All posts by Paul Moore

Epiroc renames Mobius LinkOA following full acquisition of ASI Mining

Automation, Equipment maintenance, IoT, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software

Earlier this year, Epiroc completed the full acquisition of ASI Mining. Consequently, Epiroc will no longer market its surface autonomous business under the ASI Mining name, but solely under the Epiroc brand. This transition underscores Epiroc’s commitment to delivering advanced surface automation solutions, focusing on accelerating integration and advancing functionality development.

As part of this rebranding, the ASI Mining autonomous mining solution, previously known as Mobius, has been renamed LinkOA. LinkOA, short for “Open Autonomy,” is an advanced integration platform designed to revolutionise mining operations by offering unmatched flexibility, scalability, and safety. As an OEM-agnostic solution, LinkOA empowers mining operations to seamlessly integrate fleets of various makes and models, ensuring interoperability across all mining systems.

Under Epiroc’s leadership, LinkOA will now be expanded to support a broader range of surface mining applications. The flagship products of LinkOA include the Autonomous Haulage System (LinkOA for Haulage) and autonomous drills (LinkOA for Drills).

  • LinkOA for Drills: Improves decision-making and operational safety by integrating drills into a fleet-wide autonomy ecosystem, allowing for real-time data sharing and optimised performance.
  • LinkOA for Haulage: Coordinates and controls mixed fleets of autonomous haul trucks, increasing safety, reducing downtime, and improving productivity through scalable automation.
  • LinkOA for Blasting: Enhances safety and efficiency with teleoperated, semi-autonomous, and fully autonomous blast operations, reducing personnel exposure in hazardous environments.

LinkOA marks a new era of open autonomy as Epiroc says it continues to lead the transformation of the mining industry by delivering flexible, future-proof automation solutions that enhance safety, productivity, and scalability.

Liebherr & Fortescue expand partnership to another 360 autonomous battery trucks

Automation, Bulk handling, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Sustainable mining

During an impressive event at this year’s MINExpo in Las Vegas, USA, attended by IM, Liebherr and Fortescue announced a significant expansion of their partnership and unveiled the jointly developed autonomous battery-electric T 264 truck.

Both Dr Andrew Forrest and Dr Willi Liebherr attended the event to celebrate the historic deal. Together, the two companies will develop and validate a range of zero emission mining solutions, which will result in the supply of 475 new Liebherr machines featuring Fortescue’s innovative green technology to Fortescue’s operations in Western Australia. This represents about two thirds of the current mining fleet at Fortescue’s operations.

Liebherr and Fortescue are committed to having a comprehensive and large scale zero emission mining ecosystem operational by 2030. Both companies have confirmed that, through their continued cooperation, customers will be able to access this ecosystem for their own operations in the coming years. The deal, with all of the equipment and technological innovations, amounts to the single largest deal made in the Liebherr Group’s 75-year history.

This historic deal for the development and supply of zero emission equipment was announced by Dr Willi Liebherr, Member of the Administrative Board of Liebherr-International AG, and Dr Andrew Forrest, Executive Chairman of Fortescue. The agreement between Liebherr and Fortescue will help deliver the decarbonisation targets of both companies. Once the pioneering zero emission technologies developed within the partnership enter series production, they will become available for mining companies all over the world.

The total value of the partnership, comprising the supply of machines by Liebherr and the battery power system from Fortescue Zero, is up to US$2.8 billion. This represents the single largest equipment deal in the highly successful manufacturing and technology company Liebherr’s 75 year history, and is Fortescue’s single largest ever contract.

“We are proud to have facilitated the single largest equipment deal in the entire 75-year history of the Liebherr Group. Especially as the expansion of our collaboration with Fortescue is an important step forward in our shared goal to decarbonise mining activities worldwide,” said Dr Jörg Lukowski, Executive Vice President, Sales and Marketing, Liebherr-Mining Equipment SAS. “The technology developed as part of this record-breaking deal will not only support our customers along their decarbonisation journeys but also help us honour our commitment to offer completely fossil fuel free hauling, loading and dozing solutions by the end of the decade. In fact, in the coming years, Liebherr and Fortescue Zero will be able to offer more customers within the industry a proven, large scale zero emission mining ecosystem.”

