How Mine Drones Are Improving Safety and Optimizing Mining

6 Ways Mine Drones Are Being Used

Mine drones have become a vital asset in both underground and surface mining operations. As drone technology continues to evolve, the potential for integrating these tools into mining processes is expanding rapidly.


What Is a Mine Drone?

A mine drone is specifically designed or adapted for use in mining environments, such as stockpile measurement, surveying, mapping, and inspections, including ultrasonic thickness testing. Mining is inherently dangerous, with unpredictable conditions that can change quickly, whether underground or on the surface.

While mine drones won't eliminate all risks, they can be deployed in areas where human presence is unsafe. Unlike standard consumer drones, mine drones are often built to operate without GPS, which is unavailable in many mines.

mine-drone-flyability-2Aerial drone footage of a surface coal mine

The mining industry has embraced drone technology due to its ability to improve data collection, enhance safety, and reduce costs. Here are six key ways drones are used in mining:

1. Volumetric Monitoring

Volumetric monitoring involves calculating the amount of material left in stockpiles of overburden, ore, or other materials. Traditional methods are time-consuming and less accurate, especially for large stockpiles.

Drones equipped with LiDAR or photogrammetry software can quickly generate 3D models, allowing for precise volume calculations. This helps track changes over time, optimize resource management, and reduce waste.

mine-drone-flyability-3Processing overburden into stockpiles

2. Hazard Identification

Mining sites are full of hazards like unstable rock formations, gas leaks, and dust explosions. Drones allow for remote inspections, reducing the need for human workers to enter dangerous zones.

In underground settings, drones like the Elios 3 can navigate tight, dusty spaces to detect blockages and structural issues. They also create 3D models to help identify geological features and potential risks.

3. Drilling and Blasting Assessment

Drones collect data before and after drilling and blasting operations, creating detailed 3D models. These models help assess the impact of blasts, identify hazards, and ensure safer future operations.

This data supports better decision-making and improves situational awareness, helping teams avoid dangerous areas and maintain operational efficiency.

mine-drone-flyability-4Drilling holes for explosives

4. Mine Monitoring and Planning

Mining operations involve complex systems that require constant monitoring and planning. Drones assist in various aspects, including haulage road design, equipment inspection, site security, and environmental monitoring.

They help analyze road conditions, inspect critical machinery, monitor security, and track environmental impacts, ensuring safer and more efficient operations.

5. Mine Development and Exploration

Exploring new mining areas is expensive and risky. Drones can safely access difficult-to-reach locations, providing valuable data without putting people at risk. This is especially useful for inspecting old or abandoned parts of a mine.

The Elios 3, for example, is designed to operate in confined, low-visibility spaces, making it ideal for underground exploration and mapping.

6. Processing Plant Inspections

Drones are used to inspect processing plants without disrupting ongoing operations. They can check conveyor belts, tanks, and other machinery for wear, cracks, or temperature issues.

This allows for quick, safe inspections and helps prevent costly downtime by identifying problems early.

mine-drone-flyability-5

The Benefits of Drones in Mining

Drones are transforming mining by improving safety, reducing costs, and increasing efficiency. With their ability to collect aerial data, perform inspections, and create 3D models, they offer a powerful alternative to traditional methods.

Some key benefits include faster data collection, reduced human exposure to hazardous areas, improved accuracy in measurements, and better environmental monitoring. As technology advances, the applications of mine drones will only continue to grow.

Watch the Elios inspect and map an obstructed ore pass:

 

The Best Indoor Mine Drone on the Market

Among the many drones available, Flyability’s Elios 3 stands out for its durability, functionality, and advanced capabilities. Designed for indoor and confined spaces, it offers collision tolerance, high-resolution imaging, and real-time 3D mapping.

Its dual thermal and 4K camera, along with a powerful lighting system, ensures clear visibility even in dark or dusty environments. The Elios 3 is ideal for inspecting tunnels, shafts, and other hard-to-reach areas, making it a top choice for mining operations.

