Komatsu’s FrontRunner autonomous haulage system hit a series of major milestones in
July 2024. (Photo: Komatsu)

This means that 2024, thus far, has seen a veritable smorgasbord of new machines, technologies, partnerships and deliveries presented to the market. From battery electric firsts and autonomous haulage milestones to hydrogen breakthroughs and next-gen efficiency improvements. If you’re looking to invest in a fleet, it’s a great time to be in the market. And you can bet there’ll be more to come when the lights go up in Las Vegas, USA, on September 24th. Here are some of the most exciting developments to date.

FrontRunner’s Autonomous Achievements
In July 2024, Komatsu announced it had hit a series of milestones with its FrontRunner autonomous haulage system (AHS). It’s now been 16 years since FrontRunner — the first commercially available AHS — was introduced to the market, and Komatsu has since commissioned more than 750 autonomous haul trucks globally. Customers have hauled more than 10 billion metric tons (mt) of material and are adding to that at a rate of more than 6 million mt/d. Additionally, 10 Komatsu autonomous trucks have achieved a benchmark of 100,000 autonomous hours each, which is a first in the mining industry.

“The value customers create from implementing a Komatsu AHS is tangible in terms of promoting improved safety practices, productivity and cost reduction,” the company said in its statement. “FrontRunner achieves these benefits through its predictable fleet management, dependable production, and enhanced component life by leveraging Komatsu’s people, process, and technological expertise.”

The FrontRunner team will no doubt have a strong presence at MINExpo, and Komatsu said that electrification will be another big focus for it at the event. Featured products include the PC4000- 11E electric drive hydraulic mining excavator, which offers a digging force comparable to high-performance diesel machines but with zero emissions.

The 930E PADT haul truck will also be on show. Built on Komatsu’s modular power agnostic platform that will allow operators to transition from diesel to battery, or even hydrogen fuel cell power sources, Komatsu said the 930E PADT also supports dynamic charging and trolley assist options to further reduce fuel consumption and emissions.

Komatsu Highlights Innovative Power Options
In addition, Komatsu will showcase its collaborations with other organizations, including General Motors (GM). The companies first announced their intention to co-develop a hydrogen fuel cell power module for Komatsu’s 930E electric drive mining truck in December 2023. “Lightweight and quick to refuel, hydrogen fuel cells are ideal for electrifying applications traditionally powered by diesel engines,” Komatsu said in its press release. “Hydrogen provides an effective method to package large quantities of energy onboard the vehicle, without compromising payload carrying capacity.”

Fuel cells offer a zero-greenhouse gas (GHG) emission option for ultra- class mine trucks, like the 930E, which has a nominal payload of 320-t. These vehicles typically operate at a single mine throughout their life, which simplifies the challenges of sizing and deploying hydrogen refueling infrastructure to service the vehicle fleet. GM has been conducting fuel cell research and product development for more than 50 years and is one of the only companies with advanced, homegrown technology platforms for both lithium-ion batteries and hydrogen fuel cells. The companies stated that fuel cell-powered mining trucks can provide an additional pathway for decarbonization beyond battery-trolley or battery-static charging solutions, without the need for additional charging infrastructure.

Liebherr and Fortescue are currently validating an AHS at a mine site in Western Australia.
(Photo: Liebherr)

“Based on the successful implementation at Lumwana [Barrick’s copper mining operation in Zambia], we chose to upgrade our fleet with 62 new Komatsu trucks,” said Peter Richardson, executive managing director of NGM. “Komatsu has provided us with tremendous regional support and their team in Elko has been instrumental in helping us maintain our fleet with parts and component rebuilds for our trucks, a wheel motor upgrade program, and maintenance and support for the P&H shovels that are part of our operations.”

To further support the NGM fleet and other miners in the region, Komatsu has built a 50,000 square-foot (ft2) warehouse adjacent to its Elko service center to expand local parts support. The company’s 189,000-ft2 Elko service center supports mining and construction equipment including haul trucks, hydraulic shovels, electric rope shovels and more.

Caterpillar Showcases 798 AC and 995 Loader
At the center of Caterpillar’s MINExpo booth will be the 410-mt Cat 798 AC mining truck which is configured for autonomous haulage with Cat MineStar Command for hauling. The 798 AC features a refreshed cab for operating at high altitudes, plus a three-piece window design to improve visibility. Truck messaging will focus on ways that mines can lower GHG emissions today through alternative fuel options and electric drive systems.