“Partnerships with companies and people like Liebherr and Willi Liebherr – where ambition is backed by action – are critical,” Dr Forrest says. “This is an important next step in our 2030 Real Zero target – to eliminate emissions from our Australian iron ore operations by the end of the decade. The world needs Real Zero now – it simply cannot afford to wait. The green solutions we need are here today, and Fortescue Zero is supplying them and rolling them out across our massive mining operations. Fortescue Zero developed this battery technology and jointly developed the Automated Haulage Solution, leading the way to provide green innovative solutions to eliminate emissions from heavy industry. We invite all companies in the mining, heavy industry and haulage sectors to join us. The solutions are there, and the missing ingredient is leadership. The time of others persuading you that greenwashing is a better return to shareholders and your community is over. Fortescue invites you to join us. We can together be the trailblazers who forge the world’s move away from fossil fuels.”

Of the 475 machines that make up this deal, about 360 will be autonomous battery-electric T 264 trucks, containing a battery electric power system developed by Fortescue Zero. This is triple the 120 trucks that were announced as part of the initial partnership between Liebherr and Fortescue in 2022. Fortescue considers this to be the optimal path for the replacement of critical diesel Heavy Mobile Equipment to meet its 2030 decarbonisation targets. All of the trucks in this fleet will ultimately be equipped with a zero emission battery power system developed by Fortescue Zero and the jointly developed Autonomous Haulage Solution (AHS) – both of which were built to be scalable so they can be retrofitted onto existing Liebherr haul trucks. This means that trucks purchased today are already futureproofed for tomorrow.

The AHS, which was co-developed using both companies’ expertise, also includes an Energy Management System that coordinates the static recharge assignments for the trucks and ensures the charger is fully utilised without causing queuing on site.

“We wanted to design and build an intelligent, state-of-the-art AHS that not only includes the know-how from both an OEM and a mining operator generated over the last few years but will also be able to integrate with new zero emission solutions in the future,” says Oliver Weiss, Executive Vice President, R&D, Engineering and Production, Liebherr-Mining Equipment SAS. “Therefore, control and command of zero emission mining technologies were included in the AHS from the outset. The fleet management assignment engine at the core of the AHS monitors fleet energy levels so that jobs and energy replenishment tasks can be assigned efficiently within zero emission fleets equipped with this system.”

Fortescue has developed the stationary fast charging solution to support the autonomous battery-electric truck. Equipped with robotic connection options, the charger can provide up to 6 MW of power and charge the current battery-electric T 264 in 30 minutes.

“We have an enormous amount of expertise in autonomous haulage and have used that expertise to play a leading role in the development of this system,” says Dino Otranto, Chief Executive Officer, Fortescue Metals. “We have more than 200 autonomous trucks across our mine sites, travelling the equivalent of two trips to the moon and back each month. It is imperative that they operate efficiently and at maximum capacity. We have used our strong track record of being a first mover in autonomy and our technological know-how to derisk zero emission fleets to enable the industry to break free from the pilots and prototypes. The fully integrated AHS will be a game changer for us in reducing our carbon emissions.”

Rio Tinto CEO, Jakob Stausholm, welcomed the announcement between Liebherr and Fortescue. “Fortescue’s partnership with Liebherr marks a turning point in the history of the mining industry. An order of 475 zero-emission Liebherr machines is no small feat, let alone an order of 360 massive mining trucks. It is huge in scale for our industry. It takes foresight and courage to be a first mover, and while we can’t always be first, we can be fast followers,” says Jakob Stausholm.

The T 264 battery-electric truck will commence onsite validation at the end of 2025. The approximately 360-strong T 264 truck fleet has already begun arriving to Fortescue’s Western Australian operations, with the first trucks delivered to Fortescue’s Eliwana mine in October 2023. The initial 240 t capacity trucks will be converted to zero emission powertrains before 2030. However, most of the fleet will be supplied in battery-electric configuration from first arrival.

