AI-IVMS

AI-IVMS

SAPHI developed, integrated, and now manage a cutting-edge mining IVMS, powered by advanced AI models. Our system ensures operator safety and optimizes routes for maximum efficiency.

AI imaging and recognition

What Was The Problem?

In the demanding environment of mining operations, safety and efficiency are paramount. One of our clients, a tier 1 mining company, faced significant challenges in ensuring the safety of their operators and optimizing transport routes within their mines. 

 

Their existing vehicle monitoring systems were outdated and lacked the real-time capabilities necessary to respond swiftly to hazardous conditions and operational inefficiencies. The client needed a solution that could provide real-time data in some of the most remote areas, enhance safety protocols, and optimize transportation routes to reduce fuel costs and improve productivity.

What Was The Solution?

To address these challenges, SAPHI implemented the Shellshock AI-IVMS (In-Vehicle Monitoring System), a sophisticated solution backed by the latest AI models. The Shellshock AI-IVMS was designed to provide real-time monitoring, ensuring both the safety of operators and the efficiency of mining operations.

 

Key features of the Shellshock AI-IVMS included:

  • Real-Time Monitoring: Continuous monitoring of vehicles and operators, providing instant alerts for hazardous conditions and equipment malfunctions.
  • Route Optimization: AI-driven route planning to optimize transport routes within the mine, reducing fuel costs and enhancing operational efficiency.
  • Evergreen Technology: The system is designed to be evergreen, with the capability to be remotely extended and updated. This ensures that the solution evolves with the client’s needs and the latest technological advancements.
  • Seamless Integration: Integration with existing mining management systems for comprehensive data analysis and reporting.

What Were The Results?

Our successful deployment of an AI-IVMS for our client, a leader in mining, showcases our ability to deliver tailored AI-driven solutions. This solution improved operational safety and compliance monitoring. Key outcomes included: 

 

The implementation of the Shellshock AI-IVMS solution led to significant improvements in the client’s mining operations. Key outcomes included:

  • Enhanced Safety: Real-time monitoring and instant alerts drastically improved the safety of operators, reducing incidents and ensuring compliance with safety protocols.
  • Increased Efficiency: Optimized transport routes reduced fuel costs and minimized downtime, leading to a significant boost in overall productivity.
  • Operational Insights: The integration of the Shellshock AI-IVMS with existing systems provided the client with comprehensive operational insights, enabling data-driven decision-making and continuous improvement.
  • Evergreen Capability: The ability to remotely update and extend the system ensured that the client could continuously benefit from the latest advancements and customizations tailored to their evolving needs.
  • Global Implementation: The success of the system in initial deployments led to its trial in multiple locations, including Australia, Malaysia, and India, demonstrating its scalability and effectiveness across different mining environments.

Learn More About Shellshock AI-IVMS

Click the link below to learn more about this innovative IVMS solution.

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Workshop utilisation

Workshop utilisation

SAPHI streamlined the operations of a vehicle manufacturer, optimizing its utilization rates and significantly improving throughput. By leveraging smart process enhancements and data-driven insights, we enhanced workshop efficiency.

AI company

What Was The Problem?

Workshop operations, pivotal to manufacturing efficiency, were plagued by bottlenecks and inconsistencies. The existing system lacked the capability to efficiently allocate resources, resulting in substantial downtime and underutilization. With production targets not being met and costs escalating, there was a pressing need for an innovative solution to revamp the utilization rates and bring the workshop back to optimal productivity.

What Was The Solution?

SAPHI designed a state-of-the-art machine vision solution tailored to monitor workshop operations in real-time. This system delves into the granular details, capturing utilization breakdowns—from computer time, time spent searching for parts, to actual hands-on tool operations. The system employs advanced algorithms that analyze this captured data, pinpointing inefficiencies and areas of concern. All this information is discreetly gathered without disrupting the daily operations, offering a clear lens into the heart of the workshop’s productivity challenges.

What Were The Outcomes?

Implementing our AI imaging solution revolutionizes workshop operations by addressing key challenges and enhancing overall efficiency. By leveraging advanced technology, we provide comprehensive oversight and actionable insights that empower the workshop floor and drive significant improvements in productivity and cost management.

