Tag Archives: R1700 XE

More XE underground loaders on the way, Caterpillar says

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Having additional success selling underground loaders to mining customers, Caterpillar is gearing up to release more machines that leverage that same “architecture” technology as the Cat® R2900 XE diesel-electric LHD, Mike Berry, Vice President and General Manager of Load and Haul for Caterpillar, says.

The diesel-electric R2900 XE is built on the R2900G’s platform, Caterpillar’s most popular underground loader. It features optimised lift arm and component geometry plus load-sensing hydraulics to improve breakout force by 35% over the R2900G, Caterpillar states.

The 18.5-t payload R2900 XE features a switch reluctance electric drive system alongside a Cat C15 diesel engine, which offers up to 335 kW of power. Caterpillar says the machine comes with about 30% increased fuel efficiency compared with the R2900G, with its lower engine revolutions per minute resulting in reduced fuel burn, heat, noise, vibration and exhaust emissions.

These traits have, so far, gone down well. In Australia, there are units at mines owned by Gold Fields, Westgold Resources and MMG. Newmont recently confirmed an order for nine R2900 XEs to the Subika gold mine, in Ghana, while Centamin also added at least one of these LHDs to its underground fleet at Sukari, in Egypt. In Canada, Alamos Gold recently purchased two of these machines for its Young-Davidson mine, while Cementation Americas added the diesel-electric machine to its roster, deploying it at New Gold’s Rainy River project in Ontario, Canada.

Speaking to IM at MINExpo 2024, in Las Vegas, in September, Berry said that the company planned to build on this momentum with more models set to join the platform.

“Similar to rolling out this technology from the surface with the 988 XE wheel loader to this machine [the R2900 XE], yes, we plan to take that technology up and down the underground loader product line,” he said.

Berry’s colleague, Paul Bitter, Product Value Stream Manager at Caterpillar, said the architecture of the XE platform – which also includes a battery-electric loader in the form of the R1700 XE – leaves a “great degree of freedom from a design perspective both for hauling and loading”.

He added: “We see it as platform for loaders and trucks, where, because of the electric drive, you can change power source. This means you can have a diesel machine, a hybrid machine or a fully electric machine.”

The most likely haulage and loading candidates for the ‘XE treatment’ are machines that currently only come in diesel form, have not recently been updated and have large populations out in the field.

On the theme of hybridisation, Berry said the company had no plans to combine the electric drivetrain with a small diesel energy and an on-board energy storage element for load and haul equipment. He and colleague Thad Litkenhus, Director of Product Management at Caterpillar, did raise the prospect of a form of the Dynamic Energy Transfer (DET) solution currently equipped for surface haul trucks being converted for underground use, however.

Designed to both transfer energy to large mining trucks, as well as charge a machine’s batteries while operating with increased speed on grade, the system “provides the industry with options to support both near-term and long-term sustainability strategies”, Caterpillar says.

Litkenhus added: “We define hybrid as having multiple energy sources and, if you think about the fundamental notion of a DET system, that is effectively a hybridisation of your machine to bring more energy to the machine. It just happens to be an off-board one.

“We actually think such a combination could provide the hybrid element that diversifies the power source without any drawbacks that come with having it all happen on board the machine.”

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

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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.”

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Cat R1700 XE battery-electric loader set to be showcased at major technology conference

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Attendees at CES 2024 are set to experience the “Power of Possible” at Caterpillar Inc.’s roughly 9,600 sq.ft (892 sq.m) exhibit on January 9-12 in Las Vegas, Nevada.

This year’s display focuses on Caterpillar’s electric machines and energy solutions to meet the evolving needs of customers as they electrify their job sites, Caterpillar says, with the OEM continuing to innovate and invest in electrification, alternative fuels, connectivity and digital solutions as part of this focus.

Rod Shurman, Senior Vice President of Caterpillar’s Electrification + Energy Solutions division, said: “We are delighted to return to CES to showcase our advancements in energy solutions. This event is known as the proving ground for breakthrough technologies and global innovators which makes it the ideal place for us to showcase our leadership in power systems and integrated service solutions to help our customers in the energy transition. We’re putting our expertise to work on multiple advanced power technologies to enable the energy transition solutions that our customers need to be successful in a reduced-carbon world.”

The exhibit’s centrepiece, the Cat® R1700 XE LHD underground loader, offers a 15-t payload. The zero-exhaust emission loader includes the industry’s only on-board battery, eliminating the need to handle or exchange batteries, Caterpillar claims. It charges in less than 20 minutes when paired with two of the Cat MEC500 chargers, a standalone charging system designed to charge quickly and safely as needed.

Also on display is the company’s 301.9 mini excavator, the first machine with a Caterpillar battery.

Alongside this, the company is set to showcase lower-carbon intensity on-site power production solutions, such as generators running on a variety of renewable fuels, solar panels and hydrogen powered fuel cells, plus battery energy storage solutions, including the compact XEX60.

