STARCAS · COLLISION AVOIDANCE SYSTEM
COLLISION AVOIDANCE SYSTEM
A safety copilot that rides with every operator. The radar reads up to 100 m ahead, warns early and, on the HD785 and CAT777 variant, steps in at the throttle and retarder when the gap keeps closing.
DETECT EARLIERRESPOND FASTEROPERATE SAFER
UI illustration from the STARCAS simulator. Example settings.
DETECT EARLIER
The radar reads up to 100 m ahead in real time. The active distance follows each site’s safe distance SOP, for example 50 m.
RESPOND FASTER
When the gap keeps closing, STARCAS acts in stages: a warning first, then throttle release, then retarder override on the HD785 and CAT777 variant.
OPERATE SAFER
Units keep a safe gap while the operator stays in full control, so the haul keeps moving and safe distance SOPs are followed consistently.
THE CHALLENGE
One collision, many losses
On coal hauling roads, one moment of lapse can turn into a big loss. Narrow, dusty roads with sharp bends and elevation changes make the safe gap easy to miss, while fatigue, blind spots and human error remain the deciding factors.
UNITS RISK CONTACT WITH
- Road berms
- Other haul units
- Support vehicles
- Mine infrastructure
THE IMPACT
- Financial lossUnit repair and spare part replacement costs.
- DowntimeUnits stop operating during repairs.
- Productivity lossProduction targets are missed.
- ReputationClient and owner trust in the contractor declines.
- Safety riskRisk of injury up to fatality for operators and nearby workers.
This is where STARCAS comes in: not to replace the operator, but to help them decide faster through early warnings and graduated intervention.
HOW IT WORKS
A safety copilot in every unit
Radar sensor, speed data and automatic braking work as one system. STARCAS responds in layers, from warning to automatic braking, based on distance and unit speed.
Example setting: warning at 50 m, throttle release at 35 m, stop from 20 m. Every value can be recalibrated to your site.
- LAYER 1 · 50 MEARLY WARNINGThe buzzer sounds and indicator lamps light up in the cabin and outside the unit, signalling the operator to keep distance.
- LAYER 2 · 35 MAUTO RELEASE ACCELERATORIf the gap keeps closing, the throttle pedal is released automatically and the RPM drops.
- LAYER 3 · STOP · 20 M · HD785 & CAT777AUTO OVERRIDE RETARDERIf the gap keeps closing, the system takes over the retarder and brings the unit to a stop.
Smart activation. STARCAS only acts when distance and speed are both met. Otherwise the unit runs normally and the operator keeps full control.
AVAILABLE VARIANTS
- Developed by
- SPT with a technology partner
- Radar detection & early warning
- Available
- Braking intervention (auto override retarder)
- Available
- Status
- Installed and tested on units
Both variants detect up to 100 m. The active distance is set to each site’s safe distance SOP.
KEY FEATURES
Sense it. Respond to it. Tune it to your site.
Detection and alerts, vehicle response, and monitoring with configuration, working as one. Pick a pillar to focus on it.
- Detection & Alerts
Real time hazard detection
Objects in front of the unit are read in real time, up to 100 m ahead.
- Detection & Alerts
Radar based monitoring
Distance and relative speed are calculated continuously and stay accurate in dust and low visibility.
- Detection & Alerts
Early collision warnings
The buzzer and indicators in the cabin and outside the unit light up before the distance turns critical.
- Vehicle Response
Auto release accelerator
The throttle is released automatically to lower the RPM, without waiting for the operator to react.
- Vehicle Response
Auto override retarder
The system takes over the retarder as the gap keeps closing, as a layer of help when the operator responds late.
HD785 & CAT777 variant - Vehicle Response
Progressive brake assist
Gradual braking matched to unit speed, smooth for both the unit and its load.
HD785 & CAT777 variant - Monitoring & Configuration
Adjustable detection zone
4 m wide by default and adjustable up to 10 m to the left and right, for narrow and wide roads alike.
- Monitoring & Configuration
Field configurable parameters
Response distances and logic are set directly on site, for flat roads and downhill roads alike.
- Monitoring & Configuration
Centralized monitoring dashboard
Unit data and every event are logged and monitored from one dashboard, ready for operator and SOP evaluation.
WHY STARCAS
More than an alarm. A safety layer built for mine roads.
An alarm only tells. STARCAS tells, then steps in when the gap becomes critical, and records every event.
Retarder override on the HD785 and CAT777 variant.
Three layers of response
It does not stop at an alarm. After the warning, the system releases the throttle and takes over the retarder.
HD785 & CAT777Proven in the field
Installed and tested on CAT777E, HD785 and SRT 100S units, starting from its time as PRECISE, on flat and downhill roads, empty and loaded.
CAT777E · HD785 · SRT 100SCalibrated for every site
Logic, response distances and detection zone are tuned to each mine’s roads and safe distance SOP.
No disruption to daily operations
Active only when distance and speed are both met. Otherwise the unit runs normally and the operator keeps full control.
Data ready
GPS, LTE, data logger and dashboard record every event for operator evaluation and stronger SOPs.
Born in mining operations
Developed by a team that works inside mining contractor operations, so it fits real needs in the pit.
Range up to 100 m
A longer reaction window, while the active distance still follows each site’s safe distance SOP, for example 50 m.
PLAN YOUR DEMO
Shape a STARCAS demo around your site
Tell us a little about your operation. We will prepare an agenda and fill it into the form below.
- Site briefing and road review: Sharp bends, Downhill roads
- Live demo of the three layers on HD785 or CAT777: warning, throttle release, retarder override
- Response settings for your speed limits, including the separate downhill logic
- Centralized dashboard and event logging
- Installation and field calibration plan for about 40 units
- Q&A and next steps
Focus: Reduce incident risk. Units: HD785. Fleet of about 40 units.
FAQ
Questions we often hear
What is the difference between STARCAS and PRECISE?
The technology is the same. PRECISE was its earlier name. It now carries the STARCAS name as part of SPT’s STAR product family.
Does STARCAS take full control of the unit?
No. It only acts when distance and speed are both met, and it acts in stages: a warning, throttle release, then retarder override on the HD785 and CAT777 variant. The operator stays in control.
How far can STARCAS detect?
Up to 100 m. The active distance is set to the safe distance SOP of each site, for example 50 m where a site requires at least 50 m between units.
Does it work in dust or at night?
Yes. STARCAS uses radar, not a camera, so distance reading keeps working in low visibility.
Can the settings be adjusted to our site?
Yes. The detection zone (up to 10 m to the left and right), response distances, and the flat and downhill logic are calibrated directly in the field.
Which units are supported?
There are two variants. For the Komatsu HD785 and CAT777, STARCAS was developed with a technology partner and includes braking intervention (retarder override). For the SRT 100S, STARCAS is developed in house by SPT and braking intervention is not yet available. Other units are evaluated during the site survey.
At what distance does each layer start?
For example, the early warning starts at 50 m, throttle release at 35 m, and the retarder override brings the unit to a stop from 20 m. Above 50 km/h the speed limiter engages with 40% gradual braking. Every value can be recalibrated to the speed limits, road grades and safe distance SOP of each site.
Are events recorded?
Yes. The controller logs events to an SD card and sends them over LTE to a central dashboard, ready for operator evaluation and SOP audits.
CONTACT
Bring STARCAS to your fleet
Our team will get back to you to arrange a demo, a site survey or a quotation.
Our team will review your requirements and contact you to discuss the next step.
[email protected]Have a question before you decide?
Chat with our team about STARCAS or other SPT products. We can help you explore the solution that fits your operational needs.
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