NOVEMBER 2016
INCLUDING
All-electric powertrains
Autonomous haulers
Off-world opportunities
PLUS Stage V latest
NOVEMBER 2016
VOL 24 No. 4
www.iVTinternational.com
Unearthing
MINING SPECIAL
new markets
Published by UKIP Media & Events Ltd
www.iVTinternational.com
Performance starts here.
With a legacy of developing breakthrough new technologies and a reputation of engineering excellence around the world,
Dana has proven to be the original off-highway leader. Our focus on the future, and a continuous pursuit of increasing
vehicle performance, has allowed us to set a new standard in efficiency and cost of ownership.
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Unearthing
MINING SPECIAL
The scale and scope of mining activities on our planet is quite their sheer scale. The world’s largest, highest payload capacity haul
simply staggering. Mining vehicles are the heaviest terrestrial truck is the Belaz 75710, which weighs 360 tons and can carry a load
vehicles on Earth – the very biggest of these being the 14,300 ton Bagger of up to 450 tons.
293, a one-off giant bucket wheel excavator that has been in use in a But put this, or any mine hauler (there’s a case study of Liebherr’s
brown coal mine near Hambach in Germany since 1995. It is also the latest on page 20), into one of the vast open-cast mines in which they
world’s highest land-going vehicle at 96 meters (315ft) tall and it typically operate and suddenly they don’t seem that big anymore. In
requires five operators to keep it working at its task of shifting up to fact, these monsters look like tiny toys lost in a grooved sandpit, carved
218,880 tons of soil per day. When the construction of this monster was into the mineral-rich landscape. It’s enough to make you wonder how
completed, it snatched its world records from sister vehicle, the Bagger long it will be until Earth’s resources finally run out. And when they do,
228 (pictured, below), which is the same height, but 1,000 tons lighter, where the human race will be left then…
and which was completed in 1978. The only logical answer is that, providing we’ve not blown ourselves
The cost, scale and longevity of such machines is testament to the up or been annihilated by a stray asteroid, we will have to turn to other
indispensable nature of the mining industry. As long as the human race worlds for our resources. It’s a subject that’s not as far-fetched as it might
is building things, we are going to need to extract materials from the sound. NASA has already constructed a working off-world mining
ground with which to build them. But these vehicles are also indicative vehicle prototype, and is currently on the lookout for OEMs to help it
of an industry that is used to planning for the long term, and not to take the design further. Elon Musk, CEO of Tesla and SpaceX, has a
accustomed to rapidly adopting new technologies. All that is changing concept Interplanetary Transport System that could take people and
as vehicle designers in the mining industry, as elsewhere, are hit by the heavy equipment all around the solar system. And two companies,
double-whammy of truly viable all-electric drivetrains, and rapidly Planetary Resources and 3D Systems, have succeeded in 3D printing
advancing autonomous technology. complex shapes using only materials from a meteorite. You can read
And of course, as this is our mining special, we investigate the more on p30.
history and future of both of these technologies in the pages that follow. Back down on Earth, you won’t want to miss our new-look
On page 24 you’ll find out how electric powertrain manufacturer Artisan What’s New section, which aims to keep you informed about the latest
has big ambitions – it has already partnered with multinational giant industrial vehicle news in a quick-fire format. Just turn the page to
Atlas Copco to power its new Scooptram ST7 mining vehicle and is begin your new journey.
moving to becoming a vehicle OEM in its own right. Tom Stone, editor, iVT International
On page 14 we take a look at the mining market as a whole and
discover that, while autonomous haulers are already used in some
mines, they represent a tiny percentage of the total number of
vehicles in operation. All that is set to change as ‘smart mining’
becomes the buzz phrase behind which lies greater efficiency,
safety and increased profits.
Martin Röll
Standing next to one of the gigantic haulers that are key to the
functioning of mines around the world, it isn’t hard to be amazed by
• ConExpo 2017 preview • The latest construction vehicle case studies • New powertrain
Coming up in the February 2017 issue of iVT
technology • And much, much more…
An update to EU standard EN
1755:2015 has been announced
that will require forklift suppliers,
OEMs and users to pass a more
stringent series of checks before
vehicles are deemed safe to use in
Zone 2, Zone 21 and Zone 22 hazardous areas. It will
become mandatory from November 2017. Zone 21 and
22 areas are defined as places “in which an explosive
atmosphere in the form of a cloud of combustible dust”
may occur; Zone 21 being where this is more likely, and
22 where it is less likely. Zone 2 hazardous areas are
places where explosive gases or mists may occur for
short periods of time.
Common areas that fit these definitions include food
production and storage facilities as well as chemical
factories. “A spark from unprotected electrical
equipment on a forklift, excess heat from the engine,
motors, brakes or other components, can ignite a layer
or cloud of powder in the workplace,” says Steve
Noakes, engineering manager for explosion
protection conversion company Pyroban.