The recently introduced Cat 995 wheel loader will also be on show. This next generation machine will be equipped with a 36-yd3 (27.5-m3) bucket and Cat Advansys 230 ground engaging tool (GET) system. Caterpillar said that, as the wheel loader market evolves, machine design and integration of technology are driving loader productivity and efficiency higher than yesterday’s models. The Cat 995 is the same size as its predecessor, the 994K. However, it offers a higher rated payload and bucket capacity range, so can load more material in fewer passes and burn less fuel.

For example, when loading Cat 785, 789 and 793 trucks, the 995 offers up to 33% increased production and efficiency. Specifically, when loading a 265-t truck, the 995 delivers 21% higher efficiency and 24% more production in equal operation mode thanks to the higher rated payload and 6% increase in hydraulic force. “Newer technologies introduced with today’s wheel loaders not only increase productivity but can also assist in reducing stresses on machine components to increase longevity,” the company said in a recent story. “In the case of the 995, new tire slip prevention and tire set features help to improve tire life, productivity and efficiency through automating the most difficult parts of the digging cycle.”

Caterpillar’s 798 truck will have pride of place at the company’s MINExpo 2024 booth.
(Photo: Caterpillar)

The 995’s EU Stage V / U.S. EPA Tier 4 Final compliant engine offers idle shutdown as well as on-demand throttle and enhanced economy modes. Idle shutdown automatically shuts down the machine when the loader is not utilized for a preselected time length, saving fuel and wear and tear. On-demand throttle allows operators to maintain normal operation with the left pedal and implements, while the machine manages engine speed. Further reducing fuel consumption and CO2 emissions, enhanced economy mode offers up to 8% greater efficiency and up to 13% lower fuel consumption per hour compared to horsepower plus mode.

“Comparing it to the 994K’s throttle lock operating mode, enhanced economy mode has demonstrated a 30% increase in efficiency and an 11% reduction in hourly fuel consumption, which translates to 23% less CO2 per unit of material moved,” said Caterpillar.

Pump control of the hydraulic system has also been optimized to boost efficiency on the 995 with its positive flow control hydraulic system through concurrent pump and valve control. Hydraulic oil flow is proportionate to implement lever movement, and fast, productive cycles are enabled by four electronically controlled, variable piston pumps. The system increases bucket feel and control and delivers consistent performance and efficiency with lower system heat.

Caterpillar’s Next Gen Trucks
The Cat 785, 789 and 793 (150 to 260-t productivity class) have also been upgraded recently, although these models won’t be at MINExpo. The next generation designs are built on an advanced common platform with common electronic architecture, cab and controls. All models are direct mechanical drive and boast the latest electronically controlled transmission with Advanced Power Electronic Control Strategy (APECS). Caterpillar said the transmission offers smooth gear shifts and delivers productivity and efficiency improvements. Forward momentum and torque are maintained while shifting with optimum gear selection resulting in faster acceleration.

There are more than 30 new or improved features with the next-generation truck design. The cab is built for operator comfort and efficiency. It lowers noise levels and accommodates a wider range of operators. Seats offer more legroom, and the overall travel and adjustability have increased with seat height and dampening adjustments, in addition to heating and cooling functions.

The first of 30 new XCMG electric drive trucks arrive in Africa. (Photo: XCMG)

The Truck Payload Measurement System II (TPMS II) provides improved payload measurement accuracy. “TPMS II measurements are taken under the loading tool and throughout the haul, calculating load placement bias to enhance payload accuracy and cut down the error by roughly 50%,” explained Caterpillar. “All data can be remotely accessed through the truck’s telematics.”

Next generation trucks now offer Hill Start Assist with Anti-rollback; two separate features that work together. Anti-rollback stops the machine with automatic brake application when the truck rolls in the opposite direction of the selected gear. If drive is selected, the truck won’t roll backward, and if reverse is selected, it won’t roll forward. Optional operator speed coaching tells the operator if they are running at optimum speed or leaving some room for improvement. The system maximizes asset performance by giving the truck’s ideal speed range, elevating the skill level of all operators.