Four autonomous trucks are currently in validation at Fortescue’s testing site, with the first deployment of operational autonomous trucks expected in Q1 2025. All T 264 trucks are arriving autonomy-ready and will be progressively deployed to autonomous operations across Fortescue’s sites. Validation of the full autonomous battery-electric solution is expected to be complete in early 2026.

Liebherr and Fortescue will combine their considerable expertise to jointly develop a zero emission dozer. Fortescue’s battery power system will be integrated into an electric version of the Liebherr’s flagship mining dozer, the PR 776, which is currently in development. Once developed, Liebherr will supply Fortescue with 60 units of this zero emission dozing solution to meet Fortescue’s Real Zero targets.

This historic deal also includes the supply of 55 R 9400 E electric excavators. This fleet will be a mix of backhoe and face shovel configurations. Fortescue first adopted Liebherr’s electric excavator technology in 2023, with the commissioning of Australia’s first operational electric excavator in December of that year. Three R 9400 E excavators are already operational across Fortescue’s sites.

Ensuring the successful delivery of all of these machines requires significant investment from both Liebherr and Fortescue. “We are on track with our investment plans to develop our global infrastructure to ensure that we can accommodate the expansion of our business and provide our customers with larger quantities and a wider range of zero emission technology,” says Michael Arndt, Executive Vice President, service and quality, Liebherr-Mining Equipment SAS. “We will see the outcomes of these investments soon, with many more milestones to be implemented over the next five years.”

“As the mining solutions we offer continue to expand, so must our capability and capacity to deliver and service these ever-advancing technologies. In addition to infrastructure, we are also investing heavily in our people and remote support services to be able to support these new products and technologies,” continues Arndt.

Fortescue is also boosting its capacity to supply the hundreds of batteries required for these machines – both trucks and dozers. “The T 264 battery-electric truck, powered by a Fortescue Zero battery power system, will be one of the first zero emission solutions for mine haulage in operation globally,” Otranto says. “It combines Fortescue Zero’s heritage of innovation, delivering a battery power system designed for best-in-class range and durability in all mining environments, with Liebherr’s proven haul truck excellence. The zero emission battery power system developed by Fortescue Zero also reflects Fortescue’s continued evolution into a leading technology company that is selling its innovative solutions to the world.”

The development and manufacture of this enormous fleet is not the end of the story. All 475 machines of this deal will become part of Fortescue’s iron ore hub in the Pilbara region of Western Australia. As such, Liebherr-Australia – Liebherr’s sales and service company in the country – has already begun its preparations for supporting this enormous fleet.

“This large volume of machinery presents a unique growth opportunity for Liebherr-Australia. We are significantly ramping up investments in our branches, reman facilities and our people to ensure we have the capacity to safely and efficiently maintain not only this equipment but that of our other customers,” says Trent Wehr, Managing Director, Liebherr-Australia Pty Ltd.

Komatsu showcases electrically powered PC4000-11E hydraulic mining excavator at MINExpo 2024

Bulk handling, Environmental, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, Power supply for mines, Sustainable mining

At this year’s MINExpo, Komatsu is presenting the PC4000-11E hydraulic mining excavator. The electrically powered hydraulic mining excavator merges the powerful digging force ofhigh-performance diesel machines with the lower carbon footprint of an electrically powered machine.

Built to endure the toughest mining operations, the PC4000-11E features robust components for exceptional durability and reliability in the harshest conditions.

Komatsu’s electrically powered PC4000-11E merges the powerful digging force of high-performance diesel machines with the lower carbon footprint of an electrically powered machine.

Aligned with Komatsu’s sustainability focus, the electric drive is designed toreduce emissions by up to 95%. When combined with the Komatsu Trolley Truck Assist System, electrification of production can be significantly increased, promoting more sustainable mining operations. Benefits of electrically powered hydraulic mining excavators include reduced operating costs due to the elimination of diesel fuel with zero tail pipe emissions, resulting in up to 50% savings in the total cost of ownership compared to conventional Tier 4 diesel drives.

The fully automatic cable drum is designed for easier operation of the electrically driven excavator in backhoe configuration. The automatic winding of the cable makes maneuvering in the pit significantly easier and saves time. Simplified electric machine control enables fast troubleshooting and maintenance of the electrical system and contributes significantly to increasing the overall availability of the machine and helping our customers work toward achieving the highest safety standards.

