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The Electric Mine conference shifts gear

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With just under four months to go, The Electric Mine conference is charging up to full capacity.

IM has been able to assemble a world-class speaker line-up covering the entire mine electrification process – from R&D and power infrastructure, to battery charging and electrified equipment.

The conference, to take place on April 4-5, 2019, in Toronto, Canada, will host the great and the good in this fast-evolving sector and hear case studies from real mine trials or applications.

This includes a presentation from Kirkland Lake Gold, which is currently running one of the largest in-production underground battery-electric fleets in the industry at its Macassa gold mine in Canada.

Just last month, IM heard that some 33 units were active underground at the deep and high-grade mine in Ontario and Andrew Schinkel, Senior Electrical Engineer of the Macassa Mine Complex, will most likely be able to add to that number, as well as comment on the fleet’s productivity, come conference time.

The soon-to-be-in-production Borden gold project, also in Ontario, will be under the spotlight at the event, with the involved OEMs and mining company collaborating on stage as they have during mine development.

Maarten van Koppen (pictured, left), Senior Project Engineer at Goldcorp Porcupine Mines, Jeff Anderson, Senior Mechanical Designer, MacLean Engineering, and a Sandvik Mining co-speaker (to be confirmed), will present: ‘The Borden Gold Project – lessons learned from the ‘mine of the future’ and the crucial role of partnerships in building an all-electric underground mine’.

The major mining representation does not end there.

Samantha Espley, Director of the Technology & Innovation Centre for Mining and Mineral Processing, Vale Base Metals Operations, will chart the mining company’s roadmap to underground electrification in Sudbury during her talk; expect the OEMs in the room to ask questions about the future fleet for the Creighton deep zone!

Caterpillar’s Product Manager for Underground Technology Solutions, Jay Armburger, is also set to take to the stage at the Radisson Admiral. The focus of his talk will be on heat generation, comparing battery and diesel LHDs underground. A few passing references to the proof of concept R1300G LHD trials it ran not all that long ago at an underground mine in Sudbury, Canada (pictured, right), are likely.

We’ll also hear about developments above ground.

A joint presentation from Karl Trudeau (Nouveau Monde Graphite), Michel Serres (ABB Canada) and David Lyon (MEDATECH) will shed some light on what it will take to create an all-electric open-pit mine able to produce 100,000 t of graphite concentrate at NMG’s Matawinie project in Quebec, Canada.

Those three speakers could be in the front row for Per-Erik Lindström’s talk on The Electric Site project in Sweden.

Lindström, Vice President Global Key Account Management for Volvo Construction Equipment, has seen first hand how battery-electric equipment can move the needle in terms of cost and emissions at the Skanska Vikan Cross quarry, just outside of Gothenburg, and there are more than a few miners interested in the prototype machines (pictured, left) the OEM has manufactured for this purpose.

These presentations will be complemented by a talk from Heather Ednie, Managing Director, Global Mining Guidelines Group, on the second edition of the group’s Battery Electric Vehicle guideline; an opening keynote from Ali G. Madiseh, Canada Research Chair in Advanced Mine Energy Systems, Norman B. Keevil Institute of Mining Engineering, University of British Columbia, titled: ‘The Electric Mine: a new norm in mine energy systems’; Erik Isokangas, Program Director, Mining3, discussing the value proposition for autonomous electric haulage; and Doug Morrison, President and CEO, Centre for Excellence in Mining Innovation (CEMI), looking at electrification to maximise productive capacity.

Meanwhile, Justin Bain, Chief Executive Officer, Energetique (Energy/Mobility), will fly in from Australia to pronounce the death of diesel Down Under – his firm has recently been involved in the conversion of diesel utility vehicles to battery-electric drive.

Along similar lines, Paul Miller, of Miller Technology, will talk about what goes into developing an innovative fully-electric light utility automobile, designed for continuous underground operation.

IM then has two behemoths in the mine power sector, Siemens and Schneider Electric, looking at the all-important infrastructure that goes into electrification.

