The ongoing pressure from low commodity prices is forcing mining companies to consider solutions for optimizing production and reducing costs. To remain competitive, the mining industry – rooted in tradition – is increasingly turning to smart automation solutions.
Throughout the entire value chain – from exploration and mining of mineral resources to infrastructure, processing, and delivery to the customer – all process steps must be coordinated to ensure cost-effective operations. The use of remote-controlled, intelligent systems paves the way for automated underground operations and improves safety and efficiency.
What advantages does Beckhoff offer the mining industry?
- reliable control of transportation, gas monitoring, and alarm systems underground
- rugged, durable hardware with an IP67 protection rating for environments with dust and gas
- open automation platform with a wide range of interfaces for field devices
- integrated measurement technology and condition monitoring for preventive maintenance
- unified platform for Ex and non-Ex signals with diagnostics and cloud connection
Our technologies for mining industry
The control system for process automation
Beckhoff calls on a comprehensive modular range of components and deep-rooted, cross-sector expertise to create open automation systems using PC-based control technology. All control functions, such as PLC, visualization, cloud connection, explosion protection, safety technology, and measurement technology, are integrated on a universal platform. For mines, we offer comprehensive solutions for communication from zone 0/20 all the way to the cloud – whether you need to automate new plants or retrofit existing systems.
PC-based control for mining:
- universal platform for the automation of all processes and plants
- safety functions, explosion protection, and measurement technology in a single system
- high level of interoperability due to open interfaces in hardware and software
- control and cable redundancy for increased plant availability
- PC-based control technology is established worldwide across all industries
Ideal for raw material extraction: the open EtherCAT fieldbus
As a universal and open high-speed fieldbus, EtherCAT is suitable for all areas of application – from PLC and drive technology to sensors and measurement and safety technology. With EtherCAT, you only need one communication technology for your mine and you can also benefit from the safety and optimum performance of the comprehensive EtherCAT architecture. The EtherCAT-based control is also open with regard to integrating third-party EtherCAT devices and other fieldbus systems.
Advantages of EtherCAT for the mining industry:
- fast troubleshooting through diagnostic functions
- cable redundancy for high plant availability
- implementation of flexible topologies
- Extended Distance technology for communication between distributed plants
- lean plant cabling through remote I/O
TwinCAT: the control platform for the mining industry
With its TwinCAT automation software, Beckhoff offers a central platform for control tasks in mining operations. Both text-based and graphical programming languages are available for developing traditional process control in PLCs. The implementation of control tasks is supplemented by modular software functions for visualization, communication, and evaluation of the production data.
TwinCAT highlights for the mining industry:
- control-integrated Industry 4.0 and IoT applications
- predictive maintenance and comprehensive data analysis functions
- TwinCAT Controller Redundancy for increased plant availability
- integration of safety and explosion protection on a single software platform
- support for common standards such as NAMUR, HART, and FDT/DTM
Our product highlights for the mining industry
Intrinsically safe signal acquisition in IP20 and IP67
Beckhoff’s ELX and EPX EtherCAT modules combine compact I/Os with safety barriers for the direct connection of intrinsically safe field devices from zone 0/20 and 1/21. The result is extremely compact EtherCAT I/Os for the direct connection of intrinsically safe sensors and actuators. With certification according to ATEX, IECEx, and NEC/CEC, as well as other country-specific standards, EtherCAT I/Os can be used worldwide.
The EPX modules in the EPX series with protection rating IP67 are suitable for the implementation of modular and control cabinet-free plant concepts. The robust EPX modules can be mounted directly on the plant and facilitate reliable data acquisition in hazardous areas where control cabinets cannot – or should not – be installed.
EtherCAT modules with intrinsically safe interfaces for Ex applications:
- direct connection of intrinsically safe field devices
- IP67 modules for field installation
- a wide range of high-resolution, accurate signals
- extensive portfolio of certificates for worldwide use
Connecting Ethernet-APL field devices to the modular I/O system
The increasing digital transformation, especially in the areas of diagnostics and monitoring, is currently one of the major topics in the mining industry. Plants are generally very widespread and have particular requirements that are met by the specially developed standard Ethernet-APL, which offers a transmission rate of 10 Mbit/s and a cable length of up to 1,000 meters.
Beckhoff integrates the Ethernet-APL technology into the modular terminal portfolio. The compact ELX6233 can be mounted in the control cabinet in combination with other EtherCAT Terminals. Two Ethernet-APL field devices can be connected via each ELX6233 Terminal. As with all EtherCAT Terminals in the ELX series, the ELX6233 enables direct connection of intrinsically safe field devices from zone 0.
Integrated communication from the sensor to the cloud
A networked control system is crucial in mining to ensure seamless communication across decentralized plant components. Due to its openness, PC-based control provides the ideal foundation for Industry 4.0 and IoT concepts: Flexible interfaces in both software and hardware enable both horizontal and vertical integration, such as to higher-level control systems.