“MINExpo is the perfect platform for us to connect with our global customers and those who aspire to join us. We see ourselves as partners to our customers, supporting and collaborating with them on their journey toward a more sustainable and efficient mining operation,” said Peter Buhles, Vice President Sales and Service, Komatsu Germany GmbH – Mining Division. “We are looking forward to meeting everyone in person at our booth and showcasing our latest technical solutions for hydraulic mining excavators.”

In addition to showcasing the PC4000-11E, Komatsu will demonstrate one of its latest aftermarket solutions, theKomatsu Valve Adjustment Device (K-VAD). This device enables the secure adjustment of main and secondary relief valves on hydraulic mining excavators remotely from within the operator cabin. It eliminates the need for service engineers to work next to high-pressure areas, which helps improve workplace safety.

 

Komatsu introduces first Power Agnostic 930E truck

Automation, Environmental

Komatsu today announced the launch of its first commercialised truck in the new Power Agnostic series, the Power Agnostic 930E truck. This cutting-edge haulage truck represents a significant milestone in Komatsu’s decarbonisation strategy, it says “offering unparalleled flexibility for mining operations transitioning toward zero emissions. The Power Agnostic 930E sets a new standard in mining equipment by accommodating a wide range of current and future power sources, including diesel, battery and even hydrogen fuel cells.”

The Power Agnostic 930E is built on Komatsu’s modular power-agnostic platform, allowing customers to future-proof their operations with a versatile approach to decarbonisation. This platform enables mining companies to start with conventional diesel engines and gradually transition to cleaner energy sources as needed, including utilisation of trolley assist for diesel or as one of the future dynamic charging solutions for battery trucks to reduce fuel consumption and emissions. Whether adopting battery technology, hydrogen fuel cell technology or a combination of energy systems, the Power Agnostic 930E provides the infrastructure and adaptability necessary to meet evolving sustainability goals.

“We are excited to introduce the Power Agnostic 930E truck to the industry at this year’s show,” said Dan Funcannon, Senior Vice President of Surface Haulage for Komatsu. “This truck represents a key component of our decarbonisation strategy and will provide customers operational flexibility in reaching their sustainability goals when the opportunity is right for them.”

This future-proofing capability empowers mining companies to make strategic investments in equipment that delivers strong diesel performance today and supports long-term sustainability by transitioning toward zero emissions. The truck embodies Komatsu’s commitment to delivering value and operational excellence while addressing the global demand for reduced emissions in the mining sector.

Continental expands Brazil plant to manufacture mining belts rated up to ST10000

Base metals, Equipment maintenance, Mineral processing, Mining consumables, Mining services, Sustainable mining

Continental has announced the expansion of its manufacturing plant in Ponta Grossa, Brazil to accommodate the production of heavy-duty steel cord conveyor belts. The Ponta Grossa plant is now the second location from Continental’s group sector ContiTech to manufacture belts rated up to ST10000, which is considered the world’s strongest belt rating, made to withstand extreme conditions.

“With the expansion of our plant’s capacity in Ponta Grossa, we are raising the standards in the production of the world’s most durable belts,” said Andreas Gerstenberger, Head of Business Area Industrial Solutions Americas at Continental’s group sector ContiTech. “Our goal is to double or even triple our production over the next few years, and by producing heavy duty steel cord conveyor belts in Brazil, we’ll be able to shorten product shipping timelines and better meet the needs of our customers in South America, the world’s largest regional market for heavy steel cord belts.”

As announced, Continental’s investment to expand the production of heavy-duty steel cord conveyor belts will allow the business to better address the demand from local and international markets. The expansion includes production lines featuring advanced new rubber mixing, rubber blanket calendaring, vulcanisation, and inspection technologies, with the aim of guaranteeing excellence at every stage of the process.

“Building the additional capacity at our Ponta Grossa facility is a testament to our commitment to advancing our manufacturing capabilities utilising the latest manufacturing technology,” said Tomas Kostenec, Head of Operations, Industrial Solutions Americas at Continental. “By producing the world’s strongest steel cord conveyor belts, we are not only meeting the rigorous demands of our customers for high strength belts, but also setting new standards in the industry.”

