Tag Archives: 794 AC

Caterpillar surpasses 5 billion tonnes of material autonomously hauled

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Roughly nine months after reaching the 4-billion-tonne (4.4-billion-ton) autonomously hauled milestone, trucks equipped with Cat® MineStar™ Command for hauling have now moved over 5 billion tonnes (5.5 billion tons), the OEM says.

Cat autonomous trucks are on pace to eclipse previous record totals of materials hauled in a calendar year, projected to be more than 1.4 billion tonnes (1.57 billion tons) in 2022.

Currently, more than 550 mining trucks are equipped with Command for hauling, operating across three continents. Over the last nine years, trucks equipped with Command for hauling have journeyed nearly the average distance between the Earth and Mars with zero loss-time injuries, according to the mining OEM.

Denise Johnson, Group President of Caterpillar Resource Industries, said: “In 2013, we placed our first fleets of autonomous trucks in Western Australia at FMG Solomon and BHP Jimblebar. Since that time, trucks using Command for hauling have safely travelled nearly 200 million km, more than twice the experience in autonomous operations of any automobile manufacturer. Caterpillar has grown the number of autonomous trucks in operation by 40% in the past two years.

“We believe that automation is one of many keys to implement technology that unlocks the value miners need when it comes to the energy transition toward more sustainable operations.”

One of the company’s recent contract wins on the automation front relates to BHP’s majority-owned Escondida mine, in Chile.

Marc Cameron, Vice President of Caterpillar Resource Industries, said of this agreement: “The new Cat 798 AC electric drive trucks replacing BHP’s entire haul truck fleet at the Escondida mine will feature technologies that advance the site’s key initiatives, including autonomy and decarbonisation. The agreement allows Escondida…to accelerate the implementation of its autonomy plans by transitioning the fleet with autonomous haulage system (AHS) technology.”

Caterpillar has enabled 13 customers at 23 different locations to succeed with full site autonomous haulage solutions. Starting with iron ore at Solomon (Fortescue Metals Group) and Jimblebar (BHP), its solutions now manage oil sands, copper, gold, coal, lithium and phosphate. Spanning the 190- to 370-t class sizes, the Cat 789D, 793D, 793F, 797F, and electric drive 794 AC and 798 AC mining trucks are capable of fully autonomous operation. Retrofit kits allow miners to expand Command for hauling to existing Cat mining trucks.

Since 2019, Caterpillar says it has won eight of nine greenfield autonomy sites on offer.

Sean McGinnis, Vice President and General Manager for Cat Mining, said: “In 2023, we will expand Command for hauling to the 139-t truck class at ioneer Ltd’s Rhyolite Ridge lithium-boron mine. This is the first greenfield project in North America to use an AHS. We are now seeing a shift toward autonomy requested on new Cat trucks. Whereas large mines with fleet sizes of more than 70 trucks were the early adopters of the technology, we are seeing economic viability for autonomy at smaller mines with a fleet of less than 15 trucks.”

Caterpillar says it continuously monitors the industry for opportunities to broaden the use of automation to help drive safety and efficiency.

Beyond expansion of Command for hauling to the Cat 785 for ioneer, Caterpillar sees potential for Cat autonomy in quarry and aggregates. Additionally, Caterpillar’s AHS technology has been deployed on the Cat 789D autonomous water truck (AWT) operating at Rio Tinto’s Gudai-Darri mine in Australia, the world’s first AWT, for automated watering of haul roads.

Cat to bring new D11 XE dozer, R1700 XE battery-electric LHD to MINExpo

Automation, Environmental, Equipment maintenance, IoT, Mining equipment, Mining events, Mining safety, Mining services, Mining software, Power supply for mines, , , , , , , , , , , , , , , , , , , , , , , , , , ,

Caterpillar is set to unveil the world’s largest, most powerful and efficient electric drive dozer with high drive at the upcoming MINExpo 2021 event in Las Vegas, USA, in September, in an exhibit themed around the concept, “together, we’re mining better”.

Caterpillar’s MINExpo 2021 experience, the company says, celebrates its partnership with mines and the ways it assists customers to mine more efficiently, effectively, safely and sustainably. The 5,124 sq.m exhibit will feature a broad range of product displays, new equipment introductions, previews of what the future holds and remote operating stations.