Flyability Elios 3 Specs / Features:

  • Dual Thermal/Camera Sensor: 12 megapixels HD live streaming
  • Lighting: 10k Lumen dust proof lighting with oblique lighting
  • LiDAR mapping: Real-time 3D view of the drone’s trajectory and environment. Scanner captures 1 million point per second with centimeter accuracy.
  • Flight Time: 10 minutes
  • Flight Speed: 6.5 m/s
  • Transmission System: Beyond visual line-of-sight
  • Modular payloads: Use a highly specialized LiDAR sensor and ultrasonic thickness payload to enhance the quality and type of data gathered during an inspection

mine-drone-flyability-6Elios 3

Best Fixed Wing Outdoor Mine Drones on the Market

WingtraOne GEN II

The WingtraOne GEN II is a fixed-wing drone that offers extended flight times and high-performance mapping capabilities. It can cover large areas efficiently with its 42-megapixel camera and vertical takeoff and landing (VTOL) system.

It's ideal for large-scale mining operations, offering flexibility and precision in surveying and mapping. The onboard PPK GNSS receiver ensures accurate results with minimal ground control points.

WingtraONE GEN II Specs / Features:

  • Camera Sensor: 42 megapixel Sony sensor with a full-frame sensor and low distortion lens.

  • Sensing Capabilities: Compatible with various Sony and MicaSense sensors for any job.

  • Flight Time: 59 minutes

  • Flight Speed: 16 m/s (36 mph)

  • Transmission System: Direct line-of-sight up to 10 km (6 miles) of range.

mine-drone-flyability-7WingtraOne Gen II

SenseFly eBeeX

The eBeeX is a fully autonomous drone that covers large areas with ease. Its lightweight design and long flight time make it perfect for extensive surveys and mapping tasks.

With nine interchangeable cameras, it can handle a wide range of mining applications. The eMotion flight planning software simplifies mission setup and execution, making it user-friendly for all experience levels.

SenseFly eBeeX Specs / Features:

  • Camera Sensor: Choose from 9 sensors, including aerial RGB, thermal, and multispectral imagery

  • Sensing Capabilities: Compatible with various SenseFly and MicaSense sensors for any job

  • Flight Time: 90 minutes

  • Flight Speed: 30 m/s (68 mph)

  • Transmission System: Flight range of 37 km (23 miles).

mine-drone-flyability-8SenseFly eBeeX

Best Multicopter Outdoor Mine Drone on the Market

DJI Phantom 4 RTK

The DJI Phantom 4 RTK is a top choice for outdoor mining operations. It features a high-resolution camera and a built-in RTK module for precise geolocation data.

Its OcuSync transmission system provides reliable connectivity over long distances, making it suitable for medium-sized mining sites. The Phantom 4 RTK is ideal for mapping, surveying, and volumetric analysis.

DJI Phantom 4 RTK Specs / Features:

  • Camera Sensor: 20 megapixels with 4K video resolution

  • Flight Time: 30 minutes

  • Flight Speed: 13 m/s (31 mph) in P-Mode / 16 m/s (36 mph) in A-Mode

  • Transmission System: DJI OcuSync

mine-drone-flyability-9

DJI Phantom 4 RTK

Best Mine Drone Software

DroneDeploy

DroneDeploy is a powerful mapping and analytics platform for mining. It enables users to conduct stockpile measurements, mine planning, and safety assessments with ease.

Top Features:

  • Stockpile Inventory Management

  • Mine Planning and Excavation

  • Safety and Compliance

  • Centralized Operations Management

mine-drone-flyability-10DroneDeploy software | Medium

Pix4D

Pix4D offers advanced drone mapping and 3D modeling solutions for mining. It helps identify geotechnical risks, calculate stockpile volumes, and generate detailed maps for better decision-making.

Top Features:

  • Forecast geotechnical hazards

  • Accurate and automatic stockpile volume calculation

  • Asset lifecycle management

  • Generate high-resolution interactive 3D maps

mine-drone-flyability-11Pix4D software

Propeller

Propeller’s drone software is designed to capture high-accuracy data and generate 3D models that are accessible to your entire team. It streamlines surveying, inventory management, and collaboration.

Top Features:

  • Quick and frequent drone surveys

  • Complete documentation of project lifecycle

  • Simplified inventory management

  • Collaboration and communication

mine-drone-flyability-12Propeller software

Skycatch

Skycatch provides comprehensive drone software with automated data capture, processing, and analysis tools. It includes training and support to help you get the most out of your drone operations.

