You are on page 1of 43

BenchManager

Installation and Configuration Guide
Wenco International Mining Systems Ltd.
© 2014 Wenco International Mining Systems Ltd. All rights reserved.
100 - 10271 Shellbridge Way, Richmond, B.C. V6X 2W8 Canada
email: documentation@wencomine.com
Acrobat is a registered trademark of Adobe Corporation in the USA.
Microsoft Windows and Microsoft SQL Server are trademarks or registered trademarks of Microsoft
Corporation in the USA and/or other countries.
Crystal Reports is a trademark or registered trademark of Business Objects
All other products or company names are used for identification purposes only, and may be
trademarks of their respective owners.
2/25/2014
What's in this Manual
This document contains information on installing and configuring BenchManager.
Intended Audience
This document is intended for those responsible for installing and configuring the
Wenco system programs. This includes Wenco Technical Services personnel and
may include mine site system administrators.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
i
Table of Contents
....................................................................................................................... 1 Chapter 1: Overview
.............................................................................................................................. 1 About BenchManager
.............................................................................................................................. 2 System Requirements
....................................................................................................................... 3 Chapter 2: Installing BenchManager
.............................................................................................................................. 3 Install BenchManager on the MDT
....................................................................................................................... 4 Chapter 3: Configuring BenchManager
.............................................................................................................................. 4 Step 1: Configure the Bench.ini and AGSConfig.ini Files
.............................................................................................................................. 12 Step 2: Configure Registry Keys and WLAN Communications
.............................................................................................................................. 14 Step 3: Start Wenco MDT and BenchManager Software
.............................................................................................................................. 14 Step 4: (Only ALIGN-installed Shovels/Backhoes) Calibrate ALIGN Feature
.............................................................................................................................. 15 Step 5: (If Using MDT5) Make Sure MDT3\Dispatch Buttons is Removed
.............................................................................................................................. 15 Step 6: (If Using Fleet Awareness) Set Up Proximate Equipment Display
....................................................................................................................... 17 Chapter 4: Upgrading BenchManager
.............................................................................................................................. 17 Step 1: Back Up the Bench.ini and AGSConfig.ini Files
.............................................................................................................................. 17 Step 2: Install and Configure Upgrade
.............................................................................................................................. 19 Step 3: Update Wenco Parameters
....................................................................................................................... 20 Appendices
.............................................................................................................................. 20 Appendix 1: BenchManager Registry Keys
.............................................................................................................................. 21 Appendix 2: AGS Installation for Shovels and Backhoes
.............................................................................................................................. 33 Appendix 3: BenchManager Offset Measurements
BenchManager
© 2014 Wenco International Mining Systems Ltd.
1
Chapter 1: Overview
Chapter 1: Overview
About BenchManager
BenchManager is a high-precision GNSS equipment-tracking
system that provides bench elevation monitoring and ore
quality control for loading and grading units. BenchManager
uses onboard graphical real-time displays that show
equipment orientation over the mine plan. Dig block
coordinates, ore quality information, and digital terrain model
files (DTM) are sent to BenchManager from the host computer
system, and work performance data is returned from
BenchManager.
Use BenchManager to:
 load designs and maps that are transferred to the
BenchManager unit from the dispatcher office.
 display a visual map so that the equipment unit operator
can see a realtime display of the current ramp, dump,
blast perimeters, hazardous areas, real-time floor, and
face positions.
 transmit information about the working area back to the
dispatch office for surveyors and engineers to use.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
2
Chapter 1: Overview
System Requirements
The mine system must have the following installed in order to
use BenchManager:
 a configured Wenco Server (see the Wenco Server
Installation Guide for information on the Wenco
applications and services required on a Wenco Server).
 any RTK-compatible GPS Base Station.
 a Mesh radio network for transmitting GPS corrections
and maps, and for receiving back the current floor and
face positions.
 Wenco's BenchView software (see the BenchView
Installation Guide for information on installing and
configuring BenchView and the FTP Server for
BenchView/BenchManager communications).
In addition, installation on the equipment unit requires:
 a GPS enclosure to house the Novatel dual frequency
GPS receiver and power supply.
 a GPS Antenna to receive positioning messages from
satellites.
 a Mesh Antenna/WLAN Antenna–Antennex 3dB gain
antenna for communication with the radio network.
 a Mobile Data Terminal (MDT) touchscreen computer
and display with Wenco MDT software and Wenco
BenchManager software installed to store data and run
BenchManager.
 (only if you are using MOBA or Novatron pitch and roll
sensors) one of either:
 a PEAK PC104+ board installed in the Octagon C2,
or
 a ruggedized PEAK dongle cable connected to a
USB port on the Octagon C2.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
3
Chapter 2: Installing BenchManager
Chapter 2: Installing BenchManager
Install BenchManager on the MDT
The BenchManager software is installed after the MDT
software has been installed. Exit from the MDT software
before running the BenchManager installation.