Dr Bappa Banerjee, General Manager, Mining Equipment, GE Transportation, will look at the electric future for load and haul in his keynote, Mathieu Bouffard, Project Manager, Adria Manufacture, will cover battery charging and power management of battery-electric vehicles, and Don Duval, CEO of NORCAT, will showcase some of the new technologies that have come out of the organisation’s Underground Centre in Sudbury.

This speaker line-up is only set to improve as we move into the New Year, with IM in advanced discussions with more OEMs and miners looking to present.

The first global event on mine electrification continues to charge ahead…

If you’d like to hear more about The Electric Mine conference – including presenting and sponsorship opportunities – please feel free to get in contact with Editorial Director Paul Moore ([email protected]) or Editor Dan Gleeson ([email protected]).

To view the full speaker line-up, venue details and to take advantage of the soon-to-expire Early Bird attendance rate, please visit the event homepage here.

Cat 990K wheel loader to receive payload boost with Aggregate Handler

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Caterpillar has boosted the payload of its 990K wheel loader with the introduction of its Aggregate Handler.

The attachment provides as much as a 25% payload increase compared with the standard 990K Wheel Loader, enabling customers to load trucks and railcars faster and to move more material in load-and-carry and stockpile handling tasks.

The Cat® 990K Aggregate Handler has a payload of 22 tons (20 t) and a full-turn static tipping load of 96,426 lb (43,738 kg). Additional counterweight maintains machine stability, and the robust 990K structures ensure durability in the Aggregate Handler configuration.

“The loader makes best use of general purpose and coal buckets for increased volume,” Cat says.

It is available in standard lift configuration with 13.5 ft (4,108 mm) dump clearance and in high lift configuration with 15 ft (4,569 mm) dump clearance. Increased capacity and high dump clearance enable customers to load railcars and large trucks with a better pass match for faster material handling at lower cost per ton, Cat says.

The 990K Aggregate Handler complements the smaller 986K and 988K Aggregate Handlers in the Cat large wheel loader line. The Aggregate Handler, however, is not designed for use in quarry face or other shot rock applications, according to Cat.

The new 990K Aggregate Handler is built on the proven features of the 990K wheel loader, Cat says.

“The 990K powertrain provides powerful operation with superior fuel efficiency. The Cat C27 engine powers the loader and delivers net power of 699 hp (521 kW). Lower engine speed helps drive economical fuel use. Additional fuel savings accrue with the ECO Mode (on-demand throttle), engine-idle shutdown system, and engine-idle kickdown/auto-resume system,” the company says.

Cat’s exclusive, field-proven impeller clutch torque converter uses a lock-up clutch, providing direct drive to boost fuel economy, cut cycle times and reduce heat. This is especially so in load-and-carry applications, Cat says.

“The system allows operators to balance rimpull and hydraulic power for optimum loading efficiency. Positive Flow Control implement hydraulics use a variable displacement, electronically controlled pump to precisely apportion oil flow based on operator control inputs,” the company says.

The operator station features the Cat Vital Information Management System, VIMS™ 3G, which provides customisable operator profiles, a cycle timer and an integral Payload Control System for “on-the-go payload weighing”, Cat says.

The company says the graphical information display is easy to use and keeps key information in front of the operator, while the Cat Comfort III seat provides integrated seat-mounted controls making for smooth and comfortable operation. Transmission controls, integral with the STIC™ steering lever, allow convenient travel control, Cat says.

The 990K is equipped with the Cat Vision rearview camera system and in-cab display for improved visibility. The Cat Detect object detection system, available as an option, builds on this system with radars and in-cab software that provide notification to the operator when an object is detected within the radar coverage area.

Cat’s battery-electric loader proof of concept trial exceeds expectations

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Earlier this month during a talk focused on developments in Caterpillar’s underground division, more details emerged of the proof of concept battery-electric trial carried out underground earlier this year on its R1300G LHD.

Susan Gaugush, Commercial Manager for Caterpillar Underground, said in tests at a mine in Sudbury, eastern Canada, against its diesel-equivalent, the R1300G had surpassed the company’s expectations.

“What we were expecting versus what we got was very interesting,” she told a group of journalists, including IM, at the company’s Tinaja Hills facility in Tucson, Arizona.