AutoHoist simplifies body dumping to help provide lower cycle time, and the new Dynamic Stability Control System and Anti-lock Brake System (ABS) provide operators with better truck control to improve cycle time and safety in poor underfoot conditions. The fourwheel, oil-cooled brakes in Cat mining trucks have always allowed for fourwheel braking at any speed to enhance truck controllability and safety. Now, when a locking wheel is detected, ABS regulates the brake pressure to maintain traction and truck control, so the truck keeps tracking forward.

Combining radar and cameras, the integrated Cat MineStar Detect Object Detection system warns operators about light vehicles or stationary hazards around the machines. Optional 360 Surround View gives the operator a top-down surround view of the truck. Together, these two systems give operators a complete picture on a single screen.

Liebherr Details AHS Progress
Liebherr has worked closely with Australian iron-ore miner, Fortescue, in recent years to advance its truck and shovel offerings. In July 2024, the companies announced a partnership to develop and validate a fully integrated AHS for roll out across Fortescue’s sites. Onsite validation of four T 264 autonomous trucks, along with the AHS, is currently taking place at a purpose-built facility at Fortescue’s Christmas Creek mine site in Western Australia.

As part of the AHS development, Liebherr and Fortescue will develop an integrated fleet management system (FMS) and a machine guidance solution (MGS), both capable of being used independently on human-operated mine sites. Liebherr said that, in time, the AHS will be integrated with zero-emission haul trucks that the companies are also currently co-developing. Their aim is to make it the first AHS operating zero-emission vehicles globally.

Komatsu’s PC4000-11E electric drive hydraulic excavator will be on show at
MINExpo 2024. (Photo: Komatsu)

“Our deep expertise in autonomous haulage that has come from operating over 200 diesel autonomous haul trucks across our mine sites, has enabled Fortescue and Liebherr to develop a FMS that uniquely targets efficiency and unlocks untapped capacity in our fleet,” said Dino Otranto, Fortescue Metals’ CEO. “The partnership with Liebherr has enabled us to jointly develop the FMS which provides us with an OEM agnostic solution that can be integrated with any autonomous platform including trucks, drills, watercarts or any other heavy mining equipment. This critical technology puts our business in full control of our development priorities and roadmap.”

In time, the AHS — including the FMS and MGS — will also be made available to Liebherr customers worldwide as part of its technology portfolio.

T 264 in the Spotlight
Liebherr began delivering the first of Fortescue’s T 264 diesel electric trucks in 2023, which will be converted to zero- emission technologies before the end of the decade. On May 19, 2024, the companies demonstrated a hydrogen-powered T 264 haul truck prototype. Dubbed ‘Europa,’ the prototype contains a 1.6- MWh battery (developed by Fortescue WAE) and 500 kW of fuel cells. The prototype can store over 837-lb (380 kg) of liquid hydrogen and, in its announcement, Liebherr said that Europa was heading to a Fortescue site in WA for further site-based testing and commissioning.

Liebherr also plans to showcase a T 264 at its MINExpo booth in September. The 260-mt truck will be equipped with Liebherr’s latest technology, including a Trolley Assist System, and Liebherr said it will “reveal the latest technology for the T 264 at an exciting event during the exhibition.” The Liebherr booth will also feature the R 9400 E 385-mt electric excavator. This will be equipped with the company’s brand-new cable reel solution for increased maneuverability.

Hitachi Trials Battery Ultra-class Truck
In June 2024, Hitachi Construction Machinery Co. announced it had begun a technological feasibility trial on an ultra-class, battery-powered, rigid frame dump truck at First Quantum Minerals’ Kansanshi copper and gold mine in Zambia. The tests aim to verify basic operations performance, including functions such as traveling, turning, and stopping under operating loads, as well as verification of the battery charging and discharging cycles.

First Quantum is a leader in trolley system operations, with in-house technology development and deployment capabilities. In its announcement, Hitachi said that Kansanshi provides it with the infrastructure and facilities needed to test a fully battery-powered haul truck, including overhead dynamic charging solutions and a variety of haul circuits in an operational mine environment. It added that the use of Kansanshi’s infrastructure and the collaboration with First Quantum will be key differentiators in fast tracking this evolving technology, and in creating a practical and commercially viable solution.

The battery technology behind the haul truck was jointly developed by Hitachi and ABB. It allows the trucks to continuously operate by directly charging from the overhead lines and regenerative braking. Limiting the battery volume reduces its weight as a percentage of the overall vehicle weight and helps to maximize the load capacity to enable competitive cost performance.