To install the BenchManager software:
1. Browse to the BenchManager folder on the network or
USB drive and double-click setup.exe.
2. Click Next at the Welcome screen.
3. Choose Accept on the License Agreement screen,
and click Next.
4. Click Install.
5. Click Finish.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
4
Chapter 3: Configuring BenchManager
Chapter 3: Configuring BenchManager
Step 1: Configure the Bench.ini and AGSConfig.ini Files
For each machine with BenchManager software installed, the
configuration file should be completed before the hardware is
installed on the equipment.
1. Use Windows Explorer to open the Bench.ini file
(located in the C:\Program
Files\Wenco\BenchManager\Config folder).
2. Refer to the BenchManager Parameters.xls document
to configure the Bench.ini parameters.
Below are the CRITICAL Bench.ini parameters that
must be modified. (Parameters not listed here have
default values that work for most situations.)
Note: Units of Measure (UOM) are defined by the
transformation settings under [local_grid]. All offset
measurements must be measured in the UOM used by
the site.
Parameters Common to All Equipment Types
Section Parameter
Parameter
Options
Comments
[App] elevation_unit= feet, meter
[Vehicle] gps_height_offset= float value
Difference between
the local datum and
the MSL (Mean Sea
Level) datum.
[Vehicle] antenna_height_offset=
negative float
value
Vertical offset from
the GPS antenna to
the ground.
[Vehicle] toe_radius=
positive float
value
(Defined as
dig_radius in the
BenchView
Equipment Editor.)
Used to display the
mined out area, it is
the distance to the toe
of the slope.
The toe radius will
vary from machine to
machine, based on
the equipment size.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
5
Chapter 3: Configuring BenchManager
[Vehicle] crest_radius=
positive float
value
(Defined as
crest_buffer in Wenco
Configuration
Manager.)
Distance to the crest
of the slope with
respect to the center
of the machine.
[Tilt] type= blank: Select this
if you are not
using a pitch and
roll sensor.
GPS: On a loader
or dozer, this
uses the change
in elevation to
measure the
pitch. On a
shovel, this uses
the rotation of the
shovel to
measure pitch
and roll.
MOBA: This uses
the pitch and roll
sensor by MOBA.
It must be must
be aligned with
the direction of
travel and
installed on a flat
surface.
Note: There are
additional INI
parameters to
set for MOBA
that are listed in
the [MOBA]
section of the
BenchManager
Parameters.xls
file. See the
BenchManager
Parameters.xls
file for details
and options.
Novatron: These
are the same
BenchManager
© 2014 Wenco International Mining Systems Ltd.
6
Chapter 3: Configuring BenchManager
sensors used for
the Arm
Geometry
system. See
Appendix 2:
AGS Installation
for Shovels and
Backhoes of the
BenchManager
Installation
Guide for
installation
instructions in or
on the cab.
Note: There are
additional INI
parameters to
set for Novatron
that are listed in
the [Novatron]
section of the
BenchManager
Parameters.xls
file. See the
BenchManager
Parameters.xls
file for details
and options.
[Local Grid] cmeridian=
positive or
negative integer
UTM central meridian.
[Local Grid] k1= float value
Local coordinate
transformation scale
factor.
[Local Grid] k2= float value
Local coordinate
transformation scale
factor.
[Local Grid] shiftx= float value
Local coordinate
transformation shift in
easting.
[Local Grid] k3= float value
Local coordinate
transformation scale
factor.
[Local Grid] k4= float value
Local coordinate
transformation scale
factor.
[Local Grid] shifty= float value Local coordinate
BenchManager
© 2014 Wenco International Mining Systems Ltd.
7
Chapter 3: Configuring BenchManager
transformation shift in
northing.
[Local Grid] map_orgx= float value
Easting coordinate
that defines the origin
of the cut/fill grid.
[Local Grid] map_orgy= float value
Northing coordinate
that defines the origin
of the cut/fill grid.
Parameters Specific to Shovels/Backhoes
Section Parameter
Parameter
Options
Comments
[Vehicle] type=
shovel
backhoe
[Vehicle] machine_width=
positive float
value
Used to calculate the
four corners' position
of the vehicle. It
defines the width of
the rectangle from the
center of the
machine.
This is required for
exclusion zone
detection.
[Vehicle] rear_length=
positive float
value
Used to calculate the
four corners' position
of the vehicle. It
defines the rear
length of the
rectangle from the
center of the
machine.
This is required for
exclusion zone
detection.
[Vehicle] boom_length=
float value
Scraper: negative
float value
Other types:
Measured from the
center of rotation/
center of the machine
to the bucket center.
It is also used to
define the proximity
BenchManager
© 2014 Wenco International Mining Systems Ltd.
8
Chapter 3: Configuring BenchManager
positive float
value
rectangle around the
center of the
machine.
[Vehicle] dx= float value
Offset from the GPS
antenna to the center
of the machine.
[Vehicle] dy= float value
Offset from the GPS
antenna to the center
of the machine.