The trial involved the LHD performing a brake test (to simulate driving the bucket into the muck pile), travelling forward, stopping and performing the bucket cycle (lifting and lowering) and reversing back to the brake test location. This was repeated for 30 cycle runs.

The company assumed the results would show a three times reduction in terms of heat generation when comparing the battery-electric LHD to its diesel counterpart. “We actually saw a seven-and-a-half times improvement,” Gaugush said.

Also, the energy cost was ten times less for the battery LHD based on the equivalent duty cycle, coming in at $3.66/run compared with the diesel machine’s $37.50/run.

The company is still a good few years away from launching a battery-electric machine as it looks to tackle the industry need to improve safety, reduce ventilation requirements and operate at increasing depths, but its initial trial bodes well for future developments.

Gaugush said the company had taken a lot of what Caterpillar has applied in other parts of its business – in track-type tractors, electric-drive haul trucks and micro-grids, for example – and “leveraged it into a battery-electric motor”.

While Cat and Gaugush did not want to reveal what battery chemistry the company was using for this trial – explaining this could change in the future as the sector continues to evolve – she did say the trial involved the use of fast-charging technology, which saw the loader’s battery go from a 20% capacity to full charge in around 15 minutes.

The company’s aim is to eventually create a battery-electric loader that can work continuously for some four hours before requiring re-charge, while it hopes to remove the need for continuous battery change-out through an underground charging system.

Gaugush said there was potential for the company to apply the testing process it used on this LHD to underground truck technology, but Cat, which has partnered up with at least one undisclosed company on this project, is currently pursuing further test work on the R1300G.

Jay Armburger, Caterpillar’s Product Manager for Underground Technology, previously said underground electrification will bring with it substantial industry benefits, not just a reduction of greenhouse gases.

“Mining operations are going deeper and deeper in search of larger reserves and higher-grade ore,” Armburger said. “With that depth comes significant challenges with ventilation and temperature management. It takes a lot of capital investment to put in the infrastructure for ventilation systems and air conditioning systems. Battery electric machines really bring significant cost savings to these customers.”

One customer working with Caterpillar on this solution estimated a $40 million or more saving on capital expenses by reducing the volume requirements of ventilation shafts, he said. “Their vent reduction requirements can be reduced by 40%, and inlet and return shafts can be reduced up to 24%.”

Trolley assist up and running at Boliden’s Aitik copper mine

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Boliden has installed four trolley assist truck units at its Aitik copper mine in Sweden as the company looks to step up its vision for fossil fuel-free operations, the company’s Technology Director, Staffan Sandström told attendees at Epiroc’s Power Change Days event in Örebro, Sweden, this week.

The trolley kits, supplied by Caterpillar, are running on Cat 795F haul trucks on a trolley assist line as part of a two-year trial project at Europe’s largest open-pit copper mine.

For the project, Boliden has joined forces with Eitech and ABB to supply electrical infrastructure; Pon Equipment and Caterpillar for truck modifications; and Chalmers University with supporting research on system aspects of the electrification. The project is supported by the Swedish Energy Agency and has seen an investment in a 10 MW capacity DC substation.

The aim is to examine the possibility of replacing elements of Aitik’s transport system with electrified trucks. The objective is to be able to move the majority of the 70 million or so tonnes of rock transported at the open pit each year entirely without the use of fossil fuel.

At the event this week, Sandström confirmed the first trolley line was commissioned in September and had been working well, showing a close to two times increase in speed on an incline when compared with the equivalent diesel trucks.

The real test for the trucks and trolley line was yet to come, he said.

“This is nothing new; it has been done before. The new thing here is going to be working in 40° below [freezing],” he said.

The project’s Technical Manager, Jonas Ranggård, made a similar remark recently in a Boliden press release, saying: “As we want to be able to use the electrified routes in all weather conditions year-round, the pilot project as a whole can only first be evaluated at the end of 2019/start of 2020.”

Rikard Mäki, Project Manager for the R&D project, told IM the company was already preparing for these conditions.

“Road maintenance impact is one of the parameters that will be evaluated in the pilot project in order for us to accurately take this factor into account as part of the following investment decisions. We have fitted one motor grader and a wheel loader with machine guidance systems in order to maintain correct flatness, target slope and height of the ramp.”

