Leica Jigsaw Positioning System (Jps): Ground-based

Positioning System using Locata Technology

Release A, August 2012

Brendon Lilly, Stuart Gray

Leica Geosystems

The Team at Locata Corporation

John Carr, James Earl

Newmont Boddington Gold

Abstract
Open pit mines rely more and more on machine guidance systems to improve efficiencies in
production. These machine guidance systems use high precision GNSS positioning to provide robust
3D positioning in the mine. The receivers of these positioning systems have evolved over the past
decade and can use a combination of satellite positioning constellations in order to achieve better
performance and higher availability. Locata Corporation (Locata) has invented a groundbreaking radio
positioning system that can be considered a “local GPS". Functionally the Locata system is equivalent
to a GNSS positioning constellation but is ground-based instead of satellite-based. The Leica Jigsaw
Positioning System (Jps) is the world's first commercial product to integrate the Locata signals
produced by the Locata system into a high precision GNSS+Locata positioning device. The Leica Jps
leverages the strengths of both the GNSS and Locata technologies, delivering a new and previously
unattainable level of positioning reliability in areas where GNSS-only positioning is unreliable. This
paper describes the Leica Jps components and its deployment onto machines at Newmont
Boddington Gold mine, showing that in certain conditions an improvement of 75.3% to 98.7% in
position availability over a GNSS-only system can be achieved while maintaining RTK accuracy.
Introduction
Many mines around the world are using machine guidance systems to provide operators with real-
time feedback of the design required to achieve the mine site’s plan. These guidance systems are
generally installed on drills, shovels, excavators, dozers and graders. They empower the operators to
make decisions on the work to be done, leading to improved efficiencies and productivity.

At the core of these machine guidance systems is a positioning system, which needs to provide
accurate and robust 3D positions in the mine. There are a number of different technologies for
providing these positions. The most popular and by far the most pervasive is the use of Global
Navigation Satellite System (GNSS) receivers. These receivers use signals transmitted by GNSS
satellites orbiting the Earth to calculate a three-dimensional position on or near the Earth’s surface.

In many open pit mines machine guidance systems are able to use these GNSS receivers whilst
sufficient satellites are "in view". However, as pits become deeper machines suffer from a more
restricted view of the sky, reducing the number of tracked satellites, which contributes to poor
geometry and results in reduced performance and availability. Under reduced satellite visibility
conditions the positioning system (and hence the machine guidance system) becomes unusable,
forcing the mine to resort to less-efficient, alternative procedures, such as manual surveying with total
stations. This reduces or temporarily halts the production of the mine machines, leading to less
efficient operation and output.

In 2005, Leica Geosystems started investigating a technology that would eventually prove successful
in overcoming these problems. Locata Corporation was independently developing a terrestrial
positioning system that could replicate GPS [1]. Locata had invented and patented a new
synchronization technology called TimeLoc™. TimeLoc wirelessly synchronises all the Locata devices
in the network to approximately one nanosecond (one billionth of a second) without the need for an
atomic clock. It is this core development, which allows Locata’s LocataNet™ (the resultant ground-
based Locata network) to replicate the GPS constellation on the ground. Unlike GNSS systems, the
LocataNet requires no additional reference base station or additional corrections to provide high-
accuracy positioning solutions. The transmitters, called LocataLites™, transmit multiple Locata signals
from each transmitter tower, fully replicating, at a local level, the functionality of a $100 million satellite
[2].

Leica Geosystems saw the benefit of this technology and took the opportunity to create a partnership
with Locata to develop an integrated GNSS+Locata solution, initially geared towards the mining
industry. The resultant development and deployment of the integrated solution technology has the
ability not only to provide reliable positioning for machine guidance, but resolves the problems for
other applications, such as autonomous machines.

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Initial Development
The first Locata equipment to be installed on Leica Geosystems guidance systems was in South
Africa in late 2006 [3]. This proof-of-concept system was developed and installed around the edge of
the pit, and on a drill and dozer, in DeBeers Venetia Mine. This deployment provided the initial data
and experience required to apply the new Locata technology in a real mine environment.