[Vehicle] dxr= float value
(Used in NovAtel
ALIGN GPS only.)
Offset from the
remote GPS antenna
to the center of
rotation.
(Shovels and
backhoes use
hdg_corr instead.)
[Vehicle] dyr= float value
(Used in NovAtel
ALIGN GPS only.)
Offset from the
remote GPS antenna
to the center of
rotation.
(Shovels and
backhoes use
hdg_corr instead.)
Parameters Specific to Loaders/Dozers
Section Parameter
Parameter
Options
Comments
[Vehicle] type=
dozer
loader
[Vehicle] machine_width=
positive float
value
Used to calculate the
four corners' position
of the vehicle. It
defines the width of
the rectangle from the
center of the
machine.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
9
Chapter 3: Configuring BenchManager
[Vehicle] rear_length=
positive float
value
Used to calculate the
four corners' position
of the vehicle. It
defines the rear
length of the
rectangle from the
center of the
machine.
[Vehicle] wheel_width_offset=
positive float
value
Offset from the center
of the machine to the
center of the track or
wheel.
[Vehicle] wheel_length_offset=
positive float
value
Distance from the
center of the machine
forward to the front of
the wheels or track.
[Vehicle] dx= float value
Offset from the GPS
antenna to the center
of the machine.
[Vehicle] dy= float value
Offset from the GPS
antenna to the center
of the machine.
[Vehicle] dxr= float value
(Used in NovAtel
ALIGN GPS only.)
Offset from the
remote GPS antenna
to the center of
rotation.
(Shovels and
backhoes use
hdg_corr instead.)
[Vehicle] dyr= float value
(Used in NovAtel
ALIGN GPS only.)
Offset from the
remote GPS antenna
to the center of
rotation.
(Shovels and
backhoes use
hdg_corr instead.)
BenchManager
© 2014 Wenco International Mining Systems Ltd.
10
Chapter 3: Configuring BenchManager
AGS Parameters
Section Parameter
Parameter
Options
Comments
[Vehicle] AGSInstalled=
1 - the vehicle
has AGS installed
Indicates whether or
not the vehicle has
AGS installed.
[Vehicle] joint_offset_hori=
positive float
value
Horizontal distance
from the vehicle
center to the boom
joint.
[Vehicle] joint_offset_vert=
positive float
value
Vertical distance from
the ground to the
boom joint.
3. Refer to the BenchManager Parameters.xls document
to configure the AGSConfig.ini parameters.
Below are the CRITICAL AGSConfig.ini parameters that
must be modified. (Parameters not listed here have
default values that work for most situations.)
Notes:
 Measurements will be provided by the site
surveyors.
 For the MachineName parameters, all options
are listed in the .ini file. These are your only
options.
Parameters Specific to Backhoes with AGS
(Be sure to modify the parameters associated with the correct model type.)
Section Parameter Parameter Comments
BenchManager
© 2014 Wenco International Mining Systems Ltd.
11
Chapter 3: Configuring BenchManager
Options
[<MachineName>] BoomLength= float value
Measured on the boom
from the cab pin to the arm
pin.
[<MachineName>] ArmLength= float value
Measured on the arm from
the boom pin to the bucket
pin.
[<MachineName>] BucketLength= float value
Measured on the bucket
from the arm pin to the
bucket teeth.
[<MachineName>] BucketSensorDirectMount=
F - mounted
on linkarm
Indicates whether the
bucket sensor is mounted
directly on the bucket or on
the linkage arm.
[<MachineName>] BaseLength= float value
Distance from
arm_bucket_pivot to
arm_linkage_pivot.
[<MachineName>] LinkageLength= float value
Distance from
arm_linkage_pivot to
linkage_transmit_pivot.
[<MachineName>] TransmitArmLength= float value
Distance from
linkage_transmit_pivot to
transmit_coupler_pivot.
[<MachineName>] CouplerLength= float value
Distance from
transmit_coupler_pivot to
arm_bucket_pivot.
[<MachineName>] BaseAngle= float value
Angle from
boom_arm_pivot to
arm_bucket_pivot to
arm_linkage_pivot.
[<MachineName>] Bucket_CouplerAngle= float value
Angle from bucket_teeth to
arm_bucket_pivot to
transmit_coupler_pivot.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
12
Chapter 3: Configuring BenchManager
Parameters Specific to Shovels with AGS
(Be sure to modify the parameters associated with the correct model type.)
Section Parameter
Parameter
Options
Comments
[<MachineName>] BoomLength= float value
Measured on the boom
from the cab pin to the arm
pin.
[<MachineName>] ArmLength= float value
Measured on the arm from
the boom pin to the bucket
pin.
[<MachineName>] BucketLength= float value
Measured on the bucket
from the arm pin to the
bucket teeth.
[<MachineName>] BucketSensorDirectMount=
T - mounted
on bucket
Indicates whether the
bucket sensor is mounted
directly on the bucket or on
the linkage arm.