 

  • Dramatic Cost Savings: Significant reduction in operational costs through optimized resource allocation and minimized downtime.
  • Reduced Maintenance Needs: Lower maintenance requirements due to proactive monitoring and efficient use of workshop resources.
  • Enhanced Workshop Oversight: Clear visual analytics provide comprehensive oversight, ensuring better management and coordination.
  • Top-Tier Data Quality: High-quality data is crucial for generating actionable insights and making informed decisions.
  • Substantial Cutbacks in Operational Inefficiencies: Streamlined operations lead to a significant decrease in inefficiencies and bottlenecks.
  • Immediate Feedback on Workshop Activities: Real-time monitoring and feedback improve responsiveness and operational agility.
  • Empowered Workshop Floor: Data-driven decision-making tools empower the workshop floor, enhancing productivity and effectiveness.

What Support Did SAPHI Offer After Completion?

SAPHI provides customised packages to support the full system development life cycle and implementation of upgrades to support the evolving needs of our clients and their customers.

 

Do You Have A Project You Need Support With?

Reach out to our friendly team today for a free consultation about your unique project.

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Underground Development Charging System

Underground Development Charging System

SAPHI plays an integral role in developing Orica’s latest product, Avatel – the most advanced underground development charging system ever designed. 

Underground Development Charging System

Who Is Our Client?

Orica is the world’s largest provider of commercial explosives and innovative blasting systems to the mining, quarrying, oil and gas and construction markets, a leading supplier of sodium cyanide for gold extraction, and a specialist provider of ground support services in mining and tunnelling.

What Was The Problem?

Ordinarily, to conduct an underground explosion, a technician would be required to approach the mine face using a cherry picker and manually feed the explosives into the mine face. Avatel revolutionises this process by enabling the technician to remain in the vehicle’s cab.

 

The engineering team at SAPHI plays a lead role in the development of the low-level control code that remotely delivers the explosives as well as the software for the implementation of the user interface and 3rd party app integration into the control system. SAPHI continues to support, maintain and upgrade the software to ensure the ongoing success of the system.

What Was The Solution?

The engineering team at SAPHI plays an integral role in the development of the low-level control code, implementation of the user interface, 3rd party app integration into the control system. SAPHI continues to support, maintain and upgrade the software to ensure the ongoing success of the system.

What Were The Outcomes?

  • Improved advance rates through continued safe access
    even in challenging conditions
  • Eliminating redundant face support systems
  • Reduced downtime
  • Significant safety improvements

What Skills Did SAPHI Use To Implement The Solution?

The tech stack and experience required for this job included a broad range of skills from our team of computer, electrical and software engineers, including:

  • LabVIEW Real-Time
  • FPGA Code
  • API Development
  • Adobe XD Mockup Translation
  • No SQL Database Design Implementation

What Support Did SAPHI Offer After Completion?

SAPHI has a support contract with Orica and has been providing on-going support and maintenance since 2017.

Do You Have A Project You Need Support With?

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GPS-Denied Proximity Detection

GPS-Denied Proximity Detection

Our engineering team at SAPHI developed a GPS-denied proximity detection system used to avoid collisions between assets. The asset tracking system using IoT leverages the latest in location detection technology that is 20x more precise than traditional GPS. Read on to find out more.

Industry 4.0 solutions and mining operations

What Was The Problem?

Our client required a precise proximity detection system for deployment in remote locations with no GPS access. 

What Was The Solution?

Our experienced engineers developed an advanced asset tracking system using IoT that leverages the latest in GPS-denied location tracking technology that is 20x more precise than traditional GPS. Along with asset tracking functionality, we programmed the end product to perform as a proximity detection system to prevent collisions between assets.

What Were The Outcomes?

The custom proximity detection system delivers an array of benefits and advantages over traditional proximity detection systems, including:

  • 20x more precise than GPS 
  • Improved performance reliability
  • Ability to function in GPS denied locations (inside, underground, remote locations etc.)

What Skills Did SAPHI Use To Implement The Solution?

SAPHI leveraged its broad expertise across both hardware and software to develop the bespoke solution including:

    • JavaScript – to program the logic that determines the positions of various assets in space
    • Ultra-wideband – for GPS denied location tracking
    • Real-time operating systems 
    • Angular – used to develop the web app for configuring settings

What Support Did SAPHI Offer After Completion?

SAPHI provides customised packages to support the full system development life cycle and implementation of upgrades to support the evolving needs of our clients and their customers.

Do You Have A Similar Need?

Find out more about how you can leverage the latest in asset tracking and proximity detection technology by reaching out to our team.

