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AI-Controlled Robotic Rock Breaker
For deep mines and open-pit operations
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Proven in real conditions (depth >1,000 m, nickel-copper deposit)
3 operating modes: auto, semi-auto, manual
One operator manages multiple rock breakers
Works at crusher stations and grizzly screens
THE PROBLEM
Crusher downtime is expensive. And it is getting harder to staff.
Oversize rocks that block the grizzly screen are one of the most persistent causes of unplanned downtime at crushing stations. At the same time, experienced rock breaker operators are increasingly difficult to find and retain.
  • Productivity lost to human factors
    Up to 25% of rock breaker working time is lost to shift changes, breaks, and fatigue — even when the crusher is ready to run. The machine waits for the person.
    Up to 25% lost utilisation
  • Labor cost scales linearly with equipment
    Each breaker requires a dedicated operator. For a fleet, that means a significant and growing labor cost with no natural efficiency ceiling.
    1 operator per breaker
  • Personnel in the hazard zone
    Manual operation puts personnel in direct contact with vibration and dust — a safety and compliance risk that compounds over time.
    Continuous exposure risk
  • Reactive breaking, not preventive
    Human operators respond to blockages after they occur. The AI targets rocks before they cause jams — fundamentally changing the maintenance posture of the station.
    Downstream consequence
THE SOLUTION
One operator. Multiple breakers. Consistent output around the clock.
The system has operated continuously at a deep nickel-copper mine for over 12 months. What that deployment demonstrated:

No shift-related productivity drops

Output remains consistent regardless of crew rotation. The system does not fatigue, does not take breaks, and does not require handover.
Crusher downtime from oversize reduced
The AI targets rocks before they cause blockages, not after. Intervention is predictive, not reactive.
One dispatcher manages 3–5 breakers
Not as a future possibility — as a documented operational result from 12 months of continuous deployment at a deep underground mine.
Particle size is controlled, not just managed
The system breaks rock to match the grizzly opening exactly — reducing crusher jams and excess fines that increase energy consumption and reduce recovery in the mill.
Your rock breaker runs. Your operators supervise from a safe distance. Your crusher receives correctly sized feed.
TECHNOLOGY
Built to work where conditions are worst
3D LiDAR and high-resolution cameras locate oversize rocks and guide the breaker with precision — without requiring human presence at the breaking face.
All sensors are rated for continuous operation in tropical and high-humidity conditions.
  • Protection
    IP65 / IP67 ingress protection
  • Optics
    Air purge system + mechanical wipers
  • Condensation
    Lens heating to prevent fogging
  • Components
    Control servers, industrial HUB, LiDARs, cameras, encoders, and hydraulic distributor
  • Computer vision
    Recognises fracture patterns in real time. Identifies target rocks and natural break planes automatically.
  • Decision-making
    Selects the optimal strike point along natural fracture planes to maximise fragment size reduction per impact.
  • Motion control
    Positions the boom and executes impacts with precision. Encoder feedback on all boom joints ensures accuracy.
  • Safety and monitoring
    Continuous operational oversight with defined safety zones. LiDAR-enforced exclusion zones protect personnel in adjacent areas.
OPERATING MODES
The system adapts to site conditions
Switching between modes does not interrupt operation. The dispatcher selects the mode appropriate to current conditions — the system transitions without stopping the breaking cycle.
Seamless switching between modes without stopping operation.
BUSINESS IMPACT
What changes at your operation
Measured at the deployment site over 12 months of continuous operation at a deep nickel-copper mine.

  • 25-30%

    Rock breaker productivity increase


    Shift-related idle time eliminated. The breaker runs when the crusher is ready, not when an operator is present.

  • x3-5

    Reduction in operator requirement


    One dispatcher manages a fleet of 3 to 5 breakers simultaneously. Documented outcome, not a projection.

  • 15–20%

    Hydraulic hammer wear reduction


    Strikes along natural fracture planes require fewer impacts per rock. Hammer and bushing life extends significantly.

  • OEE improves 15–20%
    Intra-shift downtime is eliminated, not reduced. The crushing plant produces at rated capacity for a larger proportion of every shift.
  • Zero personnel in the breaking zone
    Operators work from a control room. Vibration and dust exposure are removed entirely. Safety compliance posture improves structurally.
  • Downstream equipment protected
    Correctly sized feed reduces liner wear and secondary downtime in the primary crusher and into the mill circuit.
  • Mill energy consumption decreases
    Positions the boom and executes impacts with precision. Encoder feedback on all boom joints ensures accuracy.
WHERE IT IS USED
Underground and surface operations
The same system works across environments. It requires no new civil works — the hydraulic hammer already on your excavator or pedestal becomes the robot.
  • Primary crushing station
    Automatic breaking of oversize on the grizzly screen or at the crusher feed, before blockages occur. The most common deployment configuration.
  • Ore stockpiles
    Particle size maintained ahead of the mill. Prevents oversized material from accumulating at the stockpile and disrupting feed scheduling.
  • Open-pit blasting aftermath
    Remote or automatic fragmentation of oversized material without exposing personnel to post-blast hazard zones. One control room manages multiple stations simultaneously.
IT & SYSTEM INTEGRATION
Fits into your existing control environment
The system is designed to connect to your operational infrastructure without a parallel IT project. It becomes a data source — every shift produces structured operational data that feeds into your existing reporting and planning tools.
DEPLOYMENT TIMELINE
Operational in five months.
No disruption to planned maintenance.
Weeks 1-2
Weeks 1-2
Audit & 3D scanning
WHAT HAPPENS

Laser scan of the breaking zone. Baseline OEE measurement established.
WHAT YOU HAVE

Digital twin of your unit. Current downtime cost calculated.
Weeks 3-8
Weeks 3-8
Engineering & installation
WHAT HAPPENS

Brackets, sensors, HUB, hydraulics, cabling installed and tested.
WHAT YOU HAVE

Equipment installed. CAPEX confirmed.
Weeks 9-12
Weeks 9-12
Commissioning & calibration
WHAT HAPPENS

LiDAR safety zones defined. Computer vision calibrated to your ore type. Test impacts completed.
WHAT YOU HAVE

80% recognition accuracy. Live integration with control room.

Milestone: live integration with control room
Months 4-5
Months 4-5
Commercial operation
WHAT HAPPENS

Auto mode active. Staff trained. Telemetry live and feeding MES/ERP.
WHAT YOU HAVE

15–20% OEE improvement. Targets met. Data flowing to MES/ERP.

✓ System operational — productivity targets active
See the system in action
Request a demo and we'll walk you through how it operates on an active site — automatic strike point selection, mode switching, and live telemetry.
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