Check out this behind the scenes look at the development of Scania's autonomous mining hauler concept. See the engineers describe each stage of the process, and then watch the first test drive.
Cat mining truck offers performance and operating costs, meets strictest US emissions standards
The Cat 794 AC Mining Truck is now available equipped to meet U.S. EPA Tier 4 Final exhaust emissions standards. In field testing, the Tier 4 pilot trucks matched the superior performance and productivity of the Tier 2 equivalent versions of the 794 AC. The Tier 4 trucks also delivered lower operating costs by reducing diesel fuel consumption.
The 320-ton-class (290-tonne-class) 794 AC features the Cat C175-16 diesel engine. The Tier 4 truck is equipped with an exhaust aftertreatment system using a selective catalytic reduction system (SCR), which uses diesel exhaust fluid to reduce emissions of nitrogen oxides. Caterpillar selected the SCR solution, because it provides the most robust and reliable Tier 4 Final emissions compliance without sacrificing engine performance.
The modular SCR design, adopted from other Cat production machines, minimizes new content and design changes to the field-proven 794 AC. Designed for easy serviceability with readily accessible components, the aftertreatment system is aligned with truck preventive maintenance intervals to maintain high availability. This Cat emissions platform is proven through more than 20 million operating hours in the field.
Caterpillar is using the same exhaust aftertreatment platform in the process to gain EU Stage V certification of the 794 AC. The Stage V certification process is currently in progress.
Comprehensive field testing
The Tier 4 Final 794 AC design successfully completed field validation, with all the pilot trucks exceeding requirements. The machines integrated and worked seamlessly in each mine ecosystem, and customers reported excellent performance and reliability. The trucks were put to the test in a variety of applications, including hot and cold ambient temperatures, uphill hauls and flat hauls.
In a copper mine, Caterpillar conducted an on-site performance study of the 794 AC Tier 4 Final trucks and measured no loss in performance or productivity compared to the Tier 2 equivalent 794 AC trucks. In addition, the machines demonstrated up to 5.6 percent less diesel fuel burn over the haul cycle.
The 794 AC Tier 4 Final trucks have accumulated more than 10,000 hours of operating time and continue to deliver reliable and productive performance in multiple North American mines. For more information about Cat large mining trucks, contact the regional Cat dealer or go to: www.cat.com
More from Mining
Scania is adding to its autonomous family with the AXL, a fully autonomous concept truck, without a cab.
Canada is moving forward with a long-term plan to clean up contaminated sites in the North.
A U.S.-based minerals company recently began using an ALLU Transformer M 3-20 material processing attachment in its Middleton, Tennessee, montmorillonite clay mine. The company purchased the mine-duty M-Series screener-crusher attachment from ALLU to use with its Hitachi 650 excavator in order to crush mined clay down to 4-in-minus and simultaneously load haul trucks. The ALLU Transformer is allowing the facility to mine land it could not previously mine, as well as process clay from boulders. The ultimate goal is to eliminate the primary crusher in the plant. The processed material is used for production of cat litter and absorbent clay for oils.
Michelin North America has introduced a new size of the MICHELIN XDR 3 surface-mine haul tire – 37.00R57. Addressing the productivity and endurance issues found in today's surface mines, the XDR3 was developed for a range of rigid dump trucks with payload capacity of up to 400 tons. Now available in seven sizes, this new XDR3 size expands the MICHELIN XDR3 portfolio, replacing the MICHELIN XDR2 line.
Caterpillar has developed a propel drive system upgrade for Cat 7495 and 7495 HF Electric Rope Shovels. The upgrade reconfigures the crawler undercarriage to allow drive shaft and tumbler replacement from the outboard side, which improves access and decreases downtime by days. Improved component design extends durability and increases component life to reduce costs even further.