Also in 2006, in a separate project, Newmont Boddington Gold (NBG) in Australia starting installing
Leica Geosystems high precision (HP) guidance systems on several plant. Located 140kms
southeast of Perth in Western Australia, NBG currently has two active pits which have significantly
increased in depth over the last three years. With this increasing depth came loss of visible satellites
to provide consistent coverage for the Leica HP drill systems installed onto their entire drill fleet.

Newmont Boddington Gold identified this issue early on and recognised that an alternative positioning
system would be required in order for these guidance systems to continue working for the life of the
mine. Subsequently, in 2008, NBG agreed to become a development partner with Leica Geosystems
to continue the work started with the Locata technology in South Africa resulting in some initial benefit
[4,5].

Since that time Leica Geosystems has commercialised the Leica Jps with help from Newmont
Boddington Gold and Locata Corporation. The commercialised Leica Jps components include self-
surveying Jps LocataLites, tightly integrated RTK GNSS+Locata Jps Receivers, and GNSS+Locata
co-located antennas.

With a history of embracing new technologies Newmont Boddington Gold has actively assisted with
the development and testing of the Leica Jps product over the past four years. A conscious effort has
been made by NBG to look at ways of improving the efficiency and accuracy of Newmont’s global HP
drilling operations in an open pit environment. NBG were already committed to assisting Leica
2
Geosystems with continuing the development of its existing Leica J drill HP drilling product. This has
2
now evolved to incorporate Leica Jps into the J drill platform and provides a seamless amalgamation
of the two Leica Geosystems technologies.

It was in March 2012, following several years of development and testing, that the first fully integrated
GNSS+Locata Jps Receivers were field trialled at NBG, delivering immediate and measurable
success. The remainder of this paper describes the deployment of the system at NBG and the
performance that it has achieved to date.

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 Leica Jps uses the GNSS satellites that it can see
and augments with ground-based Jps LocataLites. Jps
LocataLite

Leica Jps Receiver on a Drill Jps LocataLites (synced to GPS)

Using the Jps Antenna, the transmit signals.
Jps Receiver calculates position
using GNSS and Locata signals.
Only a GNSS base is required.

The Jps LocataNet™

The Leica Jps is made up of two main components: the Jps LocataLites, which are the transmitters
positioned around the mine pit; and the Jps Receivers mounted on the machines.

The Jps LocataNet is the “local constellation” network made up of a number of Jps LocataLites. In this
network, one of the Jps LocataLites is assigned “Master LocataLite” status and the rest are assigned
as “slaves”. The slaves TimeLoc to the Master Jps LocataLite. The Master also contains a
meteorology station that measures and transmits pressure, temperature and humidity data around the
LocataNet so that is can be used in positioning computations.

Although the GNSS satellite constellations and the Jps LocataNet have extremely accurate, yet
independent time bases, it is far more convenient for the integration of GNSS+Locata combined
positioning solutions if the time bases of each system are closely aligned. Locata developed a method
to slew its internal time base to precisely align with the GNSS timebase (and hence the global-
standard UTC time). When temporal alignment is achieved, the combined solution algorithm does not
have to correct for the time offsets between systems. Leica Geosystems has integrated this capability
into the Jps LocataNet and Jps Receivers. This means the complete Jps LocataNet is synchronized
with GPS time and both GNSS and Locata signals measured at the Jps Receiver are synchronous.
Consequently all signals can be used directly and simultaneously in the position calculations.

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 Master Master
Jps LocataLite Jps LocataLite

Direct TimeLoc
Cascaded TimeLoc

Figure 1: Basic Jps LocataNet™ Figure 2 – A more complex LocataNet™ where Jps
LocataLites™ are cascaded

Figure 1 shows a basic Jps LocataNet made up of a number of Jps LocataLites all synchronized to
the Master. If some of the slave Jps LocataLites cannot see the Master due to local obstructions at
the mine, they can simply TimeLoc from another slave Jps LocataLite™ that is in view (Figure 2). This
makes for an extremely effective and flexible real-world set-up and deployment capability.

Where mines have multiple pits, the Jps LocataNet can be synchronized to a single Jps LocataLite
Master if a “Sub-Master” is positioned so that it is in view of the Master. The Sub-Master allows the
time base of the Master LocataLite™ to "cascade" TimeLoc into another pit (Figure 3). This is the
configuration used for the operational deployment at Newmont Boddington Gold, which covers two
separate pits.