On the trolley assist technology, Sandström continued: “Today, it works very well and roughly 30% of all transport has potential to be used on the trolley line at Aitik,” he said, adding it could have wider applications at the company’s Kevitsa nickel-copper mine in Finland.

Boliden said the first Aitik trolley line is around 700 m long and is expected to save some 830 m³/y of diesel. This should help the company reduce its greenhouse gas emissions by up to 80% along those routes where the technology can be implemented.

In addition to the emission benefits brought to both the wider community and those operating in the mine, Sandström said the productivity and cost benefits (reducing the amount of diesel purchased) could also have a big impact.

Mäki said: “We do see this technology as the most promising solution near term for both Kevitsa and Aitik in order to reduce fuel cost and emissions. Decision to move ahead with further extension of the system is pending results from the pilot test. The initial results are looking very positive and the operators are very engaged in the pilot test.”

In other news, but still on haul trucks and potential electrification, Boliden confirmed in its September quarter results that, on October 19, the company reached agreement with Komatsu regarding the purchase of 17 haul trucks for Kevitsa and nine mine trucks for Aitik in an investment totalling some SEK 900 million ($99 million).

The investment is being made against the background of the ongoing expansion, insourcing of transport and as a replacement for part of the existing fleet of trucks. Boliden said all of the trucks are equipped for future electrification and delivery will commence in mid-2019.

Caterpillar’s R1700 underground LHD starts to prove its worth

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Caterpillar’s recently launched Cat® R1700 Underground Mining Loader has proven its high productivity and efficiency in extended field trials and in-production studies, the company says.

The completely new design R1700 carries a size-class-leading payload of 15 t, 20% more than its predecessor, yet maintains the dimensions of the R1700G.

“A recent head-to-head study and multiple field trials show that the machine surpasses its payload advantage in faster truck loading and more productive load-and-carry operations while delivering 21% less fuel consumption per hour in a recent study,” Cat says.

The R1700 comes with cycle time advantages over its predecessor through fast bucket loading. This has been enabled through high digging forces and a new traction control system that limits tyre slip when the bucket enters the pile.

“The result is fast loading, good bucket fill factors and reduced tyre wear. Excellent machine balance and a new electrohydraulic braking system aid load-and-carry cycles,” Cat says.

Fuel efficiency is improved through on-demand adjustment of the cooling fan and the hydraulic system, as well as the proven efficiency of the Cat C13, six-cylinder engine, according to the company. The engine is turbocharged and air-to-air aftercooled, and it produces 269 kW in standard configuration and 257 kW in EU Stage V compliant form.

The engine is available in three different emissions configurations – Cat Ventilation Reduction, US EPA Tier/EU Stage IIIA, and EU Stage V – tailoring the R1700 to the mine’s ventilation needs. Aftertreatment for the Stage V engine configuration is chassis mounted for convenience and includes a Diesel Emission Fluid tank sized to match the 12-hour capacity of the fuel tank.

The R1700’s productivity is boosted even further with multiple subsystems for fast technology implementation.

“Optional Autodig helps new operators be productive the first day and reduces fatigue for experienced teams. Remote machine health monitoring, payload operating technologies are available via MineStar™ Command for underground,” the company says.

During the load or dump cycle, the harder the operator pushes the controls, the faster the machine responds. The steering system is pilot-controlled to provide a more precise feel for the operator during manoeuvres in tight places.

“Ride control is now fully integrated into the hydraulic system and engages automatically as the machine goes above 5 km/h. Electronically snubbing the cylinders protects them and provides greater operator comfort,” Cat says.

The R1700 has auto retarding which is hydraulically actuated. The system comes on automatically when the operator’s foot is lifted from the throttle, with cycle times improving as operators gain confidence and become more comfortable on downhill grades at faster speeds.

For easier maintenance, the R1700 features several components that have modular designs – they can easily be removed and replaced.

In addition to modular components, all filter and key service points have been grouped into a centralised section on the cold side of the engine. The radiator guard swings open for ground-level access to the radiator, and oil coolers and the batteries are easily accessed just under the centralised service location.