The on-board battery pack on display at CES is designed to power the 301.9 mini excavator with a total capacity of 32 kWh and a nominal voltage of 48 V. Cat battery packs consist of a modular design with factory integrated telematics and a rugged structure to endure the use on our heavy equipment, the company says.

Additionally displayed at CES will be a Cat 750 V electric motor and inverter, components that support a variety of machines and power systems. A 750 DC motor provides mechanical power for the machine movement when commanded by the operator. The inverter transfers power to the electric motor from an onboard Caterpillar machine power source like a generator or battery.

Lastly, Cat digital solutions will feature at CES, showcasing the ability to monitor Caterpillar equipment and power solutions for the provision of advanced analytics, transforming data into customer insights making it easier for customers to own and operate their equipment, the company said.

DavidRea-Tucson-ElectricMine2023

Cat R1700 XE battery-electric LHD completes the test at Glencore Nickel Rim South

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The first field follow trial of Caterpillar’s R1700 XE battery-electric loader has been deemed a success by one Glencore trial participant, with the machine anticipated to surpass the productivity performance of the equivalent diesel LHD running at Glencore’s Nickel Rim South mine, in Sudbury, Canada.

Speaking in a video, Paul Kant, Glencore’s Maintenance General Foreman at the mine, said the battery-electric loader was likely to outperform the diesel-powered Cat® R1700G it was being benchmarked against at the operation over the trial period.

The mine has been using the machine, a 15-t payload loader, as part of ongoing plans to incorporate new technology at its Sudbury Integrated Nickel Operations. This includes the development of an all-electric equipment fleet at the Onaping Depth project.

The Sudbury Integrated Nickel Operations have played a significant role in the development of the R1700 XE, hosting a proof-of-concept trial of a battery-electric R1300 LHD at one of the mines where the machine ran in trials alongside its diesel equivalent. Caterpillar used the insight gained from this testing to develop the commercial R1700 XE.

The R1700 XE is rated with a 24,190 kg lift and tilt breakout, and, according to Caterpillar, features a battery-electric design that delivers superior productivity in underground applications with the benefits of minimal heat and no engine exhaust emissions. It offers an 18 km/h top speed.

It is designed to work with the Cat MEC500 Mobile Equipment Charger, a 1,656 kg (2,037 kg with optional skid) portable charger that, Caterpillar says, eliminates the need for regular battery handling and swapping, allowing for more efficient charging and production. The MEC500 offers a 500 kW capability at a range of 300-1,000 V and up to 700 Amps. The adjustable output can be used to trickle charge or quickly charge the R1700 XE – with a single unit delivering a full charge to the R1700 XE in less than 30 minutes or two units in parallel achieving this in less than 20 minutes.

The R1700 XE in Sudbury, working alongside either one or two MEC500s, has clocked more than 11,000 machine hours. During initial test operations, the customer indicated a circa-320,000 kg reduction of CO2 emissions and displayed a more than 10% improvement in speed on grade.

According to Glencore, the R1700 XEs Caterpillar has put out in the field to date have also exhibited lower energy consumption compared with the diesel equivalent – more than 10%, in fact

Speaking at The Electric Mine 2023 conference in Tucson, Arizona, in May, David Rea, VP and General Manager, Caterpillar Inc (pictured at the top), said of the machine: “We’re delivering for our customers improvements in safety, cost, productivity and sustainability.”

Machine availability in these field-follow trials has been helped by an up to 150-minute run time between charges and an average 18.5-minute charge rate with the dual chargers.

According to Glencore, the machines Caterpillar has put out in the field to date have also exhibited lower energy consumption compared with the diesel equivalent – more than 10%, in fact. And, while trials to date have all been in manual mode, Rea said the R1700 XE units in the field could be equipped for teleremote operation and were also “factory ready” for Caterpillar’s fully autonomous loading system.

Operations are being facilitated thanks to some “800 channels of machine data” flowing off the machines to those supporting the loaders, Rea said. This has allowed personnel from Caterpillar and Cat dealers to diagnose problems in the field and optimise the machine’s charging and operating strategies.

While Caterpillar continues to clock up the operating machine hours for its R1700 XE, it is also in the process of developing its first battery-electric truck.

“We’re not just stopping at the loader; we also need a truck to go alongside that loader,” Rea said in Tucson, adding that this would be a three-pass match for the R1700 XE – therefore, a truck boasting at least a 45-t payload.

Rea confirmed the new truck would be charged by the MEC500, but the company was working on both a fast charge and battery swap option for the vehicle.

“Our alliance with Newmont is leading the development of this truck,” Rea said, referencing a strategic alliance Caterpillar and Newmont announced in 2021 to deliver “26 first-of-a-kind battery-electric autonomous vehicles in both an underground and open pit operation by 2027”.

This agreement involves the introduction of these vehicles to Cripple Creek and Victor (open pit) and Tanami (underground) in USA and Australia, respectively.

“The first deployment of this [battery-electric] truck will be at Newmont Tanami,” Rea confirmed at the event.