The Phoenix Phoenocord ST10000 conveyor belt can be manufactured in lengths weighing up to 60 metric tons. With decades of experience, research and development, Phoenix Phoenocord belts have been proven to handle the most extreme conveyor belt applications, delivering extreme durability and reliable performance with high-capacity and high-breaking strength. These capabilities Continental says make it the perfect belt for above and below ground use for a multitude of industries, including hard rock mining and other extreme material handling applications.

Features of the belt include:

  • Life-long splice methods: Splicing methods, which have been validated by Continental and on independent two-pulley splice testers, result in dynamic splice efficiencies that outperform any standard.
  • Highest impact resistance: Advanced cover compounds and the insulation gum’s superior adhesion combine to provide the impact, tear and abuse resistance that extreme applications demand.
  • Sybercord technology: The special Sybercord cord design in combination with the highest manufacturing and quality standards and advanced splicing technology provides a unique, reliable and unmatched product, performing on the highest level. Sybercord steel cords are optimised in terms of construction and design, utilised materials and processing technology.
  • Belt monitoring systems: Continental conveyor belt monitoring systems generate an overall picture of conveyor belt health. The reliable belt monitoring tools can easily be adjusted to accommodate the typical changes that occur over the life of a conveyor belt. Easy to interpret belt condition reports are objectively generated by Continental’s monitoring software.

The Phoenix Phoenocord ST10000 conveyor belt is available to customers and is on display this week at MINExpo International, taking place September 24-26 in Las Vegas, Nevada.

Komatsu unveils new underground hard rock BEVs at MINExpo including WX04B

Automation, Equipment maintenance, Mine shafts and equipment, Mine ventilation, Mining consumables, Mining equipment, Mining safety, Mining services, Power supply for mines, Sustainable mining, Uncategorised

Komatsu Ltd is showcasing its latest underground hard rock mining equipment at MINExpo 2024 this week in Las Vegas. In particular, Komatsu is strengthening its underground hard rock mining equipment business through an enhanced lineup, the development of new mining methods, and strategic acquisitions, and will showcase its latest initiatives.

First off, Komatsu says it is excited to introduce its first battery-electric powered LHD machine, the WX04B, along with a 150 kW battery charger engineered specifically for underground hard rock mining. Designed for narrow vein mines, this 4-t LHD features industry-leading battery technology with best-in-class energy density, offering up to four hours of run time on a single charge.

And one of the standout features of the WX04B is its innovative battery swap system. Unlike many traditional systems that require extensive underground infrastructure, the WX04B’s battery swap can be performed at ground level without additional equipment or risks of rigging overhead loads. This streamlined process reduces costs and complexity, making it a more efficient and user-friendly option for underground mining operations.

Additionally, key features of the 150 kW battery charger include power efficiency, broad compatibility with mining power sources (400 VAC to 1,000 VAC) and no need for an external transformer. This design minimises infrastructure requirements, offering mining operations greater flexibility without the need for a dedicated charging station.

Komatsu will also showcase for the first time two machines from GHH Group GmbH, the German manufacturer of underground mining, tunnelling and civil engineering equipment acquired on July 1 of this year, under the Komatsu brand. The WX15 is a 15 t class LHD with a maximum bucket capacity of 9 m³ and the HX45 is a mining truck with 45 t capacity—new additions to Komatsu’s lineup with these specific vehicle sizes. Both machines are designed to work in tandem, offering productive three-pass loading cycles for maximum efficiency in mining operations.

Komatsu is further excited to introduce its first medium-size class drill jumbo ZJ32 and bolter ZB31 to its lineup, further broadening Komatsu’s selection of offerings for the underground mining industry. The Z3 machines are built on a universal platform and designed with a focus on modularity and efficiency. This focus offers improved productivity that can help reduce service and maintenance costs across operations. The Z3 also boasts universal operator controls, simplifying user adoption and increasing training efficiency. In the near future, additional battery and intelligent machine control models of the Z3 series will be added to the lineup to provide customers with a comprehensive range of offerings to meet their demands.