For the entire underground loader line, Caterpillar now offers Bolt On Half Arrow ground engaging tools (GET) for bucket edges. The system is designed for high abrasion applications where weld-on GET experience high wear rates.

“With a proven and reliable retention system, the bolt-on GET offer more wear material than standard weld-on GET, and the bolt-on design enables fast and easy removal and replacement.

“Despite additional wear material, the low-profile front edge eases pile penetration and promotes fast bucket loading,” Cat says.

Cat D11 Dozer set for a revamp

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Cat is updating its D11 Dozer with new load-sensing hydraulics, high-horsepower reverse and the latest technology as the OEM looks to provide higher material movement at a lower cost per tonne.

Engineered to be rebuilt multiple times, the new D11 has a redesigned main frame delivering lower total cost of ownership over the life of the machine, Cat says. Time-saving service updates reduce daily maintenance and boost machine uptime.

The machine is being trialled in North America this year before being rolled out commercially in the June quarter of 2019.

New load-sensing hydraulics and new drive train components deliver up to 8% fuel efficiency gains compared with the previous model, Cat says.

The variable hydraulic pumps adjust output to meet demand, which saves energy, reduces heat generation and extends component life, according to the company. The new stator clutch torque divider provides improved drive train efficiency and, when combined with the new, high-horsepower reverse function, the machine delivers 4-8% greater productivity while burning less fuel.

The redesigned structures and components increase reliability and durability for higher utilisation. For example, the larger equaliser bar features an improved bearing design to increase reliability.

“The new D11 also improves on the time-tested elevated sprocket undercarriage with a more robust track roller frame to extend component service life. Replaceable bearings on the ripper and blade pin boreholes and new push arm trunnion bearing inserts offer fast replacement and extend component life,” Cat says.

The D11 is available with a choice of emissions solutions to meet regional requirements, the Cat C32 engine delivers power ratings of 634 kW forward and 712 kW reverse for increased performance. A new single-plane cooling system design better dissipates heat to maintain consistent operating temperatures, even in extreme heat, and it provides easier core cleanout. This is of importance to the Tier 4 Final solution, which generates more heat than the Tier 2 equivalent.

In addition, improved reversing fan function delivers greater reverse airflow for radiator cleanout, Cat says.

The company also highlights a 30% larger engine oil sump capacity, which extends preventive maintenance intervals to 500 hours in challenging environments, giving customers more uptime.

“The ground-level electrical centre provides convenient access to the lockout control, engine shutdown switch, and switches for access ladder raise/lower and remote-control mode options.

“Service technicians can also fill the Auto Lube system and change the coolant and hydraulic, engine and powertrain oil from the ground,” Cat says.

Standard features built into the new D11 offer improved access to the operator compartment, with the cab door mounted for either left- or right-side opening. Delayed egress lighting allows the operator to exit an illuminated dozer, while access lighting is controlled from either the cab or ground-level electrical centre.

The new operator station features high-definition touchscreen displays with scalable electronic architecture, while the dynamic fluid monitoring system displays fluid levels and warns the operator of low-fluid conditions.

Caterpillar is now offering a range of standard and optional technologies for the new D11 to allow work to be “done more efficiently, more accurately and at a lower cost”.

Standard Automated Blade Assist makes use of pre-set blade pitch position to increase efficiency while reducing operator workload. Fuel efficiency and productivity are optimised through Enhanced Auto Shift, which automatically selects the optimal gear and engine speed based on powertrain load and desired ground speed.

The D11 is also available with AutoCarry™, which automatically changes blade position to keep track slip at a minimum to optimise productivity when pushing a load. The optional Auto Ripper Control reduces operator fatigue and decreases machine wear by monitoring and automatically adjusting engine speed and ripper depth to minimise track slip.

Cat Product Link™, also available, enables remote reporting of critical operating data like machine location, operation and condition, and allows data tracking from anywhere through VisionLink™.

Available Cat MineStar™ technologies for the D11 include Terrain for grading, which guides the operator in grading to plan and boosts productivity by reducing rework. Command for dozing offers multiple levels of remote control as well as semi-autonomous operation, which enables a single remotely located operator to manage several dozers.

