RealTrac solutions for collision awareness, proximity detection, positioning of personnel and vehicles for open cast mining
Proximity detection and positioning system provides personnel and vehicles positioning and allows to trac the objects to minimize the probability of incidents
RealTrac «Open Cast Mining» a comprehensive industrial safety solution for open cast and coal mining operations. It enables real‑time positioning of personnel and machinery, collision prevention between vehicles and people.
The RealTrac “Open Cast Mining” includes the following safety and efficiency increasing products
Control of the location of miners on the territory of a quarry or section
The dispatcher can receive real-time data on the current location of all miners or mining equipment, as well as information about the path traveled by the controlled object for a given period.
Control of access levels of miners
Thanks to the creation of geofences with different access levels, the dispatcher always knows whether one or another miner is in the permitted or prohibited zone. The reporting and analytics system allows you to identify systematic violations of access levels and prevent possible incidents.
Control of working time, time spent in the geofence
The RealTrac system allows you to register the time of entry /exit of employees in a certain geofence. This allows you to control their presence in certain areas and in areas of work. And also notify the dispatcher or miner if necessary to leave the zone. At the same time, data on movements, time spent in various zones and events are stored on the server for up to 10 years.
Emergency notification of miners during drilling and blasting operations
The system allows real-time monitoring of the process of personnel withdrawal from the hazardous area where drilling and blasting operations are planned. The system also helps with evacuation: the time spent, the trajectories of workers during the evacuation announcement, and most importantly - determining the current location of workers who could not get to safe collection points in time.
Evacuation and detection of miners caught in an accident
The system allows you to monitor the evacuation process in real time: the time spent, the trajectories of the movement of miners during evacuation and, most importantly, determining the current location of workers who could not get to safe collection points in time.
Advantages of monitoring miners
Advantages of the RealTrac product Positioning for open-pit mining:
Modular industrial safety system
Different types of zonal, global positioning and hybrid positioning without drastic changes, thanks to a single infrastructure
Integration using an open protocol (API), allows you to transfer data to personnel accounting systems, automated process control systems and other mining enterprise systems.
Operating principle and components
Personnel positioning can be carried out in three directions:
Zonal positioning
Determining the location of a miner or equipment with accuracy to the zone.
- Accuracy: +/- 20 meters
- Radio detection range: up to 100 meters
- Zone configuration: from 20 meters to the zone*
* - it is possible to configure zones according to the Customer's request
- Backbone channel: BLE or other data transfer protocol**
* - According to the Customer's requirements
- Restrictions: Work only in the area of radio visibility of access points
- Implementation costs: low
Global positioning
Determining the location of a miner or equipment with an accuracy of up to a meter.
- Accuracy: +/- 1-5 meters
- Radio detection range: unlimited
- Zone configuration: from 10 sq.m.
- Backbone channel: Wi-Fi, LoRa or other data transfer protocol*
* - According to the Customer's requirements
- Restrictions: Work in visibility conditions of at least 4 satellites
- Implementation costs: low
Hybrid positioning
Combines the advantages of zonal and global positioning.
- Accuracy: +/- 1-5 (20) meters
- Detection range: unlimited
- Zone configuration: from 10 sq.m.
- Backbone channel: Wi-Fi, LoRa or other data transfer protocol*
* - According to the Customer's requirements
- Restrictions: Zonal positioning works indoors. Global positioning works in an open area
- Implementation costs: average
Equipment for monitoring the location of miners and equipment on the territory of open-pit mining:
Personal tag / Transport tag – allows you to determine the location and notify about entering the danger zone.
- Designed as a separate device / installed on machinery
- Powered by battery / on-board network of mining equipment
- Does not affect the operation of other notification systems
- Enclosure protection class IP 65, IP 67, PO Exia I Ma X (Optional)
Access point – installed in places where zonal positioning is required and provides monitoring of objects in the radio visibility zone.
- It is installed in areas where zonal positioning is required
- Power supply, both from the electrical network (100-240V) and using POE technology
- It can transmit data from tags to the system, in wired mode
- Enclosure protection class IP67, IP69 (Optional)
Software
The RealTrac Positioning product includes server and client software.
RealTrac Server
- Calculation and storage of tag location information
- Running on a server running free software and does not require additional licensing
- Availability of an open protocol (API) for integration with third-party systems
- Several quarries and processing plants on one positioning system server
RealTrac Client
- This client, does not require the installation of additional software on the workplace of the dispatcher or manager
- Visualization of current data
- Analytics and Report Builder
- Creating metrics and business processes based on geofences and other system features
- Differentiation of employee access levels for working with the web interface of the positioning system
- Ability to connect to a remote server
More about the product RealTrac Positioning Solution presentation request
RealTrac Collision Awareness
The product is designed to reduce the number of accidents associated with a collision of vehicles and machinery, as well as collisions of vehicles with miners in conditions of insufficient or poor visibility.