Master
Jps LocataLite

Sub-Master
Jps LocataLite

Direct TimeLoc
Cascaded TimeLoc

Figure 3 – Multiple pit LocataNet™ running from a

single Jps LocataLite™ Master

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Alternatively, separate Jps LocataNets can be deployed and the Jps Receiver will automatically
synchronize to whichever Jps LocataNet it is operating in (Figure 4).

Master
Jps LocataLite

Master
Jps LocataLite

Direct TimeLoc

Figure 4 – Multiple pit LocataNet™ running from

separate Jps LocataLite™ Masters

Like any other transmitter used in a GNSS-style network, it is essential for each transmit antenna
attached to a Jps LocataLite to be accurately surveyed. Any traditional survey method can be
employed, but to ensure ease-of-use for the mine the Jps LocataLite has also been designed to
autonomously "self-survey" without any surveyor input. Each Jps LocataLite Module has a built-in
GNSS RTK Receiver and the Jps Tower has a GNSS antenna incorporated at the very top (see
Figures 5 and 6). When turned on, the Jps LocataLite self-surveys the position of the Jps Tower
automatically and continuously monitors any movement of the Jps Tower (e.g. from subsidence or
blasting). This means that the Jps LocataLite can be positioned in active mining areas and be
relocated quickly when required. If RTK positions cannot be computed for the self-survey, then the
Jps Tower can be manually surveyed and its position entered into the Jps LocataLite using its web
interface.

As no special consideration for the location of a base station is required, the Jps LocataLites can be
placed in areas on the rim of the pit or just above the machines operating in the pit floor. The only set-
up requirement is that they are able to see at least one other Jps LocataLite in order to TimeLoc.

The Jps LocataLites do not require any additional communications across the Jps LocataNet,
everything is provided in the Locata signals themselves. This means that the deployment process for
the Jps LocataNet is simple. It is just a matter of placing the Jps LocataLites in locations that
maximise the benefit of signal availability to the machines they are supporting.

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 The Jps LocataLite™
Jps LocataLite
Jps Tower The Jps LocataLite is made up of
with
Antenna Array several components: the Jps
LocataLite Module, the Jps Tower with
its Antenna Array, and the power
source (such as a mobile solar trailer
or fixed solar panels).
Jps Trailer
with
power source
The Jps Tower and trailer are
intentionally separated so that the Jps
Tower can be placed in a position at
Jps LocataLite
Module
the edge of the pit in order to
maximise the signal transmission into
the pit without being limited by a co-
located tower and trailer (see Figure
5). The Jps LocataLite Module can be
mounted on the trailer for increased
mobility or at the base of the Tower for
more permanent installations.
Figure 5 – A Jps LocataLite™ comprising of a Jps Tower, Jps
LocataLite™ and trailer containing the power source.
Each Jps Tower has four antennas
mounted in an Antenna Array. The
uppermost antenna is the GNSS antenna, which is used to self-survey the top of the Jps Tower, and
hence automatically derive the positions of the Locata antennas plumbed vertically under it. This
simple vertical arrangement ensures that the system does not require additional sensors to deduce
heading or inclinations.

The Locata Transmit 1 Antenna is mounted directly under the

GNSS antenna. The Locata Receive Antenna is directly under that,
and the Locata Transmit 2 Antenna is about two meters lower
down on the Jps Tower. All the antennas are separated by a
known distance and the Locata Transmit Antennas can be tilted
down into the pit to maximise the signal broadcast into the area the
Jps Tower is servicing. The Locata Receive antenna is pointed
towards the Jps LocataLite Master, Sub-Master or slave that it is
using to achieve TimeLoc.

Each Jps LocataLite transmits four independent positioning signals

- two signals from each Transmit Antenna. These signals provide a
level of redundancy and help mitigate the problems with multipath
affecting the robustness and reliability of the positioning solution.

RF cables are connected to each of the antennas on the Jps Tower

and are mated to the Jps LocataLite with a single combined
connector, making for quick, error-free connections and
disconnections. This ensures that antennas are always connected
correctly, again making it easy to deploy and maintain an
operational Jps LocataNet.
Figure 6 – The Jps Tower with
the relative positions of the
antennae.