The TwinCAT IoT software library is available for communication between the plant control system and cloud-based services. It is designed to support the standardized OPC UA and MQTT protocols for communication with popular cloud systems such as Microsoft Azure™ and Amazon Web Services, as well as private cloud systems in the company’s own network.
Compact controllers for mining operations
High-performance industrial PCs form the basis for a central control station for managing and monitoring processes across the entire operation. With the CX series of Embedded Controllers, which are certified according to ATEX, IECEx, and NEC/CEC for use in zone 2, the control can also run locally in the control cabinet, which opens up potential for more efficient process automation, especially with regard to modularization. With their integrated interface, the controllers not only save on space and costs, but also facilitate the direct connection of I/O terminals without the use of bus couplers.
Depending on requirements, embedded controllers for decentralized control can be combined with more powerful embedded PCs, industrial PCs, and existing control systems for central control.
Scalable embedded PCs for the mining industry:
- from small-scale control through to high-performance multicore solutions
- flexible expansion through interface modules
- rugged devices with high vibration resistance and shock resistance
- extended temperature range from -25 to +60°C
- certification according to ATEX, IECEx, and NEC/CEC
Simplify the commissioning of field devices with TwinCAT
The full integration of the HART functionality into both the I/O system and the TwinCAT engineering ensures simple project planning and commissioning. The HART protocol integration allows users to integrate HART field devices directly into the controller. In addition, TwinCAT reduces the engineering effort: The TwinCAT FDT container enables the integration of field device DTMs directly into the TwinCAT Engineering and thus offers programming and field device configuration in one environment.
The Beckhoff ComDTM enables the seamless integration of TwinCAT controllers into existing process control systems. Using ComDTM, the DTMs of the field devices connected to HART-enabled EtherCAT Terminals can be integrated into any FDT containers in higher-level systems. This allows field devices to be configured and parameterized remotely without direct access to the PLC.
Control concept for the mining industry
FAQs about mining
Automation technology plays a crucial role in minimizing risks in mining by monitoring critical processes, reducing the need for dangerous manual intervention, and enabling precise control even under extreme environmental conditions. Through continuous data collection and intelligent control systems, potential hazards can be detected early and automatic protective measures triggered.
With PC-based control, Beckhoff offers a consistent, open automation architecture that combines control, measurement technology, visualization, safety functions, and cloud integration on a single platform. High-performance controllers, a broad portfolio of I/O modules – including rugged IP67 box modules – and EtherCAT’s Extended Distance functions, combined with modular TwinCAT software libraries, enable decentralized data acquisition, remote maintenance, and efficient condition monitoring for predictive maintenance and easy retrofitting in harsh mining environments.
In hazardous areas, such as those commonly found in mining, control systems must be designed to prevent the formation of ignition sources while reliably performing safety-relevant shutdown and protective functions. Modern automation solutions make this possible through intrinsically safe interfaces, continuous monitoring, and integrated safety technology.
Beckhoff’s modular TwinSAFE components enable various topologies for applications with functional safety requirements. This makes it possible to implement decentralized topologies with safety-related control functions executed directly at the field level. Due to the existing certification of certain TwinSAFE products, the safety functions can even be performed in hazardous areas.
Process and status data are a key factor in mining optimization. They enable the monitoring of plant conditions, the detection of trends, and the early identification of potential malfunctions. For example, a rising vibration signal at a conveyor bearing can provide an early indication of bearing or imbalance problems, allowing for targeted corrective action before a failure occurs. Modern automation systems continuously collect and correlate these signals and, when necessary, trigger alarms, automatic control adjustments, or scheduled maintenance tasks to prevent downtime.
Beckhoff achieves this with PC-based control and a unified EtherCAT I/O system that seamlessly integrates sensors from standard and hazardous areas. With TwinCAT Analytics and TwinCAT IoT, the recorded values are analyzed in real time and transmitted via open interfaces such as OPC UA, HART, or NOA concepts to local or cloud-based systems, where they are visualized and used for predictive maintenance, alarm management, and process optimization.
The integration of IT and IoT technologies into existing mines enables centralized data collection, networked process control, and integration with cloud-based analysis and optimization tools. Open interfaces and standardized communication protocols enable the integration of existing sensors and control systems without having to replace entire plants.
Beckhoff relies on PC-based control as a central platform to integrate IT and OT systems. With TwinCAT IoT and TwinCAT Analytics, data is transmitted via standards such as OPC UA or MQTT to Microsoft Azure, AWS, or private clouds, where it is processed and used for digital services. The modular EtherCAT architecture enables easy retrofitting, while rugged IP67 modules and Extended Distance technology ensure reliable networking even in sprawling and harsh mining environments – from the field level to the central control room.