Komatsu introduces new HD465-10 and HD605-10 haul trucks

Automation, Bulk handling, Equipment maintenance, Mining equipment, Mining maintenance, Mining services

Komatsu has introduced its new HD465-10 and HD605-10 mechanical haul trucks to the North America market, offering an upgrade from the previous -8 models. The new haul trucks are designed to help increase productivity and improve fuel efficiency in quarry, mining and aggregate applications.

The HD465-10 is a 60-ton rigid frame machine with a high payload capacity and efficient hauling capabilities. The HD605-10 mechanical haul truck is a 70-ton rigid frame machine designed for reliability and durability. Both trucks offer a tight turning radius for easy navigation on narrow haul roads and ergonomically designed cabin features for operator comfort during long shifts. With increased horsepower and higher-strength steel for reduced operating weight, the machines are built to provide excellent speed on grade.

Additional features include a MacPherson-strut-type independent front suspension that allows the vehicle to smoothly traverse uneven road surfaces, the ability to regulate fuel efficiency for lighter work with ‘economy’ and ‘economy light’ modes and controlled downhill descent with the automatic retard speed control function. New operator features include hill start assist, throttle lock, a retractable sun visor and waiting brake. Beneficial maintenance elements include a full LED light package, plastic resin wheel chocks, maintenance-free batteries, brake performance checks and ground level Komatsu Oil and Wear Analysis (KOWA) sampling ports.

“Komatsu is committed to developing equipment that supports our customers’ needs and helps them be most effective at the job site,” said Madeline Pearce, Product Marketing Manager. “The fuel efficiency and productivity benefits these products provide, combined with a number of operator-designed features, demonstrate that commitment. We are excited to provide these new models of haul trucks to support our customers across North America.”

The new HD605-10 truck will be showcased this week at MINExpo International September 24-26, in the Pronto Autonomous Haulage booth.

XCMG delivers XDE260 dump trucks to customer in Oceania

Bulk handling, Equipment maintenance, Mining equipment, Mining maintenance, Mining services

China’s XCMG Machinery says it has delivered a fleet of 230 t class XDE260 rigid dump trucks, a large-scale model designed for open pit mine operations, to an unnamed customer in Oceania, a development which it hailed as marking a new milestone, remarking that XCMG’s mining equipment is now winning recognition in the top international mining market “and filling the blank of the group’s market development map in the global mining machinery sector.”

“XCMG Mining Construction is committed to the mission and vision of ‘Leading Technology to Empower Solid Future,’ following the transformation roadmap emphasising high-end, intelligent, green, service-oriented, and international development, leveraging the opportunities of intelligent and digital transformation as well as networking capabilities to promote the high-quality development of the group, and working with our global partners to build XCMG Mining Construction into a world-class brand,” said Geng Jiawen, General Manager of XCMG Mining Construction.

The customer noted at the delivery ceremony that XCMG mining equipment’s strong engineering capabilities, top technical strength, and comprehensive after-sales services are the key reasons that prompted them to cooperate with XCMG.

It added that Oceania, a high-end market of global mining machinery, has strict requirements on the technology and quality of mining equipment products, and has established stringent standards on the safety, comfort, and reliability of the equipment. The market has to date been dominated by European and American mining equipment brands.

XCMG adds: “Compared with lightweight mining trucks, large-tonnage and heavy-duty products have a high technical threshold, and XCMG is one of the very few Chinese enterprises to develop and manufacture advanced mining equipment leveraging its global R&D platform. The group has established unique and industry-leading standards to deliver standardised and digitalised products with high quality while guaranteeing premium service.”

XCMG’s XDE260 rigid dump truck is described as a classic model that is known for its super robust transport capacity and ultra-high efficiency, and it has been exported to Europe (Serbia Zijin Copper), South America (EcuaCorriente), and other international markets with trust from customers around the world. It is equipped with a high-horsepower engine to deliver high performance and adapt to a variety of complex working conditions and utilises advanced AC frequency drive technology to deliver leading performance compared to products of the same tonnage range.