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The Jps Receiver
The Jps Receiver is the world’s first commercial positioning device capable of tracking and using both
GNSS and Locata signals. It comprises of the Jps Receiver connected to a Jps Antenna – a
specialised and rugged unit designed by Leica Geosystems in conjunction with Antcom Corporation
and Locata Corporation (refer Figure 7).

The Jps Antenna contains co-located GNSS and Locata antennas, specifically designed with well-
aligned phase centres for accurate machine positioning, and carefully-shaped reception patterns to
minimize the multipath problems inherent in this type of mining environment. For instance, the
reflection of positioning signals from pit walls and other machines.

The Jps Receiver has the ability to track all the latest GNSS satellite signals (GPS, GLONASS,
Galileo and Compass) as well as the Locata signals. Importantly, Leica Geosystems have integrated
Locata signal processing into the same Leica Core Algorithm Library (CAL) as used by the current
Leica Geosystems survey receivers. Technically, this means the Locata signals are treated and
processed by the Leica CAL in exactly the same way as the signals received from any other
constellation (i.e. GPS, GLONASS, et al.). This tight integration ensures that the decades of prior
development, maturity and robustness, which Leica Geosystems has built into the CAL are directly
utilised by the Jps Receiver.

Figure 7: Jps Receiver Connections

The Jps Receiver has been specifically developed to provide position and orientation for mine
machine guidance systems. Hence it contains two internal rovers, each comprised of a GNSS
receiver and a Locata receiver. Even though they are physically housed in one module, they are two
independent rovers sharing common interfaces. An external system communicates with the two
rovers either via RS232 serial ports or a single M12 Ethernet connection. The interface protocol
follows the open NMEA standard with some minor modifications to accommodate the Locata signal
structure, and the high number of signals that can now be tracked: consider that some older NMEA
messages, because of their inception during the GPS-only era, are limited to 12 satellites by default.

This allows the Jps Receiver to be integrated with any machine guidance system capable of using the
2
NMEA protocol, such as the Leica Jigsaw J guidance systems. The Jps Receiver only requires GNSS
corrections for the internal GNSS receivers and these can be input via the dedicated serial port or via
the Ethernet connection. As already stated, the Locata receivers in the Jps Receiver do not require
additional corrections.

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Test Setup at NBG
Following a prototyping and test-bed development period spanning several years, NBG began
running two production Jps Receivers in early April 2012 on two of its production drill rigs. These first
receivers were installed on drills as the highest priority, because the drills are the machines at NBG
that operate closest to pit walls and other obstructions. They therefore stood to benefit most from
having more reliable positioning.

For these first installations, the Jps

Figure 8: Setup on-board the drill to compare Jps with GNSS
Receivers were setup in such a way
that comparative tests against
GNSS-only position solutions could
be performed. NBG already utilised
Leica Jigsaw guidance systems, so
the Leica GNSS receivers in those
systems were used for comparisons
against the results obtained by the
Jps Receivers that were producing
GNSS+Locata solutions. The
standard GNSS-only antennas were
replaced with Jps Antennas and
GNSS signal splitters were installed
to ensure that the Leica GNSS and
Jps Receivers received the same
GNSS signals from the same
physical antenna (as shown in
Figure 8).

The twelve Jps LocataLites (shown in Figure 9) were set to TimeLoc from a single Master Jps
LocataLite located on the South Pit rim between the pits. For the results presented in this article, the
data from the North Pit only was used, as an operational Jps LocataNet was not yet completed in
South Pit at the time of the campaign. The North Pit at NBG is about 1km long, 600 meters wide and
150 meters deep. It has a significant wall on the northern side and as the mine is in the southern
hemisphere, the orbiting GNSS satellites are frequently obstructed from view of the drills operating
there. This is evident in the results presented below.

Figure 9 – The installation of twelve Jps

LocataLites™ at both the North and South
Pits of Newmont Boddington Gold during
April and May 2012.

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Positioning Performance Results
The goal of the Jps Receiver is to improve the availability of high-accuracy RTK positions with fixed
carrier phase integer ambiguities. The results presented here are therefore divided into four separate
sections:
1. The first section shows the improvements in availability over a two month period for all the data in
the North Pit.
2. The second shows the improvements in availability for an area in the pit where the GNSS is
significantly degraded
3. Section three shows a broad summary of the potential level of productivity savings in dollar terms.
4. The forth shows the accuracy results achieved and maintained in the GNSS degraded area.