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AI Traffic System

AI Traffic System

SAPHI developed a scalable smart city AI traffic system (Shellshock AI) that monitors cars, people, bikes and scooters to inform local infrastructure upgrades without traffic disruption.

Traffic Movement

What Was The Problem?

Local governments need high-quality data to make informed decisions about upgrading infrastructure, installing wayfinding infrastructure and supporting local businesses. Current methods of capturing this data often require the configuration, deployment and management of hundreds of thousands of dollars worth of IoT devices with a high margin of error.

What Was The Solution?

Our team developed Shellshock AI, leveraging advanced AI models to analyze pedestrian mobility and utilization in local government areas for a fraction of the cost and effort associated with traditional IoT solutions.

 

Key features of the solution included:

  • AI-Driven Analytics: Utilized sophisticated AI models to analyze data on community engagement and recycling program effectiveness.
  • Durable Hardware: Devices built to withstand extreme weather and environmental conditions, ensuring reliability and longevity.
  • Off-Grid Power Solutions: Integrated solar power systems and battery storage to maintain uninterrupted operation without reliance on mains power.
  • Real-Time Monitoring: Enabled real-time data capture and analysis, providing immediate insights and actionable information to optimize staff schedules and resource allocation.
  • Multi-Parameter Capture: The system can monitor and analyze multiple parameters simultaneously, offering a comprehensive view of community engagement and operational performance.
  • Remote Updates: Capable of changing what parameters it captures through remote software updates, allowing for flexibility and adaptability to evolving needs.
  • Non-Disruptive Deployment: The solution allowed for deployment and data capture without any disruption to traffic flow, as no equipment needed to be installed on the road.

What Was The Outcome?

The AI imaging system for roadway utilisation provided the local council with valuable insights for infrastructure management. Key outcomes included:

 

  • Real-Time Data: Enhanced decision-making with immediate access to roadway utilisation data.
  • Operational Insights: Improved understanding of traffic patterns, aiding in infrastructure planning and traffic management.
  • Proactive Maintenance: Identified maintenance needs promptly, allowing for timely interventions and reduced roadway downtime.
  • Cost Efficiency: Utilized existing camera infrastructure where possible, minimising costs and facilitating rapid deployment.

Want to learn more about Shellshock AI?

See Shellshock AI for yourself by clicking the link below.

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Advanced Sway Detection

Advanced Sway Detection

SAPHI revolutionized the way telecommunication tower asset owners monitor and extend the value of their assets. In an age where consistent and efficient telecommunication is vital, the role of maintaining the integrity and efficiency of telecommunication towers is paramount.

AI computer vision

What Was The Problem?

Indara faced challenges with their telecommunication towers. Traditional methods of stress assessment, which utilized photos and drawings, were not only outdated but also resource-intensive. There was a significant financial burden from manual tower stress assessments, which also became increasingly inaccurate with the transition from 3G to 4G and now, 5G. The need to manually inspect towers, coupled with overly conservative measures, was resulting in higher costs, sub-optimal operational efficiency, and missed revenue opportunities.

What Was The Solution?

SAPHI engineered an advanced sway detection solution tailored for asset integrity. Using state-of-the-art sensors, our system provides Indara with real-time tower structural insights, allowing them to maximize tower load by adding new customers, consequently boosting revenue. This not only enhances the capacity for adding more customers per tower but also introduces predictive maintenance schedules and immediate alerts for potential structural anomalies. With this newfound intelligence, Indara can judiciously space out their maintenance, shifting from fixed periods to a more “as-needed” approach, which further amplifies cost efficiencies.

What Were The Outcomes?

  • Maximized tower loadings for increased revenue.
  • Real-time structural insights enabled.
  • Predictive maintenance schedules introduced.
  • Immediate alerts for structural anomalies.
  • Shifted to “as-needed” maintenance, cutting costs.
  • Enhanced capacity for more tower customers.

What Skills Did SAPHI Use To Implement The Solution?

To realize the AI-powered crop yield tracking solution, SAPHI harnessed the collective knowledge of our interdisciplinary team of computer, electrical, and software engineers. The project leveraged a broad spectrum of our core competencies:

  • Embedded microcontroller programming.
  • Creation of robust and encrypted data communication channels.
  • Sway detection sensor integration.
  • Data visualisation.

What Support Did SAPHI Offer After Completion?

