Tag Archives: battery-electric loaders

Cat Job Site Solutions partners with mines, Cat dealers on R1700 XE ownership

Environmental, Mining equipment, Mining services, Power supply for mines, Sustainable mining, , , , ,

Particularly for the underground mining environment, battery-electric machines offer significant operational benefits over their diesel counterparts in terms of exhaust emissions and heat generation. However, battery-electric machine technology is still relatively new to underground mining, and miners need to stay focused on maintaining production targets, Caterpillar says.

Battery-electric loaders like the Cat® R1700 XE LHD with portable MEC500 fast charging capability represent a new way of charging and operating. When should the operator top off the battery? How can the LHD operate in the most efficient way to optimise run time between charges? Where should the battery charger be located? What are the different safety and regulatory issues with a battery-electric solution? What unknowns will surface along the way that can be resolved through collaboration?

This is where Cat Job Site Solutions and the Cat dealer bring value, according to the OEM. Cat Job Site Solutions provides battery equipment and incoming power management expertise, and leverages the dealer’s equipment maintenance and repair experience, delivering assurances on R1700 XE productivity and machine availability. “This allows miners to focus on what they need – keeping site goals aligned with corporate goals and maintaining day-to-day operation of site and staff,” the company says.

The R1700 XE site solution program manages battery and charger optimisation and provides data to efficiently operate the machine. “We are basically taking Cat Job Site Solutions’ ‘site solution’ model that has been very successful for surface operations and adapting it to manage the battery electric R1700 XE and power requirements in the underground environment,” Brandon Croegaert, New Product Introduction Manager for Caterpillar, explains.

Brandon Croegaert, New Product Introduction Manager for Caterpillar

Better together

The R1700 XE site solution model simplifies the miner’s responsibilities, making costs manageable, increasing uptime and optimising battery management, according to the company. This model alleviates the burden of in-house fleet management, as Cat Job Site Solutions and the Cat dealer assume responsibility of ownership cost, training, charging strategy and battery management, maintenance, service, parts and the supply chain.

The program also mitigates some of the uncertainty surrounding new technology and processes, Caterpillar says. The Cat Job Site Solutions team first conducts a site optimisation study to help maximise productivity through determining optimum charging locations. The portable Cat MEC500 charging station offers the advantage of minimum production loss, as it eliminates the need of travelling to a permanent, expensive charge bay. It also allows operators to take advantage of breaks and delays with quick opportunity charging.

Central to the R1700 XE site solution model is a dedicated fleet manager provided by Caterpillar. The fleet expert offers equipment, industry and applications knowledge, lifecycle planning and management experience, leverages data from sites around the world, and offers a single point of contact for the R1700 XE LHD.

“Offering complete transparency of operating data, the program’s fleet manager shares machine and productivity data gathered daily with key mine site personnel,” Caterpillar says. “Weekly status updates allow the fleet manager, mine site personnel and the dealer to review data and make any necessary adjustments to machine operation and charging site location. Plus, planned maintenance on a bi-weekly basis helps to increase machine uptime and availability.”

Croegaert added: “Some of our R1700 XE loaders are logging more than 400 hours per month. The data show these machines can demonstrate the same or better availability than the diesel fleet.”

Change management

Croegaert also mentions that change management is critical to the success of running battery-electric equipment in the underground environment. “Operators are used to running diesel machines for eight to 10 hours at a time before refueling,” he says. “However, the battery-electric models need to be charged throughout the shift.”

The Cat Job Site Solutions R1700 XE site solution model is paying off for mine sites, as it is offering uptime availability guarantees for the battery-electric R1700 XE similar to that of its diesel-powered counterpart, Caterpillar says

Operating efficiency is key to running battery-electric models successfully. The R1700 XE site solution model helps operators know when to come to the MEC500 for charging. They need to be aware of the schedule and take advantage of production downtime to top off the charge without impacting the production schedule. Predictive modelling using machine data also helps optimise the charging strategy.

The Cat Job Site Solutions R1700 XE site solution model is paying off for mine sites, as it is offering uptime availability guarantees for the battery-electric R1700 XE similar to that of its diesel-powered counterpart, Caterpillar says.

It added: “The fact that the machine runs with no exhaust emissions and lower heat generated is a bonus for those working near the machine. And this management model allows the mine site to focus on its core strengths while leveraging the expertise of Cat Job Site Solutions and the Cat dealer for machine management.”

Sandvik to boost battery output with higher-capacity systems, standardised processes

Automation, Environmental, Mining equipment, Mining services, Power supply for mines, Sustainable mining, , , , , , , ,

Sandvik’s higher-capacity batteries – ones that could eliminate one battery swap every shift in some mining applications – will soon start to be installed across the company’s line of battery-electric vehicles, according to Brian Huff, Vice President of New Technologies for the Load and Haul Division within Sandvik Mining and Rock Solutions.

