In a mining sector undergoing rapid transformation, where technology is key to improving performance, Québec-based Tessellate Robotics stands out with an ambitious solution: automating haul truck inspections using autonomous robots.
Developed under MISA’s Vortex program, this project pushes the boundaries of safety, operational efficiency, and equipment reliability. Fully designed in Québec, it demonstrates the strength of our local innovation ecosystem in addressing real on-site challenges. The solution not only enhances worker safety but also increases the utilization rate of haul trucks—boosting overall mine productivity. Early estimates show a return on investment within the first year of use.
Haul trucks are essential to mining operations. Models like the CAT 785 or Komatsu HD785 can carry hundreds of tonnes of ore per trip. Any failure or unplanned stoppage can result in major financial losses and pose serious risks to workers.
Yet, inspections are still largely performed manually. These procedures require long downtimes, expose workers to hazards (especially around the tires), and generate high operational costs. In this context, automation presents a strategic opportunity to modernize processes while meeting strict health and safety standards.
Tessellate Robotics’ solution integrates several cutting-edge technologies: computer vision, autonomous navigation, artificial intelligence, and dynamic planning. The goal? To create a robot that can autonomously inspect a haul truck during its regular downtime, such as during refuelling.
This innovation eliminates the need for human presence in hazardous zones and optimizes equipment usage. The robot detects the vehicle’s position, performs a predefined inspection routine, captures relevant data (visual, thermal, and 3D for now), and generates a report for the maintenance team.
The project is structured around a clear and rigorous roadmap, consisting of four phases:
Rapid Prototyping and Field Testing
– Creation of a mobile probe and validation in real-world conditions.
Detailed Engineering and Automated Reporting
– Development of the analysis system and generation of maintenance reports.
Final Adjustments and On-Site Validation
– System optimization and full demonstration in a mining environment.
Tech Showcase and Commercialization
– Presentation to industry stakeholders and market deployment.
The development is primarily carried out at Tessellate’s headquarters in Québec, with field testing in partnership with Minerai de fer Québec.
Founded in December 2022, Tessellate Robotics is a young Québec company incubated at Quantino (INO). Specializing in autonomous and collaborative mobile robotics, it uses a modular approach to tailor its solutions to the needs of the mining, industrial, and defence sectors. The company also works with local experts to ensure its technologies are adapted to Canada’s harsh climate.
What sets Tessellate apart is its ability to turn complex, high-risk operations into smart, safe, and optimized processes.
Automating haul truck inspections paves the way for a new era in mining equipment management. By enabling rapid, accurate, and risk-free inspections, Tessellate’s technology helps:
Eliminate manual inspections in hazardous areas, reducing workplace accidents
Improve the overall performance of mining operations
Minimize downtime costs
Extend vehicle lifespans through proactive maintenance
By embracing robotic autonomy, Tessellate Robotics exemplifies Québec’s innovation potential in a strategic industry like mining. This project is part of a broader industrial transformation and a commitment to equipping Canadian businesses with practical, safe, and sustainable solutions.
Combining artificial intelligence, robotics, and a deep understanding of field realities, this innovation is poised to become a benchmark in Québec’s mining industry—and beyond.
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