On June 17, 2019, BAUER Maschinen GmbH, together with a JV partner, successfully completed the first 228 m cutter bulk sample on the FalCon project in Canada. This depth has never been reached by a trench cutter in any commercial application worldwide before and proves that Bauer cutter technology can not only be used in specialist foundation engineering, but is also suitable for the exploration and mining industry. The FalCon project of Rio Tinto Exploration Canada Inc. ("Rio Tinto") and Star Diamond Corporation aims to prove the commercial viability of the Fort a la Corne kimberlite fields in Saskatchewan in Canada. Due to the low grade of the kimberlites, Rio Tinto decided to use Bauer trench cutter technology to provide large-volume, high quality kimberlite samples for the final evaluation of the project in regards to diamond content and recovered diamond quality.
Komatsu Ltd., through its wholly owned subsidiary in Australia, has agreed to acquire global mining technology and workforce optimization firm Immersive Technologies, which specializes in increasing mine profitability by optimizing the safety and productivity of equipment operators, on the condition that all necessary procedures for closing are completed.
Rolls-Royce Power Systems and XCMG, a multinational heavy machinery manufacturing company based in Jiangsu, China, have formed a strategic cooperation alliance to further develop the Chinese domestic and export mining equipment markets, providing optimized solutions to customers worldwide.
Terrapure Environmental and Vale Canada received an Environmental Leader Award for Project of the Year for their new, sustainable option for managing biosolids during winter months, when farmland application is prohibited and storage is complicated. Instead of incinerating or landfilling nutrient-rich organics, Terrapure worked with Vale to develop a program to apply treated biosolids to its Central Tailings Area for reclamation and revegetation. It was the first project of its kind in Ontario.
Rio Tinto recently signed an agreement with Caterpillar to supply and support mining machines, automation and enterprise technology systems for the new Koodaideri iron ore mine in Western Australia. Under the agreement, Rio Tinto and Caterpillar will work together in creating an automated mine operation that makes best use of data analytics and integration to enhance safety, optimize production, boost mining machine utilization and lower costs.
Hitachi has introduced the EX1200-7 excavator, which the company says will provide increased efficiency, reliability and durability for customers. The excavator, which is available in North and South America, is the third machine in Hitachi's new EX-7 series lineup, following the recent launch of the EX2600-7 and EX5600-7.
Epiroc's fifth generation Rig Control System for Pit Viper blasthole rigs takes next step toward fully autonomous mining
Epiroc has introduced the fifth generation of Rig Control System (RCS). Epiroc says that the RCS 5 is the next step toward fully autonomous mining.
After six years of development and testing, Michelin North America, Inc., introduced the MICHELIN XDR 3 surface-mine haul tire in size 27.00R49. Addressing the productivity and endurance issues found in today's surface mines, the XDR3 — developed for a range of rigid dump trucks with payload capacity up to 400 tons — is designed with new compounds and a revolutionary new tread pattern that helps provide exceptional tire life. The use of corrosion-isolating cables in the tire architecture is a significant upgrade in situations where this equipment is always moving as it is operated for up to 23 hours-per-day in extreme terrain.
With a strong expertise in electrical machines, Liebherr presented a duo of machines fitted to meet the requirements of the mines of the future at Bauma 2019: the R 9200 E and the T 236. When working together, the R 9200 E and T 236 reduce the environmental footprint of any mining operation. The R 9200 E in face shovel configuration can easily fill a T 236 in five passes, a perfect combination for scalable productivity.
Caterpillar has chosen to make the new R1700 Underground Mining Loader its first battery electric LHD platform. The design of the new battery electric Cat R1700 XE will use advanced technology for lithium-ion batteries and fast, onboard charging to advance safety and promote high production.
SMS Equipment deploys largest Komatsu autonomous truck in the world into commercial operations in Canada
This month, SMS Equipment deployed the Komatsu 980E-4AT - the largest Komatsu truck in commercial operations in the world - into production in Canada. The Komatsu 980E-4AT is modeled after the proven work horse 930E series. This 400-ton capacity truck has many of the same attributes, such as a simple and reliable hydraulic system design and proven GE drive system. Fuel efficiency is maximized due to optimized air handling with two stage turbocharging and the truck features a Cummins 3500 HP SSDA18V170 engine.
