Simulators continue to gain traction in training and upskilling the global mining workforce. E&MJ explores the latest developments.
Turnover is increasing across the global mining workforce, and skilled talent is becoming harder to find in certain markets. This coupled with the increasing level of complexity and technology used on heavy machinery means that there’s never been a greater need for owner-operators and contractors to focus in on operational excellence and correct operation.
Proper operation of mining equipment leads to enhanced production and safety, as well as cost savings through reduced wear and tear on equipment and lower fuel usage. As part of a carefully designed training program, simulation provides a safe and cost-effective means to familiarize and upskill operators on equipment before they meet the real deal, without fear of accidents or machine damage.
Operators can practice anytime and anywhere and there’s no need to take a machine out of production. Most simulators come as mobile modules and can be easily relocated between sites and/or supported with remote teaching. This allows mines to leverage global training expertise wherever their location.
Let’s look at some key developments from the past 12 months.
Immersive Kits Out US AHS, Launches IM360+ Simulator
In April 2025, Immersive Technologies, a global leader in mine training solutions, announced the expansion of its reach with the shipment of simulators, digital learning products and training services to its 52nd, 53rd, and 54th countries – Pakistan, Sierra Leone and Ethiopia. Immersive Technologies supports all mines — both surface and underground — and all OEM fleets. The company has an enviable track record that includes providing training solutions for over 360 mines globally and nine of the world’s top 10 mining companies.
A notable recent deployment was at Freeport’s Bagdad mine in Arizona in late 2024. As the mine, which is the first in the USA to use an autonomous haulage system (AHS), transitions operations to the new technology, simulators and digital learning systems from Immersive are supporting the workforce through change management and skills development. Nearly all of the world’s major autonomous mines have implemented Immersive Technologies’ AHS training solution. These are tailored to meet the individual needs of the mine, and each package includes onsite services to help manage the training technology implementation.
In Bagdad’s case, the training solution enhances proficiency for a range of equipment, including Cat autonomous trucks, P&H 4100 shovels, Cat D11T dozers, and light vehicles equipped with Cat MineStar Command for Hauling.
Immersive technologies explained that the complexity of roles for loading and auxiliary equipment operators increases with the introduction of AHS, and effective change management is vital for aligning personnel with the technology.
“Training plays a big role in getting all people working together smoothly with new systems,” said the company. “Immersive Technologies’ simulators consistently measure, assess, and optimize skills, reducing the time to achieve a ‘permit to work.’ As mines adopt AHS systems, efficiently processing large number of permit-to-work certifications has been a notable industry challenge.”
Immersive also secured contracts to provide workforce training solutions for four underground mining projects in the USA, Canada, Chile, and Indonesia in late 2024. These solutions encompass machine simulation, digital learning technologies, including virtual reality, 3D virtual machines, and training program development.
CEO David Anderson commented: “Immersive Technologies recognizes the strategic importance of underground mining and has increased its investment in new Conversion Kit developments for a growing range of underground machines. We also launched a new ‘Premium’ simulator platform optimized for underground applications at MINExpo 2024, positioned alongside new digital learning technologies to address the specific needs of underground customers.
“Underground mining is growing fast and 2024 has delivered new strategic customers which validates our increased underground research and development investment over the last few years. We see strong future growth in line with the projected growth of underground operations.”
MINExpo 2024 also saw the launch of the Immersive Technologies IM360+ simulator for underground operations. Equipped with a best-in-class visual system, the IM360+ is the first underground mining simulator to combine stereoscopic 3D, photo-realistic graphics and RealView head tracking technology.
Simformotion’s New Fletcher High Reach Scaler Simulator
In May 2025, Simformotion, another leader in heavy equipment simulator training solutions, announced the release of the Fletcher Simulators High Reach Scaler simulator. Set in an underground mining environment, the state-of-the-art High Reach Scaler simulator creates a realistic environment for operators to train in. The system features authentic Fletcher controls and machine exercises developed so operators can learn real-world scaler applications in the safety of a virtual environment.
The simulator provides multiple exercises, a motion system to help operators learn tipping points, and VR, which gives learners greater depth perception while practicing maneuvers and techniques. The exercises teach operators to conduct a proper pre-operation machine inspection, ensuring operational conditions. Operators learn correct start-up and shut-down procedures and how to accurately and efficiently remove loose or unstable rock and debris from tunnel walls and roofs, helping ensure mine site safety and prevent falls or collapses before other machines and workers enter the area.
The exercises also teach operators how to safely and effectively tram the scaler, position the machine, scaling operations and more. While operators practice their skills, the system’s built-in reporting software, SimU Campus, records their sessions and generates reports on an easy-to-read, user-friendly dashboard.
“We recognize that safety in mine operations is critical, which is why the new Fletcher Simulators High Reach Scaler system teaches operators how to accurately, efficiently and safely remove loose or unstable rock and debris from tunnel walls and roofs,” said Lara Aaron, CEO, Simformotion.
“As operators learn and practice the real-world skills on the authentic Fletcher controls, they also stay safe in the virtual, simulated mine environment. We frequently hear of the challenges mining operations have in finding operators. Fletcher Simulators help companies build their own workforce with knowledgeable, skilled operators.”
The system also features a companion SimScholars online curriculum, a one-to-one match with the simulator exercises, which can be used in the classroom or for remote learning. The interactive, turn-key curriculum solution features instructor guides, videos, quizzes and more. Simformotion said that by integrating SimScholars curriculum, operators experience a unique, blended learning experience.
At MINExpo 2024, Simformotion (which is a licensee for Cat simulators from Caterpillar Inc) announced the release of the new Cat Simulators Collaborative Worksite Training for Mining package. This teaches learners to collaborate virtually while operating a mining truck and hydraulic mining shovel.
Working as a team in a virtual mine site, operators gain real-life experience in truck spotting, loading, hauling materials, face cleaning, spillage cleanup and other real-world tasks. Simformotion said they can practice and work together without the fear of causing harm to themselves, others or equipment while in the safety of the virtual environment.
Vanessa Price, vice president, Simformotion, explained: “The package is an ideal solution for in-person operator training in any setting — be it a classroom, office, or shop — or for remote training for learners in different buildings.
“Learners can now experience hands-on training alongside their teammates in a shared virtual mine site environment. The simulator package takes heavy equipment operator training to the next level by creating realistic mining scenarios, such as the load-haul cycle. Learners must work together to complete the tasks and succeed as a team. It’s no longer just about individual learners completing their training; the next step is teams learning to collaborate efficiently, effectively and safely.”
The training package is available in multiple languages. It includes a method for recording and reporting the results of each learner’s simulation session, comparing their performance to Caterpillar expert benchmarks. Cat Simulators systems feature authentic Cat controls and VR Edition, which sets the package apart from others. With the VR headset, users experience a larger view of the environment with greater depth perception.
Quelle:
Foto: The new IM360+ Advanced Equipment Simulator equipped with an Epiroc production drill. (Photo: Immersive Technologies)
https://www.e-mj.com/features/learning-and-growing-in-virtual-reality
