/or receiver may be configured to operate in accordance with global system for mobile communication, GSM, wideband code division multiple access, WCDMA, long term evolution, LTE, 3GPP new radio access technology (N-RAT), IS-95, wireless local area network, WLAN, Ethernet and/or worldwide interoperability for microwave access, WiMAX, standards, for example. The device 90 may comprise a near-field communication, NFC, transceiver. The NFC transceiver may support at least one NFC technology, such as NFC, Bluetooth, Wibree or similar technologies.

[0060] The device 90 may comprise or be connected to a UI. The UI may comprise at least one of a display 96, a speaker, an input device 97 such as a keyboard, a joystick, a touchscreen, and a microphone. A user may operate the device and the rock processing machine via the UI, for example to move the machine and the tool, change display views, control rock processing actions, etc.

[0061] The apparatus may also be connected to position sensing unit(s) 98 and/or a scanning unit 99 providing data on scanned tunnel profiles.

[0062] The processor 91, the memory 92, the communications unit 95 and the UI may be interconnected by electrical leads internal to the device 90 in a multitude of different ways. For example, each of the aforementioned devices may be separately connected to a master bus internal to the device, to allow for the devices to exchange information. However, as the skilled person will appreciate, this is only one example and depending on the embodiment various ways of interconnecting at least two of the aforementioned devices may be selected without departing from the scope of the present invention. [0063] It is to be understood that the embodiments of the invention disclosed are not limited to the particular structures, process steps, or materials disclosed herein, but are extended to equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting. [0064] Reference throughout this specification to one embodiment or an embodiment means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Where reference is made to a numerical value using a term such as, for example, about or substantially, the exact numerical value is also disclosed.

[0065] As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary. In addition, various embodiments and example of the present invention may be referred to herein along with alternatives for the various components thereof. It is understood that such embodiments, examples, and alternatives are not to be construed as de facto equivalents of one another, but are to be considered as separate and autonomous representations of the present invention.

[0066] Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the preceding description, numerous specific details are provided, such as examples of lengths, widths, shapes, etc., to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

[0067] While the forgoing examples are illustrative of the principles of the present invention in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementation can be made without the exercise of inventive faculty, and without departing from the principles and concepts of the invention. Accordingly, it is not intended that the invention be limited, except as by the claims set forth below. [0068] The verbs "to comprise" and "to include" are used in this document as open limitations that neither exclude nor require the existence of also un-recited features. The features recited in depending claims are mutually freely combinable unless otherwise explicitly stated. Furthermore, it is to be understood that the use of "a" or "an", that is, a singular form, throughout this document does not exclude a plurality. INDUSTRIAL APPLICABILITY

[0069] At least some embodiments of the present invention find industrial application at least in underground mining.

ACRONYMS LIST

ASIC Application-specific integrated circuit FPGA Field-programmable gate array

CAN Controller area network

GSM Global system for mobile communication

LTE Long term evolution

NFC Near-field communication N-RAT 3GPP new radio access technology

UI User interface

WCDMA Wideband code division multiple access WiMAX Worldwide interoperability for microwave access WLAN Wireless local area network