"Hauling is one of the most cost-intensive components of a typical mining or quarrying operation. In addition to fuel and labor, there's plenty of maintenance involved too. To ensure cost efficiency, a haul truck should carry as much payload as possible on every round. At Metso, we set out to tackle this challenge and designed a truck body that requires minimal maintenance while maximizing payload. The result is a lower operating cost per hauled ton," says Lars Skoog, Vice President, Mining Wear Lining & Screening, Metso.
Komatsu and MineWare are officially launching their first factory-fitted payload management system, Argus PLM, at bauma 2019.
Hitachi is introducing the EX2600-7 and EX5600-7 mining excavators, which deliver enhanced efficiency, reliability and durability, to North and South America. These models are part of the new EX-7 Series line of mining excavators, which highlights Hitachi's focus on continuous improvement through fuel-efficiency technologies and advanced engineering.
Caterpillar recently introduced a new wet disk snubber upgrade for dipper doors on its 7495 Series electric rope shovels. The oil-filled snubber is maintenance and adjustment free for its 12,000-hour life before rebuild, which aligns with dipper service life.
The Cat 797F large mining truck is now available in a fuel-efficient configuration that meets U.S. EPA Tier 4 Final emissions standards. Through more than 16,000 hours of successful pilot machine operation and 100,000 hours of production truck operation in Tier 4 configuration, the system has proven its ability to deliver strong performance and greater fuel efficiency compared to the Tier 2 797F in most applications.
Accella Tyre Fill Systems has unveiled a new, vibrant color for its industry-leading TLC Tyre and Rim Protection that will deliver greater safety and functionality to field operators and drivers of Off-the-Road (OTR) vehicles working in mining and other related industries. TLC is a protective coating that conditions the tyre wheel and maintains cooler tyre operating temperatures, which helps to eliminate premature failures caused by rust and other deterioration. Accella's most recent TLC Tyre and Rim Protection formula—to be showcased at this week's 64th Annual Off-the-Road (OTR) Conference in Tampa, Florida, held February 20-23 — features a bright, highly visible "Neon Red" that will enable earlier, safer detection of dangerous tyre and rim leaks.
ALLU Group will be exhibiting and demonstrating equipment from its Transformer, Processor and other equipment ranges at bauma 2019. As well as established and proven equipment, ALLU will be unveiling its latest developments, and launching new and exciting solutions.
Terex Washing Systems (TWS) has announced further investment in their North American sales and operational teams that will enable customers to engage directly with TWS experts to discuss their requirements and collaborate in the development of innovative customer-specific solutions.
Lars Engström, President of Sandvik Mining and Rock Technology, will leave Sandvik during 2019 after the appointment of a successor.
Sandvik has acquired privately owned Artisan Vehicle Systems, manufacturer of battery powered underground mining equipment, based in Camarillo, California, USA. The core technology is battery packs, electric motors, power electronics, software and control systems. Artisan's underground mining loaders and trucks are designed with these high-powered, highly reliable and field proven battery electric powertrains. Artisan is the market leader with most battery electric vehicles currently operating in underground mining.
Komatsu America Corp. has announced the FrontRunner Autonomous Haulage System (AHS) has qualified to operate on private long-term evolution (LTE) mobile broadband technology. This is the mining industry's first AHS enabled to run on private LTE in commercial operations, making way for ultra-high system availability and reliability while adhering to Komatsu's renowned safety standards.
BossTek has updated its family of self-powered dust suppression equipment with Tier IV Final-compliant generators, ensuring compliance in all 50 states and Canada. BossTek made the announcement with the debut of the new DustBoss DB-60 Fusion, a field-proven suppression system driven by a high-reliability 25 HP electric motor and paired with a gen set powered by a heavy-duty 4-cycle indirect injection diesel engine. Designed, engineered and assembled in the USA, the generator features a dual-containment fuel cell, heavy gauge lockable enclosure and oversized brushless alternator for easy starting.