The XDE260 it adds also easy to disassemble, assemble, transport, and maintain with modular design, and it can meet customised needs of customers and flexibly match with large-scale mining excavators of over 400 tons.

Cat® 793 XE Early Learner battery electric trucks begin testing at customer sites

Bulk handling, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, Sustainable mining

Caterpillar announced yesterday that it has achieved the next milestone in the company’s battery electric truck development journey, reinforcing its commitment to providing zero-exhaust emissions solutions for customers.

The next generation of Caterpillar’s battery electric Large Mining Trucks have arrived at select customer sites for testing and validation. Caterpillar says it has now completed building and testing seven Cat® 793 XE Early Learner battery electric trucks at its Tucson Proving Ground facility in Green Valley, Arizona.

This marks the second development phase of the company’s Early Learner program following the successful demonstration of its first battery electric 793 prototype in November 2022. Caterpillar will also continue testing and validating some of the Early Learner model trucks at its proving ground facility.

The company highlighted one of these next generation 793 XEs at the Tucson Proving Grounds to a select group of media yesterday. Caterpillar also showcased a prototype 775 XE, a battery-electric version of the 70.5-ton payload diesel-powered truck.

Caterpillar Group President, Denise Johnson, says: “We added this Early Learner phase to intentionally send battery electric trucks to customer sites earlier than we have before in our traditional product development process. These Early Learner machines will be used to refine requirements, develop processes and validate both the machine and technology designs. Testing these trucks at our customers’ sites will provide invaluable feedback for our battery truck program.”

Caterpillar launched its Early Learner program in 2021 to accelerate its development and validation of Cat battery electric large mining trucks with support from key mining customers and Cat dealers. The company expanded the Early Learner program to include Off-Highway Trucks to support increasing demand from the quarry and aggregates industries.

One of the primary objectives of the program is for Caterpillar to collaborate more closely with its customers to better understand the impacts of the energy transition on a mine site’s people, processes, infrastructure and technology. The Early Learner phase of the program will be key to witnessing those impacts in real world environments. It will also be critical to validate the enhanced design elements of the 793 XE.

Caterpillar Vice President Brian Weller explains: “In less than two years, we went from retrofitting an existing piece of equipment at our proving ground to designing a ruggedised solution ready for validation at our customers’ sites. This was not a small change. Just about everything in the powertrain has been enhanced while still leveraging proven components of our Cat 793 model. With these changes, we still have learning to do with our customers in real-world applications.”

Caterpillar’s next phase of the Early Learner program will be to integrate multiple electrified trucks at sites, validating the integration of a battery electric fleet with Caterpillar’s autonomous and fleet management systems.

New Cat® Water Delivery System 2.0 allows water trucks to keep up with AHS

Automation, Bulk handling, Environmental, Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software, Mining techniques, Sustainable mining, Water management

Nearly 20 years ago, Caterpillar says it changed the dynamics of managing haul roads with the introduction of the Cat Water Delivery System (WDS). Designed to work with an existing Cat truck platform, the system controls dust and addresses underwatering and overwatering issues.

In 2015, Caterpillar engineers enhanced the Cat WDS by developing an automated water delivery feature to increase safety and efficiency compared to traditional manual watering operations. Independent of engine RPM, the software adjusts water flow based on truck speed and automatically turns the water off when stopping at intersections, reducing overwatering issues that can lead to poor traction and subsequent haul road damage.

IM Editor Dan Gleeson getting a hands on tour of Cat WDS 2.0 

Designed using customer input, the first fully integrated Cat Water Solution was introduced in 2021, connecting a Cat truck, water delivery system, tank and telematics. This ushered in a new era of intelligent watering using Cat MineStar™ to provide import data for mining and quarry operations to make informed decisions.

The new Cat® WDS 2.0 builds on a legacy of innovation by delivering more power, greater efficiency, streamlined integration and easier installation. With over two years of testing and validation at the Caterpillar Tucson Proving Ground, the system’s new water pump and Cat hydraulic motor provides a 25% increase in water output compared to WDS 1.0. This increase enables water trucks equipped with the new water delivery system to achieve accurate water application rates at 45 km/h (28 mph), keeping pace with autonomous haul truck fleets.