Speaking to IM on the side lines of the OEM’s Innovation in Tunneling event in Tampere, Finland, Huff said the last of the previous generation of batteries were being manufactured in Camarillo, California, with the new generation battery packs lined up for future installations.

The company announced the introduction of these batteries for BEV loaders and trucks back in May, claiming they could deliver 36% more energy in the same envelope as the previous generation.

At that point, the company said they would be in production from the December quarter of 2023 and equipped as standard on all new Sandvik BEV loader and truck orders.

In addition to 36% longer runtime, customers can expect a lower cost per amp-hour compared with current-generation Artisan® battery packs. The increased capacity also improves charge acceptance, enabling faster downhill speeds and better efficiency.

Sandvik-Camarillo-BEV

Purpose-built for underground mining and designed and manufactured in-house by Sandvik, the new battery maintains the modularity and ruggedness of the existing pack and features significant design improvements.

Revamped housing and increased rigidity enhance structural strength, enabling the battery to better withstand shock and vibration. Laser-welded terminals provide a stronger connection with lower resistance, reducing energy loss and heat while improving efficiency and safety.

Top and bottom cooling plates improve cooling performance to slow cell degradation and extend life. Key design improvements also include better ingress protection against dust and moisture.

Brian Huff, Vice President of New Technology for the Load and Haul Division within Sandvik Mining and Rock Solutions

The next-generation LFP battery cells are fully encapsulated in a non-conductive potting material, increasing thermal conductivity and reducing the risk of overheating and short circuit. Sandvik has also redesigned its battery management system for improved reliability and function. This safety feature monitors every cell’s temperature and voltage to ensure everything is within operational range.

Huff said the new battery modules and accompanying largely automated assembly process would enable the company to significantly scale up its offering from current capacity.

“The batteries will be assembled in a much more controlled environment than before, which will inherently lead to less human error throughout the process,” he said. “Laying this foundation will enable us to scale our battery production capacity with limited additional resources.”

Camarillo will be the first to benefit from the new assembly line, yet Huff said the in-construction plant in Malaysia will also benefit from the same disciplines to maximise productive capacity from the off.

Earlier this year, Sandvik said it was establishing a new production unit in Malaysia for manufacturing underground loaders and trucks to answer growing demand for its BEVs. Equipment production was slated to begin in the December quarter of 2023 following factory upgrades and other site improvements. It was expected to have an annual manufacturing capacity of 300 loaders and trucks and 500 battery cages by 2030.

Sandvik adds Turku plant to battery-electric vehicle manufacturing plan

Environmental, Mining equipment, Mining services, Power supply for mines, Sustainable mining, , , , , , , , ,

Sandvik is expanding its plant in Turku, Finland, to incorporate the manufacture of battery-electric vehicles (BEVs) for underground mining, it says.

Alongside the expansion, which is set to be completed in the second half of 2023, the whole of the plant for load and haul equipment is set to be enhanced and modernised.

Sandvik’s Turku Business Park project represents a significant investment of over €10 million ($9.7 million), with the investment in response to increasing demand for load and haul equipment for underground mining, together with the industry’s growing trend towards electrification and digitalisation.

The objective is to increase the capacity of Sandvik’s Turku plant and improve production efficiency. Improvements will be made to all aspects of the plant’s operations, including logistics, warehousing, production and assembly areas and quality control, Sandvik said.

The OEM will acquire an additional 7,000 sq.m of production and storage space by modifying space previously occupied by Tunturi, a manufacturer of bicycles and fitness equipment. The project will provide additional capacity for the production of BEV loaders and trucks, and includes investment in new welding robots and assembly lines.

Matti Seppälä, Project Manager at Sandvik Mining and Rock Solutions, said: “The upgraded production environment and reorganisation of operations will improve productivity, lead times and worker safety. Warehouse and recycling improvements will enhance the sustainability of our operations.”

Three completely new machine assembly lines will be built, two of which will be designated for the manufacture of BEVs – a first for the Turku plant, which has manufactured mining loaders and trucks since the early 1980s and employs around 700 people today.

The modifications that form part of the Turku Business Park project will enable flexible manufacturing of both conventional diesel and battery-electric mining equipment. The company’s plant in Camarillo, California, is currently the company’s main battery system hub for BEVs.

Mats Eriksson, President of Sandvik Mining and Rock Solutions’ Load and Haul division, added: “BEVs enable the electrification of mines, which increases productivity and improves working conditions, reducing emissions, heat and noise, although there will still remain a need for conventional diesel equipment for some time to come.”

To strengthen its development of mining BEVs, Sandvik recently acquired Akkurate, which specialises in battery technology, particularly remote battery diagnostic and prognostic platforms. Akkurate has now been integrated into Sandvik’s Load and Haul division, accelerating its expansion into battery-electric mining equipment and enhancing the current product offering.