Caterpillar lowers UG mining costs, downtime with release of bolt-together LHD buckets

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Caterpillar has launched “bolt-together” buckets for underground loaders that, it says, offer the same strength and durability as standard buckets, but reduce time and costs associated with transportation, assembly and rework procedures for underground mining.

The new bolt-together bucket does not require skilled maintenance operators for underground welding, resulting in a reduced safety risk, according to the company. On top of that, the design allows for efficient underground assembly, where the loader is working, to cut replacement time and lead to lower machine downtime and higher productivity.

“Optimised for moving abrasive underground materials, the new bucket design includes improved material thickness for increased strength and a rigid bucket assembly to aid in easier edge installation and removal,” Caterpillar says. “High-grade, 400 BHN materials used for bucket assembly components and high-grade wear protection ground engagement tools (GET) on the removeable shroud assembly deliver a long bucket service life for better cost saving and productivity. With proper GET selection and management, the Cat bolt-together bucket is designed to last through the first machine overhaul period to reduce replacement downtime.”

The buckets are modular in design for quick installation and removal, with the Cat GET available for the new bolt-together buckets including three edge options – bolt-on half arrow, modular weld-on and Durilock – shroud segments, and rock guard to deliver reduced downtime and accelerated repair.

The new bolt-together bucket is available in a range of capacities from 5.3-7.5 cu.m, specially designed for the Cat R1600H, R1700G, R1700 and R1700 XE LHD models. They are built in the same factory and go through the same stringent quality control process as Cat equipment and are supported by the global Cat dealer network, the company says.

Cat to use NMG’s Matawinie graphite mine as ‘zero-emission machine’ testbed

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Nouveau Monde Graphite and Caterpillar have signed an agreement pursuant to which Caterpillar will develop, test and produce Cat® “zero-emission machines” for the Matawinie graphite mine, in Quebec, Canada, with a view to becoming the exclusive supplier of an all-electric mining fleet for deployment at the mine by 2028.

Looking to accelerate and tailor the equipment development, Caterpillar will engage with Nouveau Monde’s team to incorporate “voice of customer” throughout the development, and for testing of the zero-emission fleet and infrastructure prior to commercial production, the companies said.

To this point, Caterpillar has only disclosed the development of a battery-electric 15 t LHD, the R1700 XE, however it came to light just over a year ago that the OEM was working on a separate project called ‘Project Verde’.

Brian Weller, Chief Engineer, Surface Mining & Technology, Caterpillar Inc, previously stated on Project Verde: “Caterpillar has responded to customers by launching a project that is focused on energy and emissions reduction, and helping customers decrease their carbon footprints through machinery and power solutions that contribute to lower greenhouse gas.”

Speaking about the latest agreement between NMG and Cat, Arne H Frandsen, Chairman of Nouveau Monde, commented: “I recall our first meeting with Caterpillar some two years ago, outlining our vision of a zero-emission mine in Québec. Our commitment to this vision has taken us to this very important moment, not only for Nouveau Monde, but for the global mining industry as a whole. Today, alongside Caterpillar, which in my opinion is the most trusted and reputable supplier of heavy-mining equipment worldwide, we can bring the zero-emission machines vision into reality.

“I think it is remarkable that Nouveau Monde, as a representative for the new style green resources industry, is part of spearheading the electrification of the industry, by collaborating with Caterpillar.”

Eric Desaulniers, Founder, President and CEO of Nouveau Monde, added: “We are proud to be a driving force for our peers as we strive to electrify our operations to meet our carbon neutrality commitments while maintaining the productivity and efficiency standards of our mining operations. Even more gratifying and important to our corporate mission is that our project can serve as a springboard for the future of the mining industry by collaborating with Caterpillar on these cutting-edge technologies.”

Denise Johnson, Caterpillar Group President, said: “The collaboration between Caterpillar and Nouveau Monde marks an important milestone in the mining industry. Through integrated technology, machines and services, the entire Caterpillar team is proud to support Nouveau Monde as they work towards constructing and establishing their first zero-emission mine.”

In November last year, NMG issued an “international call for pre-qualification” related to the fleet and charging infrastructure at Matawinie following work by the company’s International Task Force Committee. This work had allowed Nouveau Monde to explore “technologies, best practices and operational parameters to bring its vision to life in a cost-effective and technologically advanced way”.

As part of this pre-qualification program, companies were able to submit detailed proposals and performance specifications from their production equipment solutions between November 30 and January 30, 2021.

In the 2018 definitive feasibility study on Matawinie, Medatech Engineering Services Ltd and ABB Inc – both companies in Nouveau Monde’s taskforce committee – came up with the fleet outline at Matawinie.

“The mine will be using an all-electric, zero-emission mine fleet, consisting of electric battery-driven 36.3-t mining trucks, battery-driven front-end loaders, cable reel excavators and bulldozers, and battery-driven service vehicles,” the report read.

The mine, scheduled to produce 100,000 t/y of graphite concentrate, was also expected to use an electric in-pit mobile crusher and overland conveyor system to feed crushed material to the plant.

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.