It is essential to understand that the performance results shown below are actual real-world samples
of the system while operating on drills at NBG. However, it will be appreciated that GNSS satellites
are in constant motion, so GNSS-only position availability in different parts of the pit changes by the
hour. The results shown therefore only apply to the drills in those positions in the pit at that time.
Another drill a little distance away in the same pit could experience far better or far worse GNSS
availability at exactly the same time.

Results (1) – Overall Availability

The plots in Figure 10 show the performance difference between using GNSS-only (left plot) and Jps
(right plot), using the setup described above (Figure 9) The data for these plots was recorded for the
two drills that contained Jps Receivers in the North Pit during the months of April and May 2012. A
green dot represents the time the receiver had a RTK fixed solution and a red dot represents all other
lower quality position solutions – essentially when the receiver was unable to achieve the required
RTK accuracy because of insufficient signals or geometry.

Figure 10 – Plots of Availability and Position Quality in the North Pit at Newmont Boddington Gold for April and
May 2012 for GNSS (left) and Jps (right). Green = RTK Integer (Fixed) solution, Red = all lesser quality solutions.

Although the availability of GNSS-only RTK fixed position solutions was reasonably good over this
entire area, being at the 92.3% level, the Jps nevertheless provided a measurable improvement of
6.5%, to bring the total availability up to an impressive 98.8%.

Considering that during those two months the two drills spent a total of 72.24 operational days in the
North Pit, this improvement equates to nearly 4.7 days or 112.7 hours of additional guidance
availability. Figure 11 highlights the low positional quality for the GNSS-only solutions and how Leica
Jps significantly improved the availability in the areas of limited GNSS satellite visibility.

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Figure 11 – Plots showing non-RTK Quality Positions exclusively, demonstrating that Jps can help reduce lesser
quality RTK solutions. Performance in the circled area is highlighted in more detail in Figure 12.

Results (2) –Availability in Areas of Poor GNSS Visibility

The circle in Figure 11 highlights a particular location in the North Pit, where GNSS positioning
consistently struggles due to the prominence of the northern wall and to a lesser extent from the
eastern wall. Thanks to Leica Jps and its integration of GNSS and Locata signals, the improvement in
availability as shown in Figure 12 is in this case significantly greater at 23.4%.

Figure 12– Zoomed in area where GNSS performance struggled between 2 May and 4 May. The circled area is
the position of where the accuracy tests were performed.

Results (3) – Operational Savings

If the machine downtime due to not having a RTK position costs the mine approximately $1000 per
hour for each drill, the improvement in availability of 112.7 hours over the two months shown in
Results (1) above equates to $112,700 of operational cost. This productivity increase is significant,
even considering that the GNSS-only availability in this case was not severe at 92.3%. If the GNSS
availability for those two months was more like 75% as was the case shown in Figure 12 for the two
days in May, then the cost savings become significantly greater at nearly $400,000.

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Importantly, this nominal amount is only for the two machines fitted with the Jps Receivers during
April and May. NBG intends to fit out at least 10 drills, with shovels and dozers to follow. This means
that the cost savings would be multiplied by many times the above amounts. In fact, if the Leica Jps
had been fitted to all 10 drills during April and May, the cost savings (given the above results) would
have been in the order of $1,000,000.

It is clear that the savings in production costs that could be gained from improving the availability to
the guidance system has a significant impact on the ROI. It potentially covers the installation costs
within months of deployment. It should also be very clear that, as the pits invariably get deeper,
GNSS availability will degrade further and the evident production and dollar benefits of the Leica Jps
will become even larger.

Results (4) – Relative Accuracy

The above levels of improvement in availability are of no benefit if the position accuracy is not
maintained within acceptable limits, certainly at least to the level that the mine has come to expect
from their standard GNSS systems. In order to compare the relative accuracy between the two
systems, a dataset was taken from the same data above (circle in Figure 12) when the machine was
stationary.

The average position difference between the GNSS-only and Jps Receivers for the hour-long dataset
was 1.2 cm horizontally and 2.7 cm in the vertical. The spread of the position solutions for the two
receivers were comparable in the horizontal with Jps providing a slightly better HRMS value due to
the extra Locata signals being tracked, and the stronger geometry. Additionally, Jps showed a better
RMS in the vertical compared to GNSS-only because again it was able to utilise the stronger
geometry, combining GNSS satellites overhead and the LocataLites around the pit.

