Japanese engineering and electronics firm Hitachi and Swedish-Swiss tech company ABB recently completed the initial prototype of their planned all-electric dump truck for extreme mining operations.
Hitachi EH4000 AC3 Battery prototype
ABB and Hitachi’s engineers visualized a “trolley-like” overhead power connection to enable the weighed-down trucks to go in and out of the mine, as per the press release. They also utilized the truck’s own mass to generate energy from regenerative braking while traveling back down.
The engineers’ strategy to develop a combined trolley/gravity energy solution will substantially aid the electric trucks in employing megawatts’ worth of work even without MWh batteries.
It leveraged ABB’s innovative battery tech and highly energy-efficient DC/DC converters. The prototype utilized a new onboard electric system that pulls electricity from a trolley supply, directly providing power to the motor. Its regenerative braking system also charges the battery when driving downhill, lowering the charging load when the electric truck is attached to the trolley.
This solution allows the electric truck to operate continuously without charging breaks and retain high productivity. Its sophisticated battery energy and thermal management system also improves the battery’s life span.
“We are delighted to see our collaboration with Hitachi Construction Machinery reaching this crucial step. The project is not only helping to tackle the issues involved in dump truck electrification but is also contributing to enabling a low-carbon world through the reduction of greenhouse gas emissions. We look forward to seeing the prototype prove its capability in the Zambian copper-gold mine.”
Fabiana Cavalcante, Head of Mobile e-Power, ABB Traction
Final testing
In hindsight, Hitachi initially announced its plans to electrify its fleet of 2500 horsepower EH4000 244-ton diesel mining trucks in 2021 to meet the surging demand for sustainable dump trucks in this particular sector.
The prototype already passed Hitachi’s initial, in-factory testing circuit. The company also dispatched the prototype to the Kansanshi copper-gold mine in Africa last week.
The partners plan to complete the prototype’s demo and final testing in the African mine. They also expect to launch a new build spec later this year.
Benefits
ABB’s move to transition from diesel-powered dump trucks to pure electric ones will significantly aid the company in cutting carbon emissions across its mining operations.
The adoption of electric mining trucks also eliminates the need for extensive ventilation systems in underground mines to control excessive heat and exhaust fumes from diesel engines.
Electric mining trucks also enable lower sound and vibration than their diesel-powered counterparts, making them safer for underground mining operations. More notably, electric mining trucks lower maintenance costs as they have fewer moving parts than diesel trucks.