Step 2: Configure Registry Keys and WLAN Communications
Use the registry to configure the BenchManager Server
WLAN address:
1. Start regedit.
2. Go to the registry key:
HKEY_LOCAL_MACHINE\Software\Wenco\BenchMan
ager.
 MDT4: You need to enter the Server A WLAN IP
Address, Server B WLAN IP Address, and WLAN
Subnet Mask registry entries manually. Configure
the BenchManager Registry Keys .
20
BenchManager
© 2014 Wenco International Mining Systems Ltd.
13
Chapter 3: Configuring BenchManager
 MDT5: The Server A WLAN IP Address, Server B
WLAN IP Address, and WLAN Subnet Mask
registry entries are automatically set when the MDT5
resynchronizes. Check that the BenchManager
Registry Key values are correct.
3. Go to the WLAN subkey:
HKEY_LOCAL_MACHINE\Software\Wenco\BenchMan
ager\WLAN. Make sure that the values under this
registry key are set correctly.
 Note for MDT4: For MDT4 installations, this setting
can be updated using the Field Configuration
Editor (an icon for the Field Configuration Editor
is installed onto the desktop). Start the Field
Configuration Editor, click the BenchManager
WLAN tab, and add a checkmark to the Active
checkbox. Then enter the IP Address where the
BenchView Service is located. For more
configuration information, see here .
20
20
BenchManager
© 2014 Wenco International Mining Systems Ltd.
14
Chapter 3: Configuring BenchManager
Step 3: Start Wenco MDT and BenchManager Software
To start the MDT and BenchManager software:
1. Start the MDT software. The Badge In screen displays
briefly.
2. The BenchManager screen displays for a few seconds.
Note: Do not interfere during the startup process. Wait
until the BenchManager screen displays.
3. The display switches back to the MDT Badge In
screen. Badge in to the MDT.
Press the button on the MDT screen to switch
to the BenchManager screen.
Press the button on the BenchManager screen to
switch to the MDT screen.
Step 4: (Only ALIGN-installed Shovels/Backhoes) Calibrate
ALIGN Feature
Notes:
 This procedure is only for shovels and backhoes with
ALIGN GPS installed.
 The operator must be granted the ALIGN Calibration
privilege before performing the calibration.
To perform manual calibration:
1. On the GPS tab of the Position Data menu, uncheck
the Use ALIGN checkbox.
2. Have the operator rotate the shovel until the center of
rotation (COR) is calculated.
The appearance of the shovel graphic on the
BenchManager screen indicates that the COR is
calculated.
3. Stop rotation and shovel movement. Keep the shovel
stationary for about 10 seconds to ensure that the
ALIGN data is stable.
4. On the GPS tab of the Position Data menu, press the
Calibrate ALIGN button.
5. If the calibration procedure is successful, the Calibrate
ALIGN button turns green. To use ALIGN, check the
BenchManager
© 2014 Wenco International Mining Systems Ltd.
15
Chapter 3: Configuring BenchManager
Use ALIGN checkbox.
 Automatic calibration: BenchManager
automatically calibrates ALIGN if all of the following
conditions are met:
 INI::align_auto_calibration = 1, and
 the shovel has rotated wide enough to find the
center of rotation and then stopped, and
 either:
 the ALIGN has not already been calibrated,
or
 the previous calibration failed
(i.e., INI::hdg_corr does not exist, or is equal
to -9999.9).
 You can do manual calibration regardless of the INI::
align_auto_calibration setting. However, automatic
calibration can only occur when INI::
align_auto_calibration = 1.
Step 5: (If Using MDT5) Make Sure MDT3\Dispatch Buttons is
Removed
If BenchManager is working with MDT5, make sure that the
registry key
HKEY_LOCAL_MACHINE\Software\Wenco\MDT3\Dispatch
Buttons is removed.
This key contains pre-defined dump/material dispatches,
which are supported in MDT4 but not MDT5. With this key,
BenchManager displays a Next button that brings up a set of
dump/material dispatch buttons.
Step 6: (If Using Fleet Awareness) Set Up Proximate
Equipment Display
You can configure the Wenco system to display proximate
equipment in BenchManager.
To configure BenchManager to display proximate
equipment:
1. Configure PitNav, by completing all steps of the PitNav
Installation and Configuration Guide. Pay special
attention to:
 Chapter 3: Obtain a Fleet Awareness for PitNav
license for your mine site. The Proximate Awareness
BenchManager
© 2014 Wenco International Mining Systems Ltd.
16
Chapter 3: Configuring BenchManager
feature is not available with a simple PitNav license.
2. Start BenchManager from each MDT5.
3. In BenchManager's Tools menu, add a checkmark to
Show Proximate Vehicles.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
17
Chapter 4: Upgrading BenchManager
Chapter 4: Upgrading BenchManager
Step 1: Back Up the Bench.ini and AGSConfig.ini Files
Before upgrading BenchManager, it is a good idea to create a
backup of the Bench.ini file for the equipment unit.