Top Features:

  • Fastest time-to-data in the market

  • Eliminates GCPs for a safer data capture

  • Proven 5 cm accuracy across all axes

  • Process offline in the field or in the cloud

  • Precise, high-fidelity 3D models of vertical surfaces

mine-drone-flyability-13

Skycatch software

Mining Drone Case Studies

Flyability Elios 2 — Inspection

Application: High-Altitude Underground Mining Inspection

Mission: Demonstrate the ability of the Elios 2 to cut down costs and improve safety in a high-altitude oxygen-depleted mine environment. The mine is located in Campamento Minero, approximately three miles above sea level.

Results: The Volcan team conducted 40 flights with the Elios 2 inspecting chimneys, ore passes, ventilation tunnels, and stopes. 3D maps of the various flights were created using Pix4D mapping software. All planned inspections were a success, and the drone met all expectations.

Mine Drone Significance: The Elios 2 was able to operate where no other drone can. Many mines are located in high-altitude locations where regular drone use is not feasible. By using a drone to navigate the mine, miners can let the Elios 2 do the dirty work while saving time and money.

[Read the full case study here: Testing the Elios 2 at at High Altitude Mine Located in the Andes Mountains]

Wingtra— Survey

Application: Mine / Quarry Monitoring and Operational Planning

Mission: Reduce operating expenses of terrestrial and manned airplane surveys by integrating a fixed-wing mine drone platform into surveying operations. Quadcopter drones are not efficient for larger mines.

Results: The Jellinbah Group found that utilizing the WingtraOne drone resulted in a significant decline in operational expenses and time. The fixed-wing platform also alleviated the inefficiencies of quadcopters that the company had tested previously. The ROI is immediately noticed as Jellinbah can now conduct on-demand surveys compared to the time-consuming logistics of manned surveying.

Mine Drone Significance: Large mining sites are no longer limited to multirotor drones that are inefficient and impractical. The vertical takeoff and landing feature is also a game-changer and allows surveys to be conducted anywhere.

SenseFly— Survey

Application: Quarry Monitoring and Operational Planning

Mission: Survey the largest limestone quarry in a day. The quarry measures a whopping 13.7 km2, and it usually takes two months to survey.

Results: The quarry was split into three large segments; upper, middle, and lower. Four drone pilots were divided into two teams to cover the site efficiently. The team decided to use senseFly's eBeeX fixed-wing drone. The eBeeX's ability to fly for longer durations made it the perfect choice. Within a few hours, the drone’s took over 6,000 high-resolution images that were converted into orthomosaic images and 3D models.

Mine Drone Significance: Surveying a site of this size used to take up to 2 months. Not only does that cause delays, but it also increases the risks for surveyors. The benefit of using mine drones is quick turnaround time, resulting in a safer and more cost-effective operation.

DJI— Survey

Application: Quarry Drilling and Blasting

Mission: To identify how a customized drone solution for mining can deliver the safest, controlled, and cost-efficient execution of a scheduled blast operation in a quarry mine.

Results: The customized DJI Matrice 300 RTK drone and Zenmmuse H20t cameras functioned well regarding control and operational decision-making.

Here are some areas the drone excelled in:

  • Checking for compliance with minimum withdrawal distances

  • Correcting the locations of lookouts.

  • Replacement of the inspection vehicle bypass

  • Observation of blind spots

  • Overall survey and recording of mass explosion

Mine Drone Significance: The purpose of using drones in mining is to mix the miners' knowledge with the drone's digital intelligence. An operation becomes safer and less expensive to run overtime by having actionable data.

DroneDeploy— Stockpile Measurement

Application: Stockpile Volumetry

Mission: Improve the accuracy of volumetric stockpile measurements to increase safety and reduce expenses for Granite Construction.

Results: Using DroneDeploy, the company achieved accuracy comparable to traditional methods in a fraction of the time. For this site, all volume calculations were within 1% of alternatives.

Mine Drone Significance: Using aerial volumetric software is faster, safer, and half the cost of the traditional ground-based stockpile calculations.


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