Cat backs autonomy with large mining truck line roll out

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Caterpillar already has seven autonomous haul fleets running around the globe, with an eighth to come online next year at Fortescue Metal Group’s Cloudbreak iron ore mine.

Yet, the company is continuing to drive forward with its autonomous offering with plans to make its entire large mining truck class autonomy-ready.

Cat is currently running the 789D, 793F and 797F in autonomous mode with its Command for hauling module, part of its MineStar system. It has over 100 trucks in the field, which have hauled more than 600 Mt of material.

The company revealed on Thursday at its Tinaja Hills facility in Tucson, Arizona, that it has plans to roll out autonomy across the whole group of large mining trucks. This includes the newly-added electric drive 796 AC and 798 AC haul trucks.

This move shows the company’s intent when it comes to automating mine site haulage, providing various payload options across its large mining trucks.

It is also a reflection of how the benefits of autonomy are becoming apparent to Cat’s current and future customers, with Cat pointing out that mining operators are realising they can continue to reach production goals with smaller machines than previously used in manned operations.

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.

Cat scaling new autonomy heights with virtual mine site simulator

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Caterpillar has quickly become a leader in the field of autonomous haulage, with many new and retrofitted solutions found across Western Australia and the Canadian oil sands.

Yet, the company is not slowing down now it has passed more than 100 operating in the field, with its scalability lab – part of the virtual mine site at the company’s Mossville facility in Peoria, Illinois – a key driver in achieving more sales.

This lab has been in place for more than five years and was devised to stay 20-25% ahead of Cat’s biggest Command for hauling customer, IM and other mining journalists were told on Wednesday during a tour of the facility.

From this lab, and its array of monitors, operators track and orchestrate the movement of hundreds of vehicles, with controllers setting daily production goals and sending machines for maintenance or diagnostic testing. It is designed to enact a real mine site, with the simulation running 24 hours a day, five days a week.

The 20-25% goal means the company is now simulating some 400 pieces of manned and unmanned equipment using Command for hauling in its lab. It uses real-life operating data previously collected from its customers as input parameters, while having set ‘scripts’ for the operating behaviour of the equipment.

The virtual equipment currently includes some 120 autonomous haul trucks, 30 manned trucks and over 100 auxiliary vehicles.

The ability to simulate this mass of machines ensures Caterpillar stays ahead of the game.

In addition to this, the company can use a nearby test track to simulate the reaction time, hazard perception and general behaviour of autonomous trucks via fully kitted out Chevrolet Tahoes. The Tahoes are set up with components normally found on mining equipment in the field, with the generated data scaled up to the equivalent of one of its, or another vendor’s, haul trucks.

All this R&D means the company can continue with its ambitious programme of releasing two new updates of Command for hauling every year with several valuable additions.

It also allows the company to test out some 90-95% of Command for hauling functionality before it even gets to the machines operating at the company’s Tinaja proving grounds in in Tucson, Arizona.

Caterpillar to complete ultra-class electric drive haul truck line

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Caterpillar is set to add to its electric drive haul truck line, with two new ultra-class models being readied for launch.

Cat already has the 794 AC (pictured) and 795F AC in electric drive, but the 796 AC and 798 AC haul trucks will soon be added to the platform, Caterpillar Senior Product Specialist Antonio Varela confirmed on a visit to the company’s Decatur truck manufacturing facility in Illinois on Tuesday.

More details are expected later this week, but Varela confirmed the truck chassis will be a larger version of the 794 AC (previously the MT5300) chassis, which has been proven in the field at many mines.

As the brand names indicate, the new machines will have a higher payload capacity than the 291 t 794 AC and the 327 t 795F AC.

This development shows how the company is continuing to invest in both electric and mechanical drive options on even the largest of its haul trucks – a key differentiator for the company in the OEM space. It also indicates there is significant demand for electric drive at the top end of the haulage market.

Cat’s ultra-class electric drive truck platform was established with the addition of the Unit Rig™ product line. This line came with the acquistion of Bucyrus back in 2011.