To create a copy of the Bench.ini file:
1. Browse to the c:\program
files\Wenco\BenchManager\Config folder.
2. Copy the Bench.in file to a new location.
Step 2: Install and Configure Upgrade
To upgrade BenchManager:
1. Install the new software by following the instructions in
Chapter 2 of this document.
Note: It is no longer necessary to uninstall the
previous version of the application before running the
updated installation kit.
2. Open the c:\program
files\Wenco\BenchManager\Config\bench.ini file to
confirm that the file contains the same information as
before the upgrade.
3. Check the WLAN settings by following the instructions
in Chapter 3.
4. Check the readme file in the installation folder to see if
new configuration items have been added to the bench.
ini file since the last installation. If there are new items
you will need update the installed version.
To update the bench.ini file:
a) Open the updated default version of the bench.ini
file from the \program files\Wenco\BenchManager\
ConfigDefault folder.
b) Open the configured version of the bench.ini file
from the \program files\Wenco\BenchManager\
Config folder.
c) Compare the entries in the two versions of the file.
d) Copy any new configuration items from the updated
default version to the configured version.
[FTP] section: For bv_repository_path, enter the
folder where the BenchView repository files are saved.
Enter the folder that is configured in the Wenco
Configuration Manager parameter: Repository
BenchManager
© 2014 Wenco International Mining Systems Ltd.
18
Chapter 4: Upgrading BenchManager
Directory.
Example:
If the Wenco Configuration Manager Repository
Directory parameter setting is: \Wenco FTP
Site\BenchView\Repository
Then in the bench.ini file, the
bv_repository_path=\BenchView\Repository
BenchManager
© 2014 Wenco International Mining Systems Ltd.
19
Chapter 4: Upgrading BenchManager
Step 3: Update Wenco Parameters
If you are upgrading the BenchManager software, there may
be an update of Wenco Parameters that needs to be
installed on your system.
Wenco Parameters are configuration settings that are used
with Wenco applications. Each time there is new Wenco
Parameters release that is relevant for your mine, Wenco
Technical Services will send you a file containing the Wenco
Parameters update.
Note: The WencoDB Home editor Software Version History
displays the version and installation date of WP updates.
To update the Wenco system using the latest Wenco
Parameters:
1. Copy all of the files from the Wenco Parameters
installation kit or zipped file to the
<system partition>:\WencoWP folder on your Wenco
server. In the Two Server Model, copy the files onto
the Operational Server. In the Four Server Model,
copy the files onto the Operational Services Server.
2. Double click on WencoParameters.exe in the
<system partition>:\WencoWP folder to start the
Wenco Parameters Installer.
Notes:
 Refer to the Wenco Parameters Installer Guide
document for information about using the Wenco
Parameters Installer.
 A readme file with release notes is included with
each Wenco Parameters release.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
20
Appendices
Appendices
Appendix 1: BenchManager Registry Keys
The BenchManager registry keys are located in the registry
under:
HKEY_LOCAL_MACHINE\Software\Wenco\BenchManager
Name Default Description
Interface WLAN
Defines the radio modem
configuration used by the
BenchManager system.
Server A
WLAN IP
Address
These registry entries are set by
the MDT5 when it resynchronizes
to the database. The value is the
same as the value in the Wenco
Configuration Manager >
System parameter with the same
name.
Server B
WLAN IP
Address
WLAN
Subnet
Mask
BenchManager\WLAN Subkey
Name Default Description
Host
Address
IP Address of the BenchView
Service computer.
BenchManager will automatically
upate the host address when it
detects a server switch.
Refresh
Interval
120000
If the MDT unit has not seen any
traffic for the defined time (in
milliseconds), then the unit
invokes a ping cycle in order to
establish that the Host is still
functioning and is aware of the
unit’s location.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
21
Appendices
Name Default Description
UDP Port 40003
Identifies the port on which the
BenchManager sends and
receives WLAN Messages. This
should be the same as the port
used for the BenchView Service.
Ack Timeout 1500
For every transmitted message,
Ack Timeout specifies the
duration (in milliseconds) that
BenchManager waits for an Ack
message to arrive. The Ack
message confirms that the
outgoing message has been
received by the target application.
Maximum
Retries
3
For every transmitted message, if
BenchManager does not receive
an Ack message within the Ack
Timeout duration,
BenchManager retransmits its
message. Maximum Retries
defines the maximum number of
times BenchManager will try to
retransmit it.
Appendix 2: AGS Installation for Shovels and Backhoes
AGS Hardware Installation
There are five stages for installing hardware for the Wenco
Arm Geometry System (AGS):
1. Survey the Shovel or Backhoe
2. Lay Out the Boom and Arm Sensors
3. Weld the Brackets
4. Run the Cables
5. Install and Terminate the Cables
Step 1: Survey the Shovel or Backhoe
Having accurate dimensions of the shovel/backhoe is
essential for BenchManager to precisely position the shovel
bucket. Below is a description of survey measurements
required to configure a Wenco AGS shovel/backhoe system.