The exhibit will be grouped under three specific core areas: environmental, social, and corporate governance (ESG) and sustainability; technology and automation; and equipment lifecycle management solutions.

The headline exhibits come September 13-15 at the Las Vegas Convention Center will, no doubt, be the brand new Cat D11 XE dozer, the new Cat® R1700 XE battery-electric LHD (pictured, top), and new R2900 XE LHD diesel-electric drivetrain. The company also intends to display the recently released Cat 992K wheel loader, new Cat 777G water truck, Cat 794 AC electric drive truck and Cat MD6310 rotary blasthole drill.

“After waiting an extra year, the mining industry is ready to reconnect at MINExpo,” Caterpillar Resource Industries Group President, Denise Johnson, said. “We are excited to show our customers and the industry the advancements Caterpillar has made not only in equipment, technology and services but also in how we are helping customers mine more sustainably.

“While we are eager to exhibit in Las Vegas, we recognise that many of our dealers and customers will not be able to travel to the show. Therefore, we are also creating a digital Caterpillar experience at cat.com/mining, where we will place MINExpo specific content.”

Mining sustainably

Central to Caterpillar’s commitment to mining better together is helping customers meet their ESG goals and build sustainable mine sites of the future. Recognising one size does not fit all, Caterpillar has followed a strategic approach with a long-term vision of discovering, developing and delivering a broad portfolio of products, technologies, services and solutions, it said.

“This portfolio allows Caterpillar to provide a full site approach, which combines offerings with integration expertise to identify and provide the best possible solution for each specific mine,” Cat explained.

Vital to the vision of the all-electric underground mine of the future, the new Cat R1700 XE LHD will feature 100% battery-electric propulsion that generates significantly less heat and noise. It offers a 15t payload, 24,190 kg lift and tilt breakout force, and 18 km/h top speed. To optimise runtime and improve safety, batteries stay on the machine for charging, with the new portable Cat MEC500 Mobile Equipment Charger able to charge the unit in as little as 20 minutes.

The new R2900 XE LHD diesel-electric drivetrain to be displayed features a significant reduction in maintenance and repair costs, while minimising emissions. Its redesigned lift arm and components delivers up to a 39% improved lift breakout force over the R2900G, making this model up to 31 tonnes per litre more fuel efficient, Cat claims.

Cat is set to unveil what it says is the world’s largest, most powerful and efficient electric drive dozer with high drive. The new Cat D11 XE dozer will be the most advanced, lowest emission-per-tonne dozer in the industry, built to deliver the lowest cost of bank cubic meters ever.

Exhibited alongside the D11 XE, the new Cat D10 dozer (below) offers up to 4% less fuel consumption than the previous model, up to 3% more productivity with high-horsepower reverse and up to 6% more efficiency with combined load-sensing hydraulics and stator clutch torque divider, according to Cat.

The recently introduced Cat 992 wheel loader to go on show delivers up to a 32% increase in productivity. It reduces maintenance costs by up to 10% and has demonstrated in field testing up to 48% greater payload-per-fuel efficiency in applications where a four-pass match to 90.7 t trucks was achieved versus five passes with the 992K.

Caterpillar says it is committed to helping customers with their energy transitions, and the MINExpo exhibit will include a range of renewable and storable power displays, including the Cat Microgrid system. The Cat 3516 engine, meanwhile, will feature dynamic gas blending (DGB), which allows mines to save fuel and reduce emissions without sacrificing diesel performance.

Driving technology and automation

“Technology and automation are critical components for substantially improving machine uptime availability and productivity,” Marc Cameron, Vice President, Caterpillar Resource Industries, said. “Through Cat MineStar™ Solutions, Caterpillar offers customers scalable technologies to fit the mine’s specific needs. The exhibit’s technology and automation stage will focus on the real value that Caterpillar technology options provide customers.”

MINExpo will be the first opportunity for many attendees to learn more about the recently introduced Cat MineStar Edge. This solution brings visibility to the entire mining operation to show how activities early in the process impact those further down the value chain, according to the company. MineStar Edge makes it possible to measure, manage, analyse and improve the entire mining operation.