Tasks to be solved
The product solves problems in two directions of control:
Direction: Vehicle - vehicle (V2V)
Tasks
- Improving the safety of the movement of quarry transport in conditions of poor or insufficient visibility
- Reduction of costs associated with downtime and repair of quarry equipment as a result of a collision
Functions
- Fixing the fact of dangerous proximity of vehicles and mining equipment
- Notifying the driver/miner or operator about the possibility of a collision
Direction: Vehicle - personnel (V2P)
Tasks
- Helps to reduce the level of injuries associated with the impact of mining equipment on people
- Allows you to make safe maneuvers of quarry fleet with several people around it
Functions
- Fixing the fact of a dangerous incident related to hitting a miner
- Notification of the miner's presence in the danger zone for the vehicle operator and for the person in a same time
Advantages of preventing collisions between vehicles and with miners
What distinguishes the RealTrac Collision Prevention product from analogues:
360 degree control around the vehicle
Determining the distance and direction to another object with an accuracy of 0,2 meter
Three control zones with the ability to set them any size and configuration
Сontrol zones around the quarry equipment, adjustable depending on the dimensions of the equipment or the position of the working mechanism of any special fleet
Full autonomy of the system (Access to GPS and GSM signal is not required for operation)
Operating principle and components
Provides a situational understanding of the environment around the vehicle, identifying the presence of vehicles, people or objects inside previously defined zones. As soon as an object, vehicle or employee equipped with a collision awareness system tag approaches previously defined zones, the system issues a tangible, audible and visible warning.
The notification can be sent using:
Sound notification from the equipment, the inclusion of sirens or beeps
Vibration from a personal tag
Light notification from a personal tag
Flashing of the headlights of the equipment or the inclusion of other visual warning devices
The intensity of the alert can be adjusted depending on the control zone.
Equipment for miners
Personal tag (tracker) PROD TAG 720 or PROD TAG 210 - is issued to the miner and with its help the location relative to the vehicle with the installed antennas of the collision prevention system is determined. The tag is made in the form of a separate wearable device.
Equipment for vehicles
The control unit is installed on the vehicle and calculates the distance from the tag to the antennas and the direction of movement of the tag. It determines in which of the control zones the tag is located and, depending on this, displays information about objects in different zones on the driver's display and activates light-graphic or audible warning signals.
Antenna - installed in quantities of 1-12 depending on the size and configuration of the vehicle and is used to detect other antennas or personal tags (trackers).
Autonomous operation mode
The system has built-in software and has absolute autonomy from other systems and the data transmission network.
When implementing a backbone channel, the system can transmit data on recorded dangerous approaches, collisions and other information to the RealTrac system server. This allows for the subsequent analysis of incidents and the construction of work report.
EMESRT L7–L9 Collision Protection with RealTrac and Nerospec
The RealTrac Collision Avoidance System (CAS) improves the safety of vehicles and personnel in mines, open pits, industrial sites, and warehouses by monitoring «vehicle–vehicle» and «vehicle–person» interactions within three zones: «Attention», «Danger», and «Emergency».
The solution scales from basic awareness and warnings (EMESRT L7–L8) to full automatic vehicle intervention at EMESRT L9 through integration with the OEM‑agnostic Nerospec OSCON system.
EMESRT Level 7 support: awareness and situational visibility
At EMESRT Level 7, RealTrac creates a three‑zone safety field around each machine and displays it on the operator’s in‑cab screen.
The driver sees which zone («Attention», «Danger», «Emergency») other machines or people are in and can adjust their driving in advance, even in poor visibility, dust, or complex terrain.
Key L7 functions in RealTrac:
- Panoramic visualization of nearby objects around the machine in three configurable zones.
- Clear indication of system status and proximity zones to support informed decisions by the operator.
EMESRT Level 8 support: active alerts and behavioral guidance
At EMESRT Level 8, RealTrac adds multi‑level audible and haptic alerts to visual indications, ramping up driver and pedestrian attention when entering the «Danger» and «Emergency» zones.
The system automatically changes the intensity of alerts as risk increases, helping the operator slow down, increase distance, or stop in time.
L8 functions in RealTrac:
- Audible alerts with different tones and volumes for «Danger» and «Emergency» zones in the cab.
- Light indicators (on‑screen status, beacons, lights) and vibration on personal tags.
- Flexible configuration of zone size, shape, and behavior for each vehicle type and operating scenario.
EMESRT Level 9 support: automatic vehicle intervention
To reach EMESRT Level 9, a system must not only detect high‑risk interactions and warn the operator, but also automatically intervene in vehicle motion when needed - slowing or stopping the machine even if the driver fails to react.
RealTrac provides the detection, zoning, and decision logic, while integration with Nerospec OSCON adds an OEM‑agnostic vehicle intervention controller into the braking and traction circuits of any machine.
How L9 works in this combined solution:
- RealTrac CAS detects an object entering the «Emergency» zone and issues an intervention request based on configured rules.
- Nerospec OSCON, an OEM‑independent EMESRT Level 9 Vehicle Intervention Control system, takes over motion control, automatically reducing speed or performing a controlled stop.
- This combined approach supports both surface and underground operations and mixed OEM fleets, delivering a unified L9 safety standard across the entire site.
Benefits of combining RealTrac and Nerospec across L7-L9
The combination of RealTrac CAS and Nerospec OSCON turns collision avoidance from a «warn and display» solution into a full «warn, guide, and intervene when necessary» safety platform.
Sites gain an end‑to‑end safety stack that covers all EMESRT levels - from enhanced awareness (L7) and improved operator behavior (L8) to automatic prevention of severe incidents through direct vehicle intervention (L9).
An example of installing the RealTrac Collision Awareness System on mining vehicles
More about the product RealTrac Collision Awareness System Solution presentation request
Benefits of the RealTrac Open Cast Mining
- Possibility of integration with dispatching and control systems of the mining and transport complex and other enterprise systems
- Leverages existing mining infrastructure
- The modularity of the RealTrac system allows you to add functionality as needed
- Integration using an open Protocol (API)
Products from RealTrac Technologies today are:
900+
Number of trackers used in open cast mining
10+
Number of equipped open cast mining
Our clients
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RealTrac International
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