Digital Twin in Mining Industry: A Study on Automation Commissioning Efficiency and Safety Implementation of a Stacker Machine in an Open-Pit Mine

This project builds a digital‑twin framework to improve how a Stacker Machine (SM) is commissioned and monitored for safety in an open‑pit mine. The system uses a three‑layer architecture: * **Physical and link layer** – the real machine and its sensors. * **Application layer** – the software that runs the virtual model. * **Control layer** – the logic that drives both the real and virtual machines. By copying the SM’s behavior in a computer model, the digital twin lets engineers watch the machine in real time, run a virtual commissioning, and perform safety checks without stopping the mine. The implementation focuses on simulating the machine’s automation and control logic. This

lets engineers: * verify PLC code, * test safety interlocks, and * see how the machine reacts in critical situations. The result is a shorter commissioning period, less chance of damaging equipment during tests, and higher reliability and availability of bulk‑material handling in mining. The framework also provides a step‑by‑step guide for adding digital‑twin technology to existing mine‑automation processes, showing a clear route to safer and more efficient open‑pit operations.

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