SAPHI provides customised packages to support the full system development life cycle and implementation of upgrades to support the evolving needs of our clients and their customers.

 

Do You Have A Project You Need Support With?

Reach out to our friendly team today for a free consultation about your unique project.

Interested in other projects?

Check out more projects below!

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Combating Urban Heat Using AI

Combating Urban Heat Using AI

SAPHI was the technical integration lead for Australia’s largest smart green infrastructure project (SIMPACT) designed to combat urban heat in Western Sydney. 

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What Did Western Sydney University Say?

"I recently partnered with SAPHI for a complex IoT/AI project and was thoroughly impressed. Their team displayed exceptional expertise in IoT and AI, delivering solutions that were not only innovative but also enhanced the capability of our system. Their approach to project management was professional and transparent, making the entire process smooth and efficient. SAPHI's systems integration was key to the success of our project. I highly recommend SAPHI for anyone looking for cutting-edge tech solutions in a supportive, client-focused environment."
Sebastian Pfautch
Researcher

SIMPACT Project Background

Dubbed SIMPACT (Smart Irrigation Management for Parks and Cool Towns), the project is a collaboration between the NSW Government, several universities and private industry to address the growing problem of heat islands in cities.

The project aims to leverage irrigation, IoT devices and artificial intelligence to cool the park’s microclimate for residents and visitors.

What Was The Problem?

Western Sydney was grappling with the rising problem of ‘urban heat’ and significant water wastage in our parks. Cutting edge research from Western Sydney University proved theoretically that optimizing the performance of its parks could pave the way for both a reduction in temperature and water conservation. However, the challenge lay in harnessing the right technology to bring this vision to life. This is where SAPHI came in.

What Was The Solution?

To address the urban heat challenge in Bicentennial Park, our approach was straightforward yet impactful. We tapped into the potential of optimizing the park’s irrigation system. By deploying 250 IoT sensors and 4 advanced weather stations, we gathered nuanced environmental data. This data, when processed through two tailored AI algorithms, yielded an optimized irrigation schedule. The outcome was not only a noticeable 4-degree temperature reduction but also an impressive 15% annual savings in water usage. Through this initiative, we demonstrated that strategic adjustments, backed by technology, could create a cooler, more sustainable environment for the community.

What Are The SIMPACT Objectives?

The SIMPACT project has several major objectives including:

  • 4-degree reduction in temperature
  • 15% reduction in water usage within the first year
  • Fully automated irrigation management

What Support Does SAPHI Offer After Completion?

SAPHI provides customised packages to support the full system development life cycle and implementation of upgrades to support the evolving needs of our clients and their customers.

Do You Have A Project You Need Support With?

Reach out to our friendly team today for a free consultation about your unique project.

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Crop Yield Tracking Using AI

Crop Yield Tracking Using AI

SAPHI revolutionized the approach to crop management for a prominent agriculture business. Harnessing AI-driven analytics, we optimized crop yield tracking, resulting in data-informed farming strategies and increased harvest outputs.

Water protection

What Was The Problem?

In the realm of agriculture, accurate crop yield tracking is indispensable for planning and optimising harvests. However, traditional methods proved unreliable and lacked precision. The extant system faced challenges in predicting and managing yields, leading to missed opportunities and potential financial losses. With the pressing demands of a growing population and fluctuating market dynamics, there was an urgent necessity to transition to a more advanced, data-driven approach for efficient crop management.

What Was The Solution?

To address the crop yield challenges, SAPHI introduced an avant-garde AI-driven solution specifically crafted for crop monitoring. This system meticulously captured the vital details of crop growth and health using machine vision techniques. It analysed parameters such as plant height, colour variations, and other vital signs, ensuring a precise yield forecast. Utilising advanced AI algorithms, the solution identified potential issues, from pest infestations to suboptimal growth conditions. By integrating this solution, farms could make informed decisions without intruding on the natural growth process, ultimately ensuring maximised harvests.

What Were The Outcomes?

  • Significant cost reductions by sidestepping
  • Maintenance overheads were notably diminished.
  • Elevated crop monitoring through detailed AI-driven analytics.
  • High-fidelity data acquisition pivotal for accurate yield forecasts.
  • Tangible reduction in agricultural inefficiencies.
  • Swift insights into crop health and potential issues.
  • Enhanced farm operations with data-centric decision-making strategies.

What Skills Did SAPHI Use To Implement The Solution?

