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This paper presents the first part of study on the proposed automatic optimal reclaiming system. The proposed system focuses on how the reclaimer reclaims iron ore from stockpiles to fulfill quality grade target aiming for minimum reclaimer overall movement. For example, iron ore can be excavated from open-cut pits, stacked onto stockpiles and reclaimed later using bucket wheel reclaimer (BWR) for export to customers. Stockpiles here are represented by combinations of voxels each possessing certain quality distribution. The supply of iron ore closest to the target grade with lower operation cost is the main concern for the ore producer. Currently, BWRs are operated manually to meet quality grade demand involving the checking of quality periodically during reclaiming operation. In result, there is excessive movement of the large machine leading to higher energy consumption. In this paper, the combination of voxels is identified from available stockpile voxels considering BWR minimum movement to fulfill quality and quantity demand of iron ore. Achieving the desired grade with maximum efficiency will result in increasing productive rates and less impact on global warming by significantly reducing energy consumption.

Improvement on material handling systems is demanded as world mining production continuously increases. Additionally, the supply of iron ore grades close to customer demand is crucial especially due to the gradual decline, in recent times, of quality iron ore grades. Stockpiles play a major role in storing material and reducing grade variation among material. Contrary to the conventional approach of treating stockpile as a single entity, the voxel based approach was proposed by previous studies in reclaiming material from stockpiles. Voxel is defined as a volume element with custom defined shape. However, voxel profile has always been defined as a simple rectangular shape without taking into account the reclaiming pattern of the bucket wheel reclaimer (BWR) which can be seen as a gigantic robotic arm. The objective of this paper is to highlight the drawbacks of defining rectangular shaped voxel in reclaiming using the BWR. A kinematics model of the full BWR including its buckets is derived and the simulation of reclaiming trajectory leading to the future study of defining the optimal profile of voxel is also discussed.

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