Catch a glimpse of Caterpillar’s future in mining at MINExpo 2024

The Caterpillar MINExpo 2024 booth will show visitors what Cat says is the mine site of the future. The exhibit will feature technologies, advancements in the energy transition, and customized solutions designed to increase efficiency, safety, and profitability.

"Caterpillar's legacy is to deliver an exceptional experience at every job site through customer-focused solutions and services," says Denise Johnson, Caterpillar Resource Industries' group president. "As our exhibit shows, together with our customers, we are mining better, smarter and safer. And this is just the beginning of our closer-than-ever-before collaborations with customers."

Caterpillar's energy transition

The 372-tonne (410-ton) Cat 798 AC mining truck has the highest standard payload in its class. The 798 AC is configured for autonomous haulage with Cat MineStar Command for hauling.

"We believe systems, such as Command for hauling, are essential to optimize mine site performance, both with our current product line and as we introduce new offerings like our battery electric solutions," comments Marc Cameron, senior vice president of Caterpillar Resource Industries. "Autonomous technology will help monitor and orchestrate the complex balance of onboard energy, available charging assets and production targets to achieve the lowest operating costs."

Caterpillar's underground Cat R1700 XE load-haul-dump (LHD) loader features battery-electric propulsion that produces zero exhaust emissions and generates less heat than a reciprocating engine-powered model. The Cat R2900 XE LHD provides a high-efficiency switch reluctance electric drive system that meets the mining industry's needs for bigger payloads, faster loading, and lower emissions. The 12.2-metre (40-foot) PGS 1260 HD energy storage system (ESS) module offers energy storage for charging battery electric machines. The MEC500 provides mobile equipment charging for the underground mining industry.

"Since MINExpo 2021, our teams have made incredible progress with the development of our electric technology and supporting solutions," comments Brian Weller, vice president of electrification at Caterpillar Resource Industries. "We have been working side-by-side with select customers to accelerate the deployment of Caterpillar's first battery-electric haul trucks. These machines will soon be operating at our customers' sites where they will be tested and validated across a variety of applications."

Optimizing mining processes through technology

Caterpillar provides scalable building block technology packages to meet the needs of mining operations. Visitors to Caterpillar's exhibit will be able to experience interactive engagement with MineStar fleet management solutions for surface and underground operations at the exhibit's conversation stations. A third station allows attendees to explore precision mining solutions dedicated to site optimization.

Every piece of equipment that will be on the show floor utilizes various levels of technology. In addition to the ultra-class 798 AC featuring Command for hauling, the R2900 XE LHD will be equipped with Cat MineStar Command for underground that enables remote machine operation. The diesel-electric LHD will also feature MineStar Detect for underground to safeguard against unintended interactions between personnel and assets and enhance operator alertness. Optional technologies available for the Cat 995 wheel loader include Payload Overload Prevention, Operator Assist, Operator Coaching, and Terrain for loading.

Caterpillar is set to launch two new technology offerings to the MineStar ecosystem at the show:

• Delivering the next layer of safety, the Collision Awareness System (CAS) is a site-wide solution that enhances situational awareness by warning operators of potential machine interactions before they happen. CAS will be highlighted on the 995 and 798.
• A new office application for Terrain Payload Management expands the payload tracking technology to Cat Electric Rope Shovels and Draglines.

Attendees will be able to get into the cab of the Cat 7495 electric rope shovel and the 6060  hydraulic mining shovel through a virtual reality experience. Showcasing the capabilities of Cat Command technology, two remote operating stations will give visitors the chance to operate a dozer or rotary blasthole drill located hundreds of miles away from the Caterpillar exhibit. A third station will offer simulations of Cat Command for underground.

"Customers will experience our latest technology innovations and autonomous developments throughout the Caterpillar show floor at MINExpo," says Sean McGinnis, vice president and general manager of technology and global sales support for Caterpillar. "Mine site automation makes significant impacts in operations and not just with autonomous haulage."

Aftersales support

The in-booth Caterpillar service bay and nearby displays will highlight options available to mining customers for maintaining the machinery and meeting production targets. Trackpad displays for rope and hydraulic shovels and dozers will show offerings designed to maximize undercarriage life.

Attendees will be able to step inside a service van, which makes customized hoses and couplings on-site. The van offers the capability of quickly returning a machine to service by making the necessary size and length of the hose for repair. 

Conversation stations allow team members to engage with customers on a range of topics including repair options, parts and component remanufacturing, machine rebuilds, various truck body options, bucket choices, and more. Also, a range of 3D printed parts will be displayed along with multiple engine exhibits, including the Cat C32 Reman, C32 core, upgraded 3512 E, and C175 cutaway.

Spanning machines to technology to services, Cat Job Site Solutions offers customized, scalable solutions. Team members will meet with attendees to demonstrate how working with the dealer Cat Job Site Solutions provides a strategy with intended outcomes and an action plan that meets the challenges of the mine site.

The iron

The 798 AC features an updated cab for operating at high altitudes plus a three-piece window design to improve visibility. Truck messaging will convey the number of ways mines can lower GHG emissions through alternative fuel options and electric drive systems. Additionally, video stories will show how customer rebuild efforts are driving sustainability at mines, while scale truck bodies will cover the range of options Cat trucks offer for payload and hauling program efficiency.

he recently introduced Cat 995 will anchor the "loading better" display. The loader is equipped with a 27.5 cubic metre (36 cubic yard) and Cat Advansys 230 GET system. Built to the same size as the 994K, the 995 features a higher-rated payload and:

• Demonstrates 21 percent higher efficiency and 24 percent more production than the 994K in equal operating mode.
• Enhance Eco Mode, demonstrates up to a 30 percent increase in efficiency and an 11 percent reduction in hourly fuel consumption versus the 944K in throttle lock mode

For the underground space, the displayed diesel electric R2900 XE LHD features an lift arm and component geometry plus load-sensing hydraulics to improve breakout force. Compared to its predecessor, the R2900 XE LHD also delivers:

• 52 percent quicker acceleration 
• 7 percent higher speed on grade 
• Up to a 20 percent increase in productivity

Beyond zero-exhaust emissions and fast charging, the battery electric R1700 XE LHD has a 15-tonne (33,069-pound) payload, 18 kph (11.2 mph) fully loaded top speed and up to 2.5 hours of run time between charges. Five bucket size options offer capacities ranging from 5.7 to 7.5 cubic metres (7.5 to 9.8 cubic yards).

The Cat 24 motor grader will represent the range of haul road maintenance machines, including the 14, 16, and 18 models. The C24's high-performance circle (HPC) provides a 16,000-hour service life and eliminates frequent inspection, wear strip replacement, and circle shoe adjustments. It will be displayed with Caterpillar's 8.5-metre (28-foot) moldboard option – 16 percent longer than the standard blade – to enhance safety at larger mines by reducing the amount of time spent in the middle lane to clear the windrow.

The exhibited MD6310 rotary drill shares a common platform, parts, components, and technologies across the product line. Ideal for high-production drilling on 12- and 15-metre (39.4- and 49.2-foot) bench heights, it is capable of drilling up to 311-millimetre (12.25-inch) hole diameters and offers up to 30-degree angle hole drilling for cast blasting. With building-block technologies through semi-autonomous operation, the MD6310 was one key contributing factor to global mining services provider, Thiess, surpassing the 1 million metres autonomously drilled milestone using Cat drills.