ipico df rfid 20060428 1
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IPICO Dual Frequency RFID IPICO Dual Frequency RFID
May 2006IPICO Engineering
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 2
Limitations of Conventional RFID TechnologyLimitations of Conventional RFID Technology
Active RFID: High cost of tags ($20-50) prevent all equipment from being
tagged Long active read ranges prevent active from being used as
access control technology Limited battery life implies additional costs to maintain batteries
Passive RFID: choice between Low Frequency (LF) – 125-134 kHz High Frequency (HF) – 13.56 MHz Ultra-high Frequency (UHF) – 860-960 MHz Microwave (uW) – 2.45 GHz
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 3
Limitations of LF and HF Passive RFID Limitations of LF and HF Passive RFID
Low Frequency (125/134 kHz): Read range limited by carrier / signal ratio Low frequency of data carrier implies low data rates Low data rates implies limited anti-collision, i.e. not many tags
can be read in a short time period Too slow to read several assets carried by person walking
through gate
High Frequency (13.56 MHz): Restrictive power limitations for energising tags at 13.56 MHz Very limited read range in noisy environments (<200 mm) - too
low to read assets carried by people through turnstiles
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 4
Limitations of UHF and uW Passive RFID Limitations of UHF and uW Passive RFID
Ultra-high Frequency (860-960 MHz): UHF waves do not penetrate human body – absorbed by
liquids Assets carried by people are invisible to UHF reader if
screened off by person’s body Tag directly on human body difficult to read even in case of
line-of-sight – not sufficiently reliable for safety systems
Microwave (2.45 GHz): Same limitations as UHF for people and assets carried by
people, but much more limited read range (~1m) Also not suitable for this type of safety system
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 5
Alternative Technology: Dual Frequency RFIDAlternative Technology: Dual Frequency RFID
IPICO developed patented Dual Frequency (DF) RFID to overcome many of the limitations of LF, HF, UHF and uW RFID
DF has following characteristics: Utilises magnetic induction both for energising tags and for
communication (similar to LF and HF) Low Frequency signal is used for energising tags – less
restrictive regulations compared to HF band allows longer energising range
High Frequency signal is used for communication from tag to reader – sufficiently high data rates can support good anti-collision, i.e. many tags can be read in short time period
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 6
DF Tag and Reader Air InterfaceDF Tag and Reader Air Interface
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 7
DF Reader and Tag Functional BlocksDF Reader and Tag Functional Blocks
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Unique Capabilities of Dual Frequency RFIDUnique Capabilities of Dual Frequency RFID
Based on its inherent characteristics, DF RFID offers the following benefits: Offers much longer read range than HF (1.2 – 2 m compared
to 0.6 – 0.7 m in ideal circumstances) Offers much faster anti-collision than LF (~100 tags/sec
compared to < 5 tags/sec) Can read through liquids, in contrast with UHF and uW –
suitable for tracking people and assets carried by people Performs reliably and consistently in close proximity to metals,
in contrast with UHF and uW
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 9
RReal eal LLife ife EExamplexample: Anglo Platinum Mines: Anglo Platinum Mines
Paardekraal shaft of Anglo Platinum mine outside Rustenburg in South Africa, with ~5000 cap lamps, required RFID solution
Assortment of multiple RFID technologies is a nightmare to manage – required one RFID technology to solve all problems
Technology options considered by Paardekraal: Use active tags on the batteries for the continuous tracking of these assets
- cost too high (10 times passive tags) LF (125 kHz) technology found to be highly susceptible to electromagnetic
interference, which is severe in mines HF (13.56 MHz) had too limited read range (100 mm) to read small tags
over sufficient read range through turnstiles uW (2.45 GHz) had too limited read range and incompatible with people
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 10
RReal eal LLife ife EExamplexample: Anglo Platinum Mines : Anglo Platinum Mines (cont’d)(cont’d)
Practical trial with UHF RFID: About 4-5 years ago Paardekraal decided to put UHF RFID on trial (4W
EIRP readers and passive tags, operating at 915.3MHz) A criterion for using the UHF tags was to increase the read range from
proximity reading provided by HF (100mm) to 600mm to realise a hands free environment through turnstiles
Cap lamp battery compartments were fitted with tags whilst readers were installed at issuing bays and at turnstiles
Results: system failed for two reasons Primay reasons: Data integrity of the system was unsatisfactory due to
limitations of passive UHF technology in an environment where people, wet goods and metals are involved
Secondary reason: Wrong packaging techniques resulted in tag failures due to corrosion of unprotected tags
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 11
IPICO SolutionIPICO Solution
After the failures with other technologies, Anglo Platinum approached IPICO for an alternative
Although IPICO also manufactures UHF tags/readers, DF was recommended due to nature of application
Advantages of DF over UHF was easily demonstrated during a live pilot period of 4 weeks
The first phase operational system at Paardekraal included 14 DF short range master readers, 4 slave readers and 5000 DF linear tags (read range +/- 600mm with Short range reader)
Based on this success the DF system was then implemented at one of Anglo Gold Ashanti’s largest mines (Kopanang in Orkney, South Africa); the deployment included tags for about 5000+ cap-lamps, 200+ SCSR, 900+ GDI’s and proximity readers for 76 issuing and registration points as well as 14 medium range portal readers
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 12
Packaging Requirements for TagsPackaging Requirements for Tags
Before : Unprotected UHF tag
After: iPico’s Sealed DF tag
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Reader Installation RequirementsReader Installation Requirements