Sandvik and Artisan reveal new 18 t battery-electric LHD

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

Sandvik Mining and Rock Technology has matched its decades of engineering expertise with Artisan Vehicle Systems’ 18 years of innovative powertrain technology and battery system expertise to come up with the new 18 t payload LH518B battery-electric loader.

Sandvik acquired Artisan last year, in the process gaining 10 years of mining battery-electric vehicle (BEV) deployment experience. The latest BEV loader, which comes on top of Artisan’s 4 t and 10 t capacity loaders – plus its 50 t payload truck – is the first true collaborative design effort between the two companies.

The LH518B from Sandvik has been designed from the ground up, entirely around the loader’s Artisan™ battery system and electric driveline to best leverage the possibilities that the battery technology brings, Sandvik says.

“It was not enough to replace some components or redesign only a part of the equipment: the designers were compelled to rethink the whole machine,” Sandvik said.

The most powerful 18 t loader ever built, according to Mike Kasaba, Managing Director of Artisan, a Sandvik Mining and Rock Technology business unit, the new LH518B can fit in a 4.5 x 4.5 m tunnel and features independent front and rear drivetrains, allowing high payload capacity while keeping a low overall height, Sandvik says.

This low overall frame height of 2,565 mm – significant lower than other machines in its class – provides “for better manoeuvrability in low back height applications while increasing stability”, Kyle Hickey, VP of Engineering for Artisan, said at the Innovation in Mining virtual event on September 29.

“The use of smaller diameter tyres in the rear is an example of how this machine has been optimised for the application,” he added.

The LH518B is equipped with three 2,000 Nm permanent magnet motors, 450 kN of tractive effort, can operate at speeds up to 30 km/h and has 560 kW of continuous power output (peak power output of 660 kW).

“With no torque converter, transmission or engine to rev up, the loader is fast and agile,” Sandvik says. This means it can travel at a speed of 12 km/h fully loaded on a 20% grade ramp.

In practice, changing the loader battery is easy and quick, thanks to the patented AutoSwap feature, Sandvik says.

This self-swapping system for the Artisan battery pack has been developed to offer a minimum amount of manual handling. According to Sandvik and Artisan, changing the battery only takes about six minutes, and it can be done in a passing bay or old re-muck bay with no need for overhead cranes or external infrastructure.

“The new AutoConnect feature, available for the first time on the LH518B, is making swapping even easier and faster by automatically connecting and disconnecting the battery pack to the machine,” Sandvik says. “Aside from unplugging and plugging in the charger, the operator doesn’t need to leave the cabin, which saves minutes on the swapping procedure and decreases effort and risk in the swapping process.”

This is aided by a stability system, within the Artisan battery system, that allows the battery to be dropped off at any location without any prepared infrastructure, according to Hickey.

Kasaba said the LH518B is the “only battery loader capable of dropping off and picking up its own battery”. This process of tramming between battery swaps is enabled by the LH518B having a small on-board battery that remains in place at all times, according to Hickey.

Brian Huff, VP of Technology for Artisan, explained during the event that the LH518B is built for automation and will be available in the future with AutoMine integration.

The LH518B will be available to customers in North America this year, followed by select other areas in 2021, he added.

Sandvik concluded on the subject of BEVs: “Currently, Sandvik is expanding the battery-electric vehicle loader and truck offering and prepares to enter new market areas, which will happen in phases and model by model. When the battery loaders and trucks are introduced to new markets, Sandvik will be ready to offer full product support and aftermarket services for its customers.”

Included in this is the company’s Battery as a Service offering which IM understands will help miners adopt these new battery-electric vehicle solutions, which currently come with a higher capital cost than the diesel equivalent.

Sandvik to show off newest battery-electric loader next week

Environmental, Mining equipment, Mining events, Mining services, Power supply for mines, Sustainable mining, , , , , , ,

Sandvik Mining and Rock Technology is set to announce details of its new battery-electric LHD at its Innovation in Mining Virtual Event next week, Brian Huff, has confirmed.

Speaking on ‘The Next Generation of Battery-Electric Vehicles’ event on Tuesday, Huff, Vice President of Technology at Artisan Vehicle Systems, a Sandvik Mining and Rock Technology Business Unit, said a new machine would be announced on September 29 at the virtual event. He later confirmed the loader in question would be on show.

Not too many details were given away about this new BEV, but Huff confirmed it would be “another machine to fill out our weight class” and host, Martina Lundgren, said the loader represented the first joint project between Artisan and Sandvik since Sandvik acquired Artisan in 2019.

In addition to announcing this news, Huff also confirmed that “there will be a larger class…haul truck intended mainly for the Australian market” coming from the company in later years.

As it stands, the company’s largest payload battery-electric haul truck is the Z50 50 t machine (pictured), which has been trialled at the Barrick Gold-owned Turquoise Ridge gold mine, in Nevada, USA.