21
23
26
26
27
BenchManager
© 2014 Wenco International Mining Systems Ltd.
22
Appendices
Shot Location Comment
Four or more shots
on the circular ring
on the undercarriage
Use to determine the center of rotation.
One shot on the
center line of the
bucket
Use this point and the center of rotation point from above to
determine the center-line of the machine.
One shot on top of
each GPS antenna
One shot on the
boom joint
Use to determine the boom joint height above ground.
One shot on each
pivot point on the
arm
Use to measure components of the arm. Take shots for each of
the pivot points (P1 to P5) as illustrated in the image below and the
backhoe bucket image on page 9. Survey shots on arm:
Survey shot locations:
One or two shots at
the track level below
the boom joint
Used to determine the elevation difference between the GPS
antenna and the ground. A shot on both sides of the machine near
the center of rotation is best.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
23
Appendices
Step 2: Lay Out the Boom and Arm Sensors
Once the surveyor has taken the above measurements, the
surveyor has enough information to mark reference points on
the boom and arm. Use a felt or grease pen to mark these
reference lines.
Notes:
 When mounting the sensor on the linkage (see sensor
ID 101 picture below), the terminated end of the sensor
MUST be pointing parallel along the line from P4 to P3
(i.e., towards the piston coupler).
 The sensors must be mounted on the left side of the
machine.
Boom layout (sensor ID 103):
Lay out two points just in front of the cab along the
line between the boom-joint and the joint
connecting the boom to the arm (P5). The welders
will use this line as a reference to place the AGS
sensor base plate. The base plate must be parallel
to this line, and as close to the boom joint as is
practical (which is just in front of the cab). Refer to
the pictures below.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
24
Appendices
Arm sensor layout (sensor ID 102):
Lay out two points along the line from P5 to P1 that
defines the arm length. The welders will use this as
a reference line. The sensor mounting plate must
be placed parallel to this reference line. Just above
point P5 is the preferred location. Refer to the
pictures below.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
25
Appendices
Cab sensor (sensor ID 105):
The cab sensor must be located on a flat surface
somewhere on the body/cab of the shovel. Refer to
the pictures below for a typical installation.
Linkage Sensor (sensor ID 101):
The bucket sensor will most commonly be placed
on the linkage assembly near the bucket. It must
be placed in a plane parallel to the plane of the
boom and arm sensors. The boom and arm
sensors are placed on the left side of the machine.
The bucket sensor is placed on the inside of the
right-hand linkage assembly. It is in the same
orientation as if it were on the outside face of the
linkage on the left side of the machine. It is not in
the same plane as the other sensors but it is
parallel to the plane of the boom and arm sensor.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
26
Appendices
A good location for the linkage/bucket sensor is on
the inside of the linkage assembly. Refer to the
pictures below.
Step 3: Weld the Brackets
Have a welder weld the brackets in place as shown in the
pictures above.
Step 4: Run the Cables
Cables are fastened with cable ties to existing hoses and
cables as shown in the pictures above. Whenever possible,
fasten the cable to rigid (stationary) hydraulic lines. Have a
qualified person operate the machine and observe its
movements prior to attaching the cable, to ensure proper
routing.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
27
Appendices
Step 5: Install and Terminate the Cables
Install and terminate the cables, following the steps below.
1. Install cables as noted in Step 4: Run the Cables and
cut to required length.
2. Slide on crimp sleeve (provided in the plastic bag
attached to the cable).
3. Slide on heat shrink (provided in the plastic bag
attached to the cable).
4. Remove approximately 2 inches of stainless steel outer
braid.
5. Remove approximately 1.5 inches of cable jacket.
6. Use coax crimpers to crimp the sleeve over the outer
braid.
7. Terminate the connector according to the
manufacturer's instructions (located on the bag).
Note: Sensor cables are coded by color to match the
BenchManager
© 2014 Wenco International Mining Systems Ltd.
28
Appendices
color-coded positions on the back of the M12 connectors.
Wire Color
M12 Connector Position
Color
RED RED
BLACK BLACK
BLUE BLUE
WHITE WHITE
GREEN GREY
BROWN NOT USED
BenchManager
© 2014 Wenco International Mining Systems Ltd.
29
Appendices
AGS Software Installation
Configuration parameters for the AGS are set in two
configuration files:
 Bench.ini : parameters relevant to the vehicle.
 AGSConfig.ini : parameters relevant to the AGS.
The parameters should be set from measurements gathered
during the installation of the AGS sensor hardware (refer to
the document BenchManager Parameters.xls).
30
31
BenchManager
© 2014 Wenco International Mining Systems Ltd.
30
Appendices
Bench.ini Parameters
Note: The information about the parameters below is added
as of BenchManager version 3.5.2007. The measurements
are in meters or feet, depending on the site.