UHF readers requiring screening
DF Short range readers requiring no screening
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Various DF tags on equipmentVarious DF tags on equipment
Because of magnetic coupling between the readers and tags, human bodies, fluids, and even some kinds of metals pose no problem
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 15
DF Short-range DF Short-range RReader eader PPortalortal
DF Short-range reader portal with single body access reading the tag in the Cap-lamp battery as well as the tag on the SCSR pack
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 16
DF Short-range DF Short-range RReadereader InstallationsInstallationsPhotos: Courtesy Willard: Paardekraal mine – AmplatsPhotos: Courtesy Willard: Paardekraal mine – Amplats
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 17
DF Medium DF Medium RRange ange RReader eader PPortalortal
DF Medium range reader portal for free flow tracking at the turnstiles to cover a larger area
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 18
Lamp room Management System Lamp room Management System (LMS) at Kopanang (LMS) at Kopanang Source: Courtesy Lamp room Solutions and Source: Courtesy Lamp room Solutions and
Consulting (Pty) LtdConsulting (Pty) Ltd
LMSReader Controller LAN
10Mb TCP/IP
Mine LAN100Mb TCP/IP
MineHR application
MineAccess control and T/A application
MineOther ERP applications
LMS ServerMS Win XPMS Dot Net
MS SQLLMSSupervisorFrontend
LMSReport
interface
Equipment IssueStations
- iPico OEM readers- Barcode readers- Keyboards- Displays
Gas TestStations
- iPico OEM readers- 2x Display
Equipment Testand Repair Stations
- iPico OEM readers- Barcode readers- Keyboards- Displays
Free FlowMonitoring Portals- iPico Portal readers- iPico DIMI-SA-4
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 19
The ResultsThe Results
Evaluation of iPico’s equipment started in Sept 2003 for a period of a month using 150 tags and 4 readers
Orders were placed in November 2003, and system was commissioned in Jan 2004
100% shift clearance reports at Paardekraal since installation – 24 hour operation all year
Seamless integration into existing IT and Lamp room management system
Automated logging and issuing, increasing operational through-put
Trouble free access control speeds up shift entrance and clearance at the turnstiles
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 20
The ResultsThe Results (cont’d)(cont’d)
Maintenance cycles on batteries can now be managed intelligently and cost effectively
Huge savings have already been achieved because battery theft and losses are under control
Billing of asset usage is more accurate Data integrity of battery movement is 100%. No more manual logging of
items are done During the first 2 weeks after commissioning the RFID installation,
accurate shift clearance information resulted in saving an employee’s life. The management system flagged an incident of a person not entering the Lamp room on time. A proto-team was send down the mine were they found the disorientated employee just in time before the blasting session commenced
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 21
Expanding RFID Systems to Productivity Expanding RFID Systems to Productivity ManagementManagement
Required benefits for Productivity Management systems: Improvement of utilisation of production assets Measuring productivity of individuals and teams Improving accuracy of maintenance management
New RFID requirements to support Productivity Management systems: Tracking of assets and people not only through turnstiles at
lamproom but also through wider gates at cage and in haulage to cover operational areas
Tracking of underground vehicles Tracking of assets taken from shafts to maintenance depots
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Required Functional Extensions of RFID Required Functional Extensions of RFID Systems to support Productivity ManagementSystems to support Productivity Management
Tracking people and assets through underground operations need at least 3m wide portals, i.e. 1.5m read range from each antenna – DF is only viable option, but requires increase in reader power levels
To sustain increased DF read ranges in noisy environments, increased noise robustness is required – digital signal processing (DSP) techniques will be employed as part of DF receivers
Large assets transported above ground in trucks need even larger read ranges – UHF best choice for assets too large to be carried by people, but requires structured operations to ensure line-of-sight
RFID readers must be integrated with underground telemetry systems When RFID is integrated into much wider scope of operational activities,
buy-in from trade unions is essential to ensure support from miners and to prevent “Big Brother Watching” syndrome
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Current Status of Integration of RFID into other Current Status of Integration of RFID into other Operational SystemsOperational Systems
IPICO is working with specialist system and service providers in several application areas to make RFID part of mainstream operations: RFID readers will be linked to telemetry systems to make RFID information
available to various MIS systems without requiring additional infrastructure – RFID becomes just another data capturing system, similar to environmental monitoring, fire alarms, etc.
RFID will provide existing software applications with more complete and more accurate data on the location and status of people and assets
Time-and-Attendance: DF RFID will be used in combination with mag-stripe / Smartcards for general T&A applications, including access of to hostel facilities and clock-card systems
IPICO RFID for Mining Applications May 2006 COPYRIGHT © 2006, IPICO INCPage 24
ConclusionsConclusions
Dual Frequency RFID technology is a successful method deployed as part of Asset Management Projects
Dual Frequency RFID technology provides a wonderful tool for People Tracking and Product Spotting solutions
Systems installed for safety applications can be extended to productivity improvement systems using the Dual Frequency Technology
The Dual Frequency Technology can be deployed in solutions where the current EPC UHF technology would never work, harsh conditions, bodies of liquid, metals
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