Equipped with MineStar Command for hauling, the new Cat 777G water truck provides a glimpse into the future for autonomously lowering dust levels at the mine site while maintaining haul road safety. Featuring the market’s first autonomous water delivery system, the machine integrates truck, tank and sprayer, and knows where and when to water haul roads.

Representing the Caterpillar fleet of autonomous trucks, the displayed Cat 794 AC electric drive (pictured below) will be factory-installed with Cat MineStar Command for hauling. Recently, autonomous trucks using Command for hauling surpassed 3 billion tonnes of material hauled, safely traveling more than 110 million km.

Accurate to the centimetre, the exhibited Cat MD6310 rotary blasthole drill offers technology, efficiency, safety and productivity improvements. Fully integrating Caterpillar’s components and systems, including technology and automation, the drill is capable of up to 42,149 kg of bit load and targets 203-to-311-mm hole diameters.

Exhibiting how technology can improve safety at the mine site, the Cat MineStar Detect Driver Safety System (DSS) display details how the system monitors eye closure and head pose to alert the driver via seat vibration and/or audio alarm the moment fatigue or distraction is identified. DSS has been shown to reduce 97% of the most significant fatigue events, 80% of average fatigue events and 91% of distraction events, Cat says.

Several Cat Command stations and trailers will be on display for attendees to experience effective remote control and semi-autonomous drilling, dozing and underground operations from many kilometres away.

Lifecycle solutions

Highlighting Caterpillar’s rebuild services capability, the rebuilt Cat C175-16 engine, which produces up to 2,550 kW, on display reduces overall owning and operating costs.

Team members will also be available to explain to attendees how MineStar Health maximises equipment availability and reliability by connecting the machine to the office. The service assists with proactive maintenance services and predictive equipment analysis by collecting equipment data, monitoring critical machine parameters, obtaining real-time alerts, analysing operational trends and patterns, predicting failures and receiving repair recommendations, Cat says.

Partnership and expertise

In addition to teams of workers with machine and technology expertise, representatives of Cat Financial and Cat Solutions will be on hand to share information on safety, fleet management and productivity offerings that can be combined into full site solutions.

A ThoroughTec® Simulation training will provide an opportunity to experience the 7495 electric rope shovel. In addition, attendees will be able to experience two next generation machine cabs – one for mining trucks and another for the 6060 hydraulic mining shovel – via actual cabs on display.

Caterpillar, Barloworld to talk up mining equipment and power solutions at Indaba

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Caterpillar and its southern Africa dealer, Barloworld Equipment, are set to present a broad range of machines, technology and support services at next week’s Mining Indaba, in Cape Town, South Africa.

The Caterpillar exhibit at Indaba, running from February 3-6, will feature digital displays of electric power generation systems, surface and underground mining equipment, and Cat MineStar™ technology capabilities – ranging from vehicle safety systems, such as operator fatigue monitoring, to production systems using teleremote, semi-autonomous and autonomous machine operation.

Caterpillar has recently introduced several new underground hard-rock mining vehicles in Africa. The new R1700 underground LHD brings the latest technology for semi-autonomous and fully autonomous operation to the region. The loader also delivers more than 30% greater fuel efficiency, 65% more lift and tilt force, and 15 t capacity – 20% more than its predecessor, yet in the same dimensional envelope, according to Cat.

Using MineStar Command for underground, the new R1700 (pictured) can be operated from a remote location to keep miners away from potential hazards, Cat says. “The system also boosts utilisation by allowing immediate entry after blasting and by reducing shift change time to nearly zero.”

In addition to the R1700, Caterpillar has introduced several LHDs and underground trucks equipped with EU Stage V engines and emission controls. “Reducing emissions helps miners improve the underground working environment,” it said. On top of this, and with the goal of zero underground emissions in mind, Caterpillar is continuing to develop the battery-powered R1700 XE.

Erik Elsmark, Region Manager for the Caterpillar Underground Mining Division, said: “Caterpillar and Cat dealers are supporting the whole African continent and all types of underground mining applications – big and small mines and all minerals.