To realize the AI-powered crop yield tracking solution, SAPHI harnessed the collective knowledge of our interdisciplinary team of computer, electrical, and software engineers. The project leveraged a broad spectrum of our core competencies:

  • Embedded microcontroller programming 
  • Creation of robust and encrypted data communication channels.
  • Integration with specialised agricultural sensors and imaging systems.
  • Comprehensive data analytics tailored for agronomic insights.
  • Development and calibration of bespoke AI models for crop analysis.

What Support Did SAPHI Offer After Completion?

SAPHI provides customised packages to support the full system development life cycle and implementation of upgrades to support the evolving needs of our clients and their customers.

 

Do You Have A Project You Need Support With?

Reach out to our friendly team today for a free consultation about your unique project.

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Air Quality Monitoring Using IoT

Air Quality Monitoring Using IoT

SAPHI architected, procured, validated, configured and supported an air quality monitoring system using IoT for deployment throughout the City of Newcastle for tracking critical parameters of interest such as coal dust.

SAPHI

Who Was The Client?

City of Newcastle is a local government authority in NSW, Australia. Council employees over 900 staff helping residents and visitors live, work and play in Newcastle. Newcastle has six beaches, two ocean baths, five inland pools, 630km of footpaths, 350 parks and fields, 118 playgrounds, 634 buildings and structures, 798.5km of roads and plenty more. Council also manages Newcastle Art Gallery, Newcastle Museum, Civic Theatre and nine branch libraries.

What Was The Problem?

The City of Newcastle was determined to accurately map heat islands and coal dust movement throughout the City to gather insights into the effects on public health and which areas must be addressed. The innovative smart cities team needed a specialised integrator to source, validate, configure, deploy and manage a powerful air quality monitoring system to conduct their city-wide assessment.

What Was The Solution?

The engineering team at SAPHI architected and designed an air quality monitoring system using IoT to capture, store and transmit data into the existing council platforms. The data could then be visualised to monitor the heat islands within the city and the widespread movements of coal dust. This provides the necessary data to make informed decisions to make the city a safer and more pleasant place for residents

What Were The Outcomes?

  • Improve decision making
  • Improved quality of data for reporting
  • Safer environment for the public
  • Improved public sentiment 
  • Improvement of liveable spaces

What Skills Did SAPHI Use To Implement The Solution?

The tech and experience required for the air quality monitoring system using IoT included a broad range of skills from our team of computer, electrical and software engineers, including:

  • Embedded device configuration
  • Encrypted communication development
  • Solar and mains power integration
  • Device analysis & validation
  • Data integration into an existing platform

What Support Did SAPHI Offer After Completion?

SAPHI provides customised packages to support the full system development life cycle and implementation of upgrades to support the evolving needs of our clients and their customers.

 

Do You Have A Project You Need Support With?

Reach out to our friendly team today for a free consultation about your unique project.

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Dust Monitoring

Dust Monitoring

The development team at SAPHI produced an integrated real-time dust monitoring system for mass deployment throughout key sites for a large Australian Mining Company. 

Dust Monitoring

What Was The Problem?

The Australian based client required real-time data on the dust emissions at key mining sites throughout Australia for compliance and safety purposes. The solution could not be met by an off-the-shelf dust monitoring solution and required a team of specialised integrators to integrate the data into the client’s existing systems.

What Was The Solution?

The engineering team at SAPHI developed a custom, real-time dust monitoring system to capture dust levels and movements throughout the mine sites. The system was designed to include automated alarms that would trigger and notify key personnel when pre-defined limits were exceeded. 

What Were The Outcomes?

  • Improved safety compliance
  • Improved reporting 
  • Improved data reliability
  • A scalable dust monitoring solution for mass deployment
  • Safer work environment for staff

What Skills Did SAPHI Use To Implement The Solution?

The tech and experience required for the dust monitoring system included a broad range of skills from our team of computer, electrical and software engineers, including:

  • Embedded microcontroller development
  • Encrypted communication development
  • Solar & battery power integration
  • Low power device analysis
  • Custom PCB design & implementation
  • Industrial enclosure design

What Support Did SAPHI Offer After Completion?

SAPHI provides customised packages to support the full system development life cycle and implementation of upgrades to support the evolving needs of our clients and their customers. 

 

Do You Have A Dust Monitoring Project You Need Support With?

Reach out to our friendly team today for a free consultation about your unique project.

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