Bench.ini
Vehicle AGS Parameters
Parameter Comment
AGSInstalled
Set to 1 to indicate that the AGS is installed on
the vehicle.
joint_offset_hori
Horizontal distance from the vehicle center to
the boom joint.
This will generally be the same for each model.
joint_offset_vert
Vertical distance from the ground to the boom
joint.
This will generally be the same for each model.
under_scoop_offset
Adjust the candidate bucket elevation by this
amount.
The following parameters define the “Bucket Zone” used to trigger bucket detection. They
should be adjusted after the AGS accuracy has been confirmed.
horizontal_dig_limit
Do not calculate a bucket if the bucket is this
distance away from the boom joint.
min_forward_distance
The bucket must move forward in the zone at
least this distance.
scoop_height
The bucket must move upwards in the zone at
least this distance.
vertical_limit
Do not calculate a bucket if the bucket is this
distance above the boom joint.
vertical_trigger
Start calculating the bucket if the vertical
distance from the boom joint exceeds this
value.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
31
Appendices
AGSConfig.ini Parameters
Notes:
 The information about the parameters below is added as
of BenchManager version 3.5.2007.
 The following parameters are only required if
BucketSensorDirectMount=F:
BaseLength, LinkageLength, TransmitArmLength,
CouplerLength, BaseAngle, Bucket_CouplerAngle.
 The measurements are in meters or feet, depending on
the site.
AGSConfig.ini
AGS Parameters
Parameter Comment
MachineName
Set this value to one of the predefined
configurations in the file (e.g.,
Hitachi_EX3600_Backhoe).
BoomLength
Measured length between the pins on the
boom.
ArmLength Measured length between the pins on the arm.
BucketLength
Measured value between the pin on the bucket
and the tip of the teeth.
BucketSensorDirectMount
Set to T if the sensor is mounted on the bucket
– usually shovels.
Set to F if the sensor is mounted on the linkage
arm – usually backhoes.
BaseLength
P1–P4: Measured length between the bucket
pin (P1) and the linkage pin on the arm (P4).
LinkageLength
P4–P3: Measured length between the arm pin
(P4) and the transmit pin (P3) on the linkage
arm.
TransmitArmLength
P3–P2: Measured between the linkage pin (P3)
and the coupler pin (P2) on the transmit arm.
CouplerLength
P2–P1: Measured length between the transmit
pin (P2) and the bucket pin (P1) on the coupler.
BaseAngle
A2: Measured angle from the boom pin (P5) to
the bucket pin (P1) to the linkage pin (P4) on
the arm.
Bucket_CouplerAngle A1: Measured angle from the bucket teeth to
BenchManager
© 2014 Wenco International Mining Systems Ltd.
32
Appendices
the bucket pin (P1) to the transmit pin (P2) on
the coupler.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
33
Appendices
Appendix 3: BenchManager Offset Measurements
BenchManager Shovel Offset Measurements
The following descriptions refer to the diagrams shown above
and below. Record all measurements in meters. Convert to
feet afterwards if required.
Note: The recommended location of the GPS antennas is
to the rear of the machine to minimize shadowing from the
pit wall. The locations shown above are just for illustrative
purposes.
The following parameters are inserted into the Bench.ini
configuration file.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
34
Appendices
Measurement Description
dx
Distance from the center of the machine rotation to the
center of the Master GPS antenna as shown above. Take
note of whether the antenna is on the left (negative value)
side or right (positive value) side of the machine. The GPS
Master-GPS Remote diagram above shows the GPS
antenna on the left side of the machine.
dy
Distance from the center of rotation to the center of the
Master GPS antenna as shown above. Take note of
whether the GPS antenna is forward (positive value) of the
center of rotation or to the rear (negative value). The GPS
Master-GPS Remote diagram above shows the GPS
antenna to the rear of the machine’s center of rotation.
dxr
Distance from the center of rotation to the remote antenna.
The GPS Master-GPS Remote diagram above shows the
remote antenna on the right side of the machine.
dyr
Distance from the center of rotation to the remote antenna.
The GPS Master-GPS Remote diagram above shows it
forward of the center of rotation.
antenna_height_offset (J)
Distance from the phase center of the GPS antenna to the
bottom of the tracks (ground level). The bottom of the GPS
antenna shows the offset from the base of the antenna to
the phase center of the antenna. Enter this as a negative
(-) value.
boom_length (D)
Estimated distance from the center of rotation to the
cutting edge of the shovel bucket.
rear_length
Distance from the center of rotation to whatever is sticking
out the furthest at the back of the machine.
toe_radius (B + C)
Estimated distance from the center of rotation to the toe of
the slope. This is usually the same value as the
boom_length or a little longer.
crest_radius
Estimated distance from the center of rotation to the crest
of the digging face. The distance from the toe of the slope
to the crest can be calculated by knowing the slope of the
pit wall and its height. For example:
Slope = 1:3
Height = 15 meters
Toe to Crest distance = 15 * 1/3 = 5
crest_radius = boom_length + 5
BenchManager
© 2014 Wenco International Mining Systems Ltd.