“In the past several months we have delivered machines covering our full product range, demonstrating that we are well positioned to meet our customers’ needs.

“Starting with our AD22 underground articulated truck to our R2900 LHD, our equipment delivers exactly the size class and power needed for the application. With distribution centres in Southern Africa and Middle East and our dealer network in all countries of the African continent, we are able to achieve world-class service.”

The extensive line of Cat surface mining machines and technologies will also be a talking point at the event.

Caterpillar has recently expanded its line of electric drive mining trucks in the past year to include the 794 AC, 796 AC and 798 AC. Recently, a South Africa mining operation took delivery of several 794 AC trucks (pictured above), which have 291 t capacity, the company said. “This model has already proven its high productivity and superior speed on grade in a wide variety of applications,” Cat remarked.

In the Cat drill line, the latest model is the MD6200 rotary blasthole drill, designed as a production drill with the flexibility to do pre-split drilling – all in a package that Caterpillar says is its most transportable rotary drill yet. The MD6200 is designed to perform rotary or DTH drilling in single-pass or multi-pass modes and can drill holes of 127 to 200 mm in diameter, according to Cat.

Cat MineStar Command now includes systems for autonomous operation of mining trucks, semi-autonomous operation of dozers, and semi-autonomous as well as autonomous rotary drills. These systems enhance safety, boost production and lower cost per tonne, Cat says.

Mine power experts will also be on call at the show, with the representatives keen to talk about the ability for Cat generators to deliver reliable, continuous power, temporary power, or a combined heat and power solution. “The Cat team customises and installs systems for every phase of mining,” it said.

Caterpillar says it offers the industry’s widest range of diesel, gas and dual fuel generator sets; automatic transfer switches, and switchgear for seamless integration. Additionally, it offers microgrids, fully-integrated power systems that utilise solar panels, energy storage and monitoring and control systems in conjunction with any configuration of Cat gen sets.

Caterpillar talks up its new ultra-class electric drive mining trucks

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Caterpillar has announced more details on the two new ultra-class mining trucks to join its portfolio, the Cat 798 AC and Cat 796 AC.

IM was on site in Tinaja Hills, Arizona, to witness the grand unveiling and saw the 798 AC in action.

The company said the decision to add the new models was based on providing its customers with more options at the highest end of its payload scale regarding electric or mechanical drive.

The 798 AC features a 372 t payload and joins the mechanical-drive Cat® 797F in the 400-short-ton size class. The 797F has been a popular choice with more than 1,000 sold to the oil sands, copper, coal and iron ore markets.

The electric-drive 796 AC delivers 326-tonne (360-ton) payload. With Cat deciding the 795 AC will not being offered in Tier 4 Final configuration, the 796 AC is likely to act as a replacement in regions where engine emissions are highly regulated, such as the US and Canada.

When comparing field test data of the 795F and 798 AC, the new and larger model was shown to carry, on average, carry 12.9% more payload, boost productivity by 17.2% and exhibit 4% faster cycle times.

Cat’s Jeff Castleman, in charge of new product introduction in the large mining trucks range, said at the truck unveiling the company was able to move from design to production in the field with the 798 AC in just one year.

It was able to achieve this as the machine is based off the old Unit Rig MT6300 AC design, a product line that came with the 2011 acquisition of Bucyrus.

Cat says both trucks will be available in June quarter of 2019, but IM understands two 798 ACs have been undergoing trials at Arch Coal’s Black Thunder coal mine in Wyoming, US, for close to six months, an operation that formerly used at least one MT6300 AC.

While the company expects the mechanical drive 797F to remain a leader in the Canadian oil sands sector – around a third of sales have been to this market segment – studies comparing the two showed the new 798 AC could more than hold its own when it comes to hauling on grade and getting out of the sticky underfoot conditions sometimes present at these mines. This is also backed up by the fact two MT6300 ACs previously operated in the Canadian oil sands.

The design of the new trucks focuses on delivering class-leading payload, high reliability and simple serviceability, Cat says. These attributes are built on the frame and chassis design proven in 18 million hours of legacy truck operation and now used by the Cat 794 AC.