Cat WDS 2.0 delivers increased water cannon output and spray distance. Depending on the cannon nozzle orifice and pipe size, maximum water output of the cannon at high idle is 7,192 l/min (1,900 gal/min), up to 15% higher than WDS 1.0. It also provides up to a 20% increase in maximum cannon spray distance of 73 m (240 ft).

“The Cat Water Delivery System is the culmination of nearly 20 years of collaboration with our dealers and customers,” says Dave Freeman, WDS engineering manager. “Cat WDS 2.0 is a continuation of that journey, showing our dealers and customers we’ve listened. Connected with Cat MineStar data tracking, we believe we’re providing our customers with the most advanced water solution for the next 20 years.2

Designed for streamlined integration

WDS 2.0 is engineered with a high output, proprietary Cat hydraulic motor connected with a new water pump assembly. This motor is optimised to work with the hydraulic output of Cat rigid frame trucks. The water delivery system is now integrated into the truck’s hoist controls to regulate the optimal amount of hydraulic power from the hoist pump to the hydraulic motor. This design helps provide precise water output while eliminating the need for a separate hydraulic tank, reducing service and maintenance costs. The motor and pump assembly use a dry coupling that reduces the need for lubrication, eliminating leaks and failures associated with wet couplings.

Auto Mode, an advanced feature built into the Cat Water Delivery System, uses software to automate the watering process, while allowing operators to deliver a more efficient watering technique with enhanced precision and control. Caterpillar engineers designed this feature to solve issues common with traditional watering systems that deliver water at a constant rate and require operator adjustments. Guided by automation, WDS 2.0 can help junior operators perform at a higher experience level to increase sitewide production.

Knowing when, where and how much water is applied aids mine sites in water conservation while meeting dust suppression requirements. Patented self-cleaning spray heads produce larger, heavier water droplets designed to reach the ground, losing less spray to wind and evaporation. Caterpillar-designed hydraulic controls regulate water pump starts and stops to increase system life. The WDS 2.0 software provides additional protection against damage, shutting down when water is no longer pumping. This allows the operator to use all available water in the tank, reducing carryback when returning to the refill station.

An in-cab touchscreen allows the operator to view critical water delivery system information like tank level, spray head selection and water application rate. An easy-to-reach keypad allows the operator to select and control the spray heads. The new water camera system provides visibility to the back of the spray bar and top of the refill chute. Reducing the potential for slips and falls, the operator can remotely fill the water tank while remaining inside the cab. Cat WDS auto shutoff integrates with fill points to prevent overfilling.

Scalable technology with Cat MineStar

The Cat WDS is the market’s most advanced water control system. The ability to track water data is a game changer in the industry. The new WDS 2.0 connects with cloud-based Cat MineStar telematics, allowing customers to collect data to measure key performance indicators (KPIs) like operator watering procedures, cycle duration, fuel utilisation, volume of water distribution and tank level when reaching the fill station.

To help manage the site more safely and productively, Caterpillar offers a choice between two connectivity options. Cat WDS MineStar Basic uses Equipment Tracking to monitor the water truck and tracks how it is being utilised. Cat WDS MineStar Premium adds Production Recording, helping address sitewide watering needs in conjunction with other water trucks and equipment. With scalable levels of connectivity, customers can start with the Basic package and easily upgrade to Premium, gaining additional features like water distribution maps and future enhancements.

Supported by Cat dealers

Cat Water Solutions provides a complete line of water delivery trucks and retrofit options for mining and large quarry operations to help manage dust. Truck tank capacities range from 76,000 l (20,000 gal) up to 159,000 l (42,000 gal), spanning the Cat 777 (07), 777 (05), 785D and 789D model sizes. The Cat 789D water truck platform is capable of fully autonomous operation to integrate into autonomous haul fleets.

All Cat Water Solutions are fully supported by the Cat dealer and parts network. Covered by a Caterpillar factory standard warranty, the water truck is eligible for Cat equipment protection plans (EPP) and customer value agreements (CVAs). For haul truck conversions and retrofit installations, WDS 2.0 uses fewer parts and requires less installation time to help lower total cost of ownership compared to the previous delivery system.