Clay mining operations present a high-risk, high-movement environment, where visibility, safety, and fuel efficiency are critical. Coordinating fleets of excavators and haul trucks across loading, unloading, and restricted zones requires more than GPS — it demands precision logic and real-time automation.
ThingsBoard delivers a robust answer to this challenge. Built with scalability, real-time analytics, and geospatial control at its core, the platform transforms how mine operators monitor and manage their equipment — all without using Rule Chains.
This Clay Mine Site solution leverages calculated fields, geofencing logic, and alarm rules only to streamline configuration, reduce deployment time, and drive intelligent insights from the ground up. With zero-code automation and dynamic dashboards, operations become more predictable, safer, and easier to scale.
Real-time excavator monitoring using ThingsBoard platform
Bus A route playback and history visualization in ThingsBoard
Real-time telemetry dashboard for Bus A in ThingsBoard
The solution architecture consists of GPS-enabled excavators and haul trucks, transmitting telemetry to ThingsBoard via MQTT or HTTP protocols. Devices report location, fuel levels, speed, pressure, and more.
Instead of traditional rule chains, all processing is handled by Calculated Fields, allowing operations teams to configure logic like: zone detection via Geofencing Calculated Fields, fuel burn rate and hydraulic pressure thresholds, speed analysis and usage KPIs, machine state transitions (idle, working, unloading).
All alerts are configured through Alarm Rules, creating a clean, no-code environment that is easy to maintain and adapt across multiple sites.
The solution includes a set of modular dashboards designed to give mine operators full situational control — from zone-level events to individual machine analytics. The primary Mine Overview Dashboard presents a full satellite view of the site with color-coded zones (Loading, Unloading, Restricted), live machine positions, fuel levels, and telemetry streams. Interactive widgets highlight: machines per zone, fuel usage per day, active alarms with severity, zone-specific transitions and KPIs
This dashboard displays a full satellite map of the mine with real-time overlays for each vehicle. Vehicles are color-coded by type and zone, while the right panel shows a live machine list with fuel status and operational state. KPIs summarize daily consumption, number of vehicles in each zone, and triggered alarms. It enables full operational awareness at a glance.
Focused on Excavator A, this dashboard tracks its speed, fuel level, and operational alarms. The map zooms into the loading zone, while the sidebar lists alarms for low fuel and hydraulic pressure. Operators can easily monitor zone-specific performance and address machine-level issues in context.
Displays Excavator B actively working in the unloading area with fuel and minor speed violations. Alarms are logged instantly. This dashboard provides quick access to machine status and zone compliance — a key element for high-traffic unloading areas.
This screen shows Haul Truck B parked in a restricted zone, triggering a critical overload alarm. The map provides immediate zone context, and the alarm panel flags violations in real time. This visual enforcement helps prevent unsafe operation or zone breaches.
A telemetry-rich screen featuring fuel usage, fuel level, pressure, and route playback. Historical data and live metrics provide clear insight into machine performance and workload, while alarm logs support proactive maintenance.
Highlights repeated speed limit violations, fuel burn, and load data. The route history is shown with all zone transitions. This enables supervisors to analyze driver behavior, optimize travel paths, and reduce excess wear or unsafe driving.
Shows a vehicle in a restricted zone with 28-ton load and no movement. An active overload alarm is triggered. This dashboard is essential for spotting inefficient use of assets or safety violations that need immediate action.
Monitors hydraulic pressure, movement, and fuel trends. Alarm logs indicate repeated pressure spikes. Used in tandem with maintenance schedules, this helps detect early signs of mechanical stress.
Vehicle is detected outside of the mine’s geofence, triggering a critical perimeter breach alarm. Combined with a low-fuel warning, the system prompts immediate resolution — reducing risk and ensuring operational boundaries are respected.
The admin interface shows all backend logic built through calculated fields — fuel formulas, geofence status, speed over limits, etc. Everything is visual, editable, and instantly applied to the data model — zero Rule Chains required. This low-code logic layer drastically reduces setup complexity and speeds up scaling across fleets.
This dashboard displays a full satellite map of the mine with real-time overlays for each vehicle. Vehicles are color-coded by type and zone, while the right panel shows a live machine list with fuel status and operational state. KPIs summarize daily consumption, number of vehicles in each zone, and triggered alarms. It enables full operational awareness at a glance.
Focused on Excavator A, this dashboard tracks its speed, fuel level, and operational alarms. The map zooms into the loading zone, while the sidebar lists alarms for low fuel and hydraulic pressure. Operators can easily monitor zone-specific performance and address machine-level issues in context.
Displays Excavator B actively working in the unloading area with fuel and minor speed violations. Alarms are logged instantly. This dashboard provides quick access to machine status and zone compliance — a key element for high-traffic unloading areas.
This screen shows Haul Truck B parked in a restricted zone, triggering a critical overload alarm. The map provides immediate zone context, and the alarm panel flags violations in real time. This visual enforcement helps prevent unsafe operation or zone breaches.
A telemetry-rich screen featuring fuel usage, fuel level, pressure, and route playback. Historical data and live metrics provide clear insight into machine performance and workload, while alarm logs support proactive maintenance.
Highlights repeated speed limit violations, fuel burn, and load data. The route history is shown with all zone transitions. This enables supervisors to analyze driver behavior, optimize travel paths, and reduce excess wear or unsafe driving.
Shows a vehicle in a restricted zone with 28-ton load and no movement. An active overload alarm is triggered. This dashboard is essential for spotting inefficient use of assets or safety violations that need immediate action.
Monitors hydraulic pressure, movement, and fuel trends. Alarm logs indicate repeated pressure spikes. Used in tandem with maintenance schedules, this helps detect early signs of mechanical stress.
Vehicle is detected outside of the mine’s geofence, triggering a critical perimeter breach alarm. Combined with a low-fuel warning, the system prompts immediate resolution — reducing risk and ensuring operational boundaries are respected.
The admin interface shows all backend logic built through calculated fields — fuel formulas, geofence status, speed over limits, etc. Everything is visual, editable, and instantly applied to the data model — zero Rule Chains required. This low-code logic layer drastically reduces setup complexity and speeds up scaling across fleets.
The fleet tracking approach can be easily adapted to various heavy industry and logistics sectors
Track machines across loading, transport, and restricted zones using automated alarms and fuel analytics.
Monitor heavy machinery in temporary or mobile zones, ensuring route compliance and operational safety.
Use geofencing to protect environmental boundaries and track equipment in remote forest sectors.
Automate alerts when haul trucks or loaders enter, leave, or overload in processing areas.
Gain visibility over fleet movement across bridges, tunnels, or time-sensitive zones during large-scale builds.
Track machines across loading, transport, and restricted zones using automated alarms and fuel analytics.
Automate alerts when haul trucks or loaders enter, leave, or overload in processing areas.
Monitor heavy machinery in temporary or mobile zones, ensuring route compliance and operational safety.
Gain visibility over fleet movement across bridges, tunnels, or time-sensitive zones during large-scale builds.
Use geofencing to protect environmental boundaries and track equipment in remote forest sectors.
ThingsBoard’s Clay Mine Monitoring Solution sets a new benchmark for no-code industrial IoT. By eliminating Rule Chains and relying solely on calculated fields and alarm rules, it reduces configuration overhead, speeds up deployment, and empowers teams to operate smarter and safer. The platform provides everything needed for real-time tracking, performance analysis, geofencing control, and automated alerts — all through a powerful and flexible dashboard layer. Whether applied to clay mines or other heavy equipment scenarios, this solution offers unmatched operational clarity and scalability.