Sustainability is a trending topic and that extends to mining as well. The focus extends well beyond the areas of energy consumption and the use of resources: All industries are currently searching for alternative, low-priced and environmentally friendly raw materials and energy sources. Global discussions and technology transfers are the key factors in efforts to successfully encourage sustainability in mining. bauma 2019 will serve as the perfect platform for the focal point of mining.
- Mining to be one of the focal topics of bauma 2019
- Key players to highlight potential and showcase technologies
- Mining, an issue of the future: bauma 2019 to bring together all key players
This April 8 to 14, Liebherr will give attendees of Bauma 2019 a unique chance to experience its latest innovations first-hand, ranging from construction machines to material handling, mining and components. Visitors can look forward to seeing many new technologies and other practical innovations at Liebherr's 14,000 m2 outdoor stand (809-813) and its indoor stand in hall A4, number 326.
Sulzer Mixpac USA, Inc. offers the MIXPAC MixCoat cartridge-based system for a variety of mining applications, including applying abrasion-resistant coatings on pipes and transportation equipment, bores, walkways, and conveyor equipment.
Haver & Boecker offers a conversion kit for older model H-Class vibrating screens. H-Class models V-50 and older can be updated to the current V-85 H-Class model to reduce operating noise to levels below 100 dBA, gain better control over the running frequency and decrease maintenance costs by as much as 50 percent.
XCMG, a global leading construction machinery manufacturer, unveiled ambitious new initiatives, including the establishment of a high-end innovation centre for construction machinery and core components, and a strategic alliance to promote technological development at bauma China 2018, the premier gathering for the Asian construction machinery industry. The company also showcased 79 of its latest products and 41 pieces/sets of core components at the event.
From November 27 to 30, sister companies Volvo Construction Equipment (Volvo CE), Volvo Penta, Volvo Financial Services (VFS) and SDLG are revealing a star lineup of construction equipment and technologies designed to handle the region's rapid infrastructure growth in the most sustainable way possible. Under the theme of ‘Building Tomorrow,' the stand in the Shanghai New International Expo Center (SNIEC) is showcasing to an audience of 200,000 visitors how it has the machines, services and network to adapt to a dynamically changing world.
Dana Incorporated has introduced the Spicer® Electrified™ with TM4® eSH81 e-Hub Drive, a fully integrated electro-mechanical system for heavy-duty mining and construction applications that leverages Dana's leading portfolio of vehicle electrification technologies.
The solution for Brønnøy Kalk AS consists of limestone being transported by six autonomous Volvo FH trucks on a five kilometer stretch through tunnels between the mine itself and the crusher. Tests of this solution have been carried out successfully and will continue throughout 2018 to become fully operational by the end of 2019.
Komatsu America Corp. has announced that the FrontRunner Autonomous Haulage System (AHS) has achieved the unprecedented milestone of more than two billion tons of surface material moved autonomously. The FrontRunner system has now hauled more than all other commercial mining autonomous haulage systems combined.
Cat mining trucks working within MineStar Command for hauling recently reached a milestone of one billion tonnes hauled. Caterpillar deployed the first six commercial autonomous trucks in 2013, and the fleet has now grown to more than 150 with six different mining companies operating Command for hauling in iron ore, copper and oil sands.
Battery-electric equipment allows a mine to unlock a number of benefits: improved health and safety, reduced greenhouse gas emissions and decreased operating costs. "We are leading the charge towards sustainability in mining through battery electric, zero-emission equipment," says Stevan Topalovic, Vice President Marketing Underground Rock Excavation division at Epiroc. "At Power Change Days, we proudly present our second generation electric battery 14 and 18-tonne loaders, our 42-tonne truck and our mid-sized drilling family including face drilling, production drilling and rock reinforcement rigs."