XCMG Delivers Guinean Truck Order
In other news, Chinese OEM, XCMG Machinery, announced the dispatch of 30 XGE105 electric mining trucks to a mine site in the Republic of Guinea in June 2024. The XGE105 is equipped with a permanent magnet synchronous electric-drive system, heavy-duty high-strength axles, and amaintenance-free high-shock-resistant battery system for operation in harsh mining environments.

XCMG said the model also features an efficient energy recovery braking system and is fitted with variable damping oil/gas (nitrogen) suspension cylinders at the front, and modular balanced suspensions at the rear to enhance lateral stability.

The trucks have undergone rigorous validation across extreme temperatures ranging from -40°C to +40°C, at various latitudes. XCMG said the XGE105 mining trucks have been operated in multiple countries, with one unit covering over 62,000 miles (100,000 km) and running for more than 1,200 days without interruption.

Dispatched from Shanghai’s Luojing Port Area, the new fleet arrived in Africa at the end of June, and XCMG service technicians travelled ahead to oversee the truck’s arrival and prepare for operations.

Scania Greenlights Autonomous Truck Sales
In May 2024, Scania began sales of autonomous mining trucks. “The realization of autonomous transport is taking a big step forward as Scania opens up for orders of the company’s self-driving mining solutions,” the company said in its announcement. “It is now possible to place orders for Scania’s 40-mt autonomous heavy tipper for mining, with the 50-mtt model to follow shortly afterwards.” Sales will be offered in Australia first, with initial deliveries and start of operations scheduled from 2026. The next market will likely be Latin America; a region where Scania has a significant market presence in the mining segment.

Scania began commercial sale of its autonomous mine haul trucks in
May 2024. (Photo: Scania)

Scania’s mining solutions with smaller, civil-class trucks offer various potential advantages over the industry’s traditional heavy haulage trucks. Scania said that by using its autonomous mining trucks, the overall mining footprint including energy and infrastructure requirements can be reduced, meaning that capital and operating expenses may also be reduced at suitable sites. Scania’s autonomous trucks can also be smoothly fitted into existing mining operations, thanks to their interoperability with other systems and vehicles.

“Another benefit with our solution is that it allows mining companies to more quickly take the next step towards zero-emission operations. It’s easier to electrify operations with Scania’s autonomous trucks compared with traditional heavy haulage trucks,” added Hafmar.

Over the past 10 years, Scania has invested heavily in the development of self-driving vehicles. Innovations include applications for hub-to-hub transport on highways as well as autonomous vehicles for confined areas, such as mines. The autonomous tipper truck was developed in close cooperation with Scania’s mining customers, providing extensive testing in harsh real- life conditions.

Hexagon, Scania and Fidens Debut Teleoperated 8x4 Mine Truck
In July 2024, Hexagon, Scania and Fidens successfully debuted Brazil’s first remotely operated 8x4 mining truck. The collaboration brings together industry knowledge across integrated technology, heavy equipment and situational expertise that the companies said will result in significant operational gains for mines in Brazil and worldwide.

The initiative combines Hexagon’s HARD-LINE TeleOp remote operation technology with Scania’s G 500 8x4 XT model mining truck and Fidens’ expertise in mining operations. The result is a remotely operated, super-capacity heavy tipper that prioritizes safety while heightening speed and productivity in challenging mining environments.

HARD-LINE TeleOp serves as a virtual command chair for the truck operator, enabling safe navigation of vehicles from miles away. Thanks to the solution’s onboard cameras and sensors, operators can perform all normal driving tasks from the chair, positioned in an office-like environment, even from a considerable distance.

With Brazilian regulators recently mandating the decommissioning of hazardous tailings dams, this teleoperation — which can be adapted to any model Scania truck — is an important development. The deployment of autonomous solutions can help mine operators safely accelerate work in such high-risk areas while reducing environmental risks and costs.

Rodrigo Couto, president, Latin America, Hexagon’s Autonomous Solutions – Mining, said: “We are shaping a new reality, demonstrating with our partners how technology can help mines be more productive and address the critical need for tailing dam decommissioning. Because TeleOp is adaptable to other truck models, this is just the beginning of what we know will be a highly impactful and positive transformation for the industry.”