The AC powertrain of each of the two new trucks draws from the Cat 795 AC and Cat 794 AC, which have been operating successfully for about 5 million hours. The electric drive is developed and manufactured by Caterpillar and is the single source for the entire powertrain, a key selling point of the truck when it comes to serviceability and operation in the field.

The Cat C175-16 diesel engine powers both trucks. With more than 21 million hours of operation in mobile equipment and power generation, the engine can be configured to meet US EPA Tier 4 Final emissions regulations and offers a choice of 2,610 kW (3,500 hp) or 2,312 kW (3,100 hp) to meet the mine’s needs.

“To further adapt to the mine, software changes can adjust system power to help meet production targets or to work smoothly in mixed fleets,” Cat says.

Both truck models are designed to minimise empty machine weight, as configured in the field, enabling the 798 AC to carry its class-leading payload of 372 t and to haul more material each cycle on 59/80R63 tyres.

Both new trucks feature four-corner, oil-cooled disc brakes as well as dynamic braking for stable handling and fast stopping. Superior retarding capability, blended braking and the Cat Traction Control System help boost productivity and enhance safety.

The Cat AC drive is a high voltage system (2,600 volts) that operates at lower current than most competitors’ systems. When combined with full integration of the power train, the result is lower heat generation, smaller and lighter components, and longer component life.

In terms of the trucks’ body design, the Cat High Efficiency body is sized and configured to meet the specific needs of the mine, dictated by fragmentation, abrasion, cohesion and the loading tool. The curved floor, front, and canopy strengthen the entire body, which is integral to the truck. The body is sized to meet the payload requirements without compromising vehicle balance, braking or control.

Open engine access and service platforms ease maintenance tasks, with the modular design allowing easy removal and installation of components. The engine, traction alternator, motors, inverter, grid and final drives can be removed independently, again speeding up maintenance tasks.

Traction alternator and optional inverter platforms allow for easier inspections, diagnostics and component swaps. The result is less service time and greater uptime, Cat says.

WesTrac brings in four Cat 794 ACs on rising Western Australia mine demand

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WesTrac, one of Australia’s leading Caterpillar dealers, has responded to rising demand for ultra-class haul trucks out of Western Australia by ordering four Cat 794 ACs to its Reid Road assembly facility.

The trucks, which arrived recently, offer improved safety features, serviceability and performance over its competitors in this class of off-highway truck, WesTrac said.

The 794 AC made its debut at the MinExpo show in Las Vegas in September 2016. Following extensive field testing, controlled rollout of the new truck started in 2015.

The haul truck hosts a fully-integrated Caterpillar electric drive system that delivers improved fuel efficiency and speed on grade, ably supported and backed by WesTrac’s branch locations throughout Western Australia, according to the dealer.

WesTrac CEO Jarvas Croome said the 794 AC performs better in every way to competitor brands, with the 290-tonne class haul trucks becoming a popular choice for leading miners around the world.

“Caterpillar remains focused on providing its customers with both mechanical and electrical drive haulage solutions, but is also proving to have a competitive edge when it comes to electric drive systems,” he said.

In tests against competitors, the Caterpillar 794 AC displayed 19% higher stall torque, delivering stronger performance in soft underfoot conditions. This adds to faster cycle time when pulling away from a loading tool on softer ground.

“The Cat 794 AC gives operators much more confidence on steep downhill hauls and displays 40% more retarding capability versus its competitor with 5,480 horsepower (4,086 kW) continuing retarding power to the competitor’s 3,900 HP (2,908 kW),” Croome said.

Caterpillar’s study showed the 794 AC has both an empty machine weight and payload advantage, with the 794 AC typically delivering around 10-t more payload and better tonne per litre fuel consumption. The Cat fully-integrated drive and high voltage system achieves 1-2% better powertrain efficiency to the ground and, overall, it demonstrates a fuel advantage of up to 5% and 10% improved tyre life.

The 794 AC also offers a ground level service centre and less maintenance than its competitors – with brushless AC grid blower motors, brushless alternator and a sealed, pressurised and filtered inverter cabinet, WesTrac said.

Croome concluded: “We are excited to have four 794 AC off-highway mining trucks in stock now and available to the mining industry, cutting down the usual waiting period between order and delivery.”