35
Appendices
To measure dx, dy using a tape measure
To determine the correct heading of the machine based on a
center of rotation calculation, we need to know the location of
the GPS antennas with respect to the center of rotation.
Unfortunately, the center of rotation is not easily defined.
What is more easily defined is the center-line of the shovel.
1. Measure the perpendicular distance from the center of
the antenna to the center-line of the shovel. This should
be accurate to within a couple of centimeters if care is
taken. This is the dx measurement.
2. Now measure the perpendicular distance from the
antenna center to the center of rotation as best you can.
This is not as obvious to locate. This is your dy
measurement. You can refine this measurement later
once BenchManager is running (see step 4 below).
3. Enter these values into BenchManager’s ini file as dx
and dy.
4. To refine the dy measurement:
a) Run BenchManager in COR (center of rotation)
mode.
b) Go to the Tools page and look at the Radius label.
This displays the calculated radius (R) from the
COR to the antenna. Take note of this value and let
it calculate two or three times.
c) Take the average radius value and calculate dy
using Pythagoras’s formula:
dy = sqrt(R^2 - dx^2)
BenchManager
© 2014 Wenco International Mining Systems Ltd.
36
Appendices
BenchManager Loader Offset Measurements
The following descriptions refer to the diagrams shown above.
Record all measurements in the same units as the coordinate
system.
Note: Locations of the antennas shown above are for
illustrative purposes only. Try to place the Master receiver
near the center-line of the machine.
Measurement Description
dx
Distance from the center of machine to the center of
the GPS antenna as shown above. Take note of
whether the antenna is on the left (negative) side or
right (positive) side of the machine. The diagram
above shows the Master GPS antenna on the left
side of the cab.
dy
Distance from the center of the cab to the center of
the GPS antenna as shown above. Take note of
whether the GPS antenna is forward (positive) of the
cab center or rear (negative) of the cab center. The
diagram above shows the Master GPS antenna to
the rear of the cab center.
dxr
Distance from the center of rotation to the remote
antenna.
dyr
Distance from the center of rotation to the remote
antenna.
antenna_height_offset (C)
Distance from the phase center of the GPS antenna
to the bottom of the tracks (ground level). The
bottom of the GPS antenna shows the offset from
the base of the antenna to the phase center of the
antenna. Enter this as a negative (-) value.
boom_length
Distance from the center of the cab to the cutting
edge of the loader bucket. The cut/fill is calculated
here. Wheel_width_offset is also used to determine
where the cut/fill is calculated (see below).
BenchManager
© 2014 Wenco International Mining Systems Ltd.
37
Appendices
wheel_width_offset (B/2)
Distance from the center of the loader to the center
of the wheels, or, half of dimension B in the
cross-sectional diagram shown above. Cut/fill values
are calculated at two locations on each side of the
machine based on these offsets.
rear_length
Distance from the center of the cab to whatever is
sticking out the furthest at the back of the machine.
In the diagram above, it is the fender.
machine_width Width of the loader bucket as shown above.
toe_radius
Estimated distance from the center of the cab to the
toe of the slope. This is usually the same value as
the boom_length or a little longer.
crest_radius
Estimated distance from the center of the cab to the
crest of the digging face.
BenchManager
© 2014 Wenco International Mining Systems Ltd.
38
Appendices
BenchManager Bulldozer Offset Measurements
The following descriptions refer to the diagrams shown above.
Record all measurements in metres. Convert to feet
afterwards if required.
Note: These measurements apply when there is only one
antenna.
Measurement Description
dx
Distance from the center of the machine to the
center of the Master GPS antenna as shown above.
Take note of whether the antenna is on the left side
or right side of the machine. The diagram above
shows the GPS antenna on the right side of the cab.
dy
Distance from the center of cab (the crease in the
roof of the cab) to the center of the GPS antenna as
shown above. Take note of whether the GPS
antenna is forward of the cab center or rear of the
cab center. The diagram above shows the GPS
antenna to the rear of the cab center.
antenna_height_offset (J)
Distance from the phase center of the GPS antenna
to the bottom of the tracks (ground level). The
bottom of the GPS antenna shows the offset from
the base of the antenna to the phase center of the
antenna
wheel_length_offset
Distance from the center of the cab to the cutting
edge of the dozer blade. The cut/fill is calculated
here. Wheel_width_offset is also used to determine
where the cut/fill is calculated (see below).
wheel_width_offset (A/2)
Distance from the center of the dozer to the center of
tracks, or, half of dimension A in the cross-sectional
diagram shown above. The cut/fill values are
calculated at two locations on each side of the
machine based on these offsets.
rear_length
Distance from the center of the cab to whatever is
sticking out the furthest at the back of the machine.
In the diagram above, it is the ripper. If the machine
BenchManager
© 2014 Wenco International Mining Systems Ltd.
39
Appendices
does not have a ripper, then just measure to the limit
of the machine.
machine_width (B) Width of the dozer blade as shown above.