GNSS-only Jps Difference

Horizontal Position -32.743013982 ° -32.743014021 ° 0.012 m
Average 116.345888196 ° 116.345888076 °

Height Average 133.745 m 133.772 m 0.027 m

Horizontal RMS 0.021 m 0.010 m

Vertical RMS 0.079 m 0.015 m

Table 1 – Comparison of relative accuracy and RMS between the GNSS-Only and Jps Solutions.

The scatter plot in Figure 13 shows the spread of horizontal positions for the Jps Receiver where 0,0
is the mean horizontal position during this time. Note that all the positions are grouped within ±2cm of
the mean without any outliers.

The plot in Figure 14 shows the corresponding spread in the vertical positions. These are well within
the acceptable accuracy limits required by the machine guidance systems used at the mine.

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 Figure 13 – Scatter plot of the positions from the Jps Receiver over a period of over an hour.

Figure 14 – Plot of the vertical positions for the same sample set as Figure 13.

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Conclusion
The Leica Jigsaw Positioning System (Jps), powered by Locata, provides substantial improvements in
positioning availability compared to normal RTK GNSS receivers, while maintaining RTK quality
position accuracies. Leica’s Jps Receiver is the world’s first commercial GNSS RTK receiver to use
the new Locata signals for positioning, utilising the existing, mature positioning technologies
developed by Leica Geosystems. The Leica Jps has been designed specifically as an OEM device
and it can therefore be integrated easily into any high precision machine guidance system.

The Jps LocataNet is capable of covering specific areas in a single pit or multiple pits on a mine site.
If additional coverage is required, then the system can be scaled to meet the customer’s needs. By
simply adding more Jps LocataLites to the area, or by moving the existing Jps LocataNet to a more
appropriate configuration, the mine can ensure reliable and accurate positioning signals are always
available where and when they are needed.

Based on the experiences at Newmont Boddington Gold, use of the Leica Jigsaw Positioning System
has improved the operational availability of open-pit drilling machines by at least 6.5% by reducing the
outages in 3D positioning caused by poor GNSS satellite visibility commonly associated with deep
pits. When Jps is subjected to much harsher conditions closer to high walls, the Jps continues to
perform. The improvement in availability (compared to GNSS-only) is more significant, while still
maintaining acceptable limits of accuracy.

The additional availability achieved translates directly into cost savings in production. Even with a
small number of machines and the GNSS-only availability not being severe in the mine at the time, a
pay back of months for a Jps LocataNet is possible.

Professional Recognition
The authors would like to thank the many people that have contributed to the development of the
Leica Jps product. The Leica Geosystems Machine Control Core and CAL teams in Brisbane and
Switzerland, other Hexagon companies such as Antcom Corporation and NovAtel, the Locata
Corporation team in Canberra, and the people at Newmont Boddington Gold that have gone out of
their way to make the Leica Jigsaw Positioning System a success.

References

[1] BARNES, J., RIZOS, C., KANLI, M., PAHWA, A., SMALL, D., VOIGT, G., GAMBALE, N., &
LAMANCE, J., 2005. High accuracy positioning using Locata's next generation technology.
18th Int. Tech. Meeting of the Satellite Division of the U.S. Institute of Navigation, Long
Beach, California, 13-16 September, pp2049-2056.

[2] Inside GNSS Magazine Cover Article. “Truth on the Range” – CRAIG, D. et al; June 2012
Edition: http://www.insidegnss.com/node/3071

[3] Barnes, J., Lamance J., Lilly, B., Rogers, I., Nix, M., & Bals, A., Leica Geosystems, DeBeers
and Locata Corporation, An integrated Locata & Leica Geosystems positioning system for
open-cut mining applications, Institute of Navigation Conference (ION), Fort Worth Texas,
Sept 2007

[4] GPS augmentation for mining, Mining Magazine, Oct 2010.

[5] RIZOS, C., LILLY, B., ROBERTSON, C., & GAMBALE, N. (2011). Open cut mine
machinery automation: Going beyond GNSS with Locata. Proc. 2nd Int. Future
Mining Conf., Sydney, Australia, 22-23 November

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