The updated standard must now be considered
in conjunction with the other relevant regulations:
ISO 3691-1:2011 and ATEX Directive 2014/34/EU,
which was also recently updated, in April 2016.
Here we summarize the key points that should be
noted in all the currently active standards…
CONSTRUCTION FOCUS
SIMULATION TESTING
New software set to speed up product design process
An agreement has shortened so that more robust
been made between products can be delivered faster.
Ansys and Caterpillar Using simulation at early
for the production of software stages of the product design
that enables multiphysics process enables engineers to
analyses to be performed with work together more efficiently
a single engineering simulation and to better innovate product
solution platform. design by eliminating the need
With Ansys’ unified simulation for manual data handling, which
platform solution, mining and can cause delays and errors.
construction equipment The technology enables
engineers and designers can organizations in all industries
optimize products in a virtual to imagine high-quality,
testing environment. This means innovative and sustainable
that physical prototype testing product designs that have an
times can be reduced and accelerated time to market.
product development cycles www.machineryoutlook.com
INCOMING
Multiphysics: CRANES
SIMULATION
it will unveil its new Cummins diesel engine that meets
LRT 1090-2.1 and LRT current emissions regulations. The
1100-2.1 rough-terrain cranes at engine develops 194kW (264bhp)
ConExpo in Las Vegas, Nevada, and supplies a maximum torque of
in March 2017. 990Nm (730lb-ft). A 6-speed
As part of its Thecomprehensive
models will be launched set ofas powershift
solutions transmission from Dana
for engineering
simulation, the ANSYS
first mobile cranes thatnew
introduces and large
meettechnology 29.5 R25 tires guarantee
developments
that make multiphysics
global safety standards simulations
and comply faster,
themore
required seamless
off-road and capability for
higher-fidelity with all — as well as more accessible than ever.
COMPACT POWER global regulations
the US standard ANSI B30.5, the
such as the cranes. Their maximum speed
is 25km/h (15mph), and all-wheel
European EN 13000, Australian and crab steering ensure easy
Wacker Neuson launches new mini-excavator By Chris Wolfe, Lead Product Manager for Multiphysics, ANSYS
Standards (AS) and the Russian handling and high maneuverability
German OEM Wacker digging depth of approximately © 2014 ANSYS, INC.GOST standard. in constricted conditions.
ANSYS ADVANTAGE Volume VIII | Issue 2 | 2014 6
AGRICULTURAL OUTLOOK
Farm hands
From November 9-13 the EIMA International Agricultural
and Gardening Machinery Exhibition took place in Bologna, Case IH
Italy. Here we bring you the vehicle highlights Optum CVX
Winner of 2017
Tractor of the
Year
6.7 liter
six-cylinder FPT engine
Continuously
variable Case IH
Idle speed management,
CVX transmission
cuts engine speed from
850rpm to 650rpm if the
tractor stands still without
moving for two minutes
16,000kg
11,000kg maximum gross
unladen vehicle weight vehicle weight
3.4-liter
Common Rail F5C New
engine with ECOBlue Holland
Compact HI-eSCR T5.120
87hp
technology and Low
Tony Rate EGR Winner of 2017 ‘Best
9800 TR Utility’ in Tractor of
the Year Awards
Showcased by 4-cylinder
Antonio engine with a
Carraro synchronized PTO
set at 540/540E
491Nm
torque
at 1,500rpm
15,600
Fully reversible with
four electronically lumens
controlled speed light output
ranges from high-power
LED lights
The best of
MINExpo
ON SEPTEMBER 26-28, LAS VEGAS, NEVADA, HOSTED THE
ONCE-EVERY-FOUR-YEAR GATHERING OF THE WORLD’S
MINING INDUSTRY. iVT WAS THERE TO REPORT ON THE
BEST INDUSTRIAL VEHICLE INNOVATIONS ON SHOW…
Scania
showcased
its fuel-efficient
engines, including
stone crushers
SCANIA SHOWCASES NEW PROFIT-BOOSTING SOLUTIONS
Scania had a wide range of mining framework of tools and methods impact on our mining customers’
products and solutions to promote designed to support mining bottom line.
at MINExpo. On display at the operators in improving their total “We have expertise from
Scania stand were a range of operating economy. industries such as bus and
fuel-efficient engines, such as “For mining enthusiasts like us, long-haulage transportation, and
screening devices, stone crushers MINExpo is a very exciting event,” can bring that to bear in the mining
(pictured) and gensets. They are said Björn Winblad, head of Scania industry. Our modular approach
part of Scania’s new Site Mining. “It’s particularly exciting for means that the services already
Optimisation program for potential Scania because I believe our exist which we can use to fulfill
customers. This constitutes a offerings could have a huge positive wide briefs,” Winblad concluded.
CATERPILLAR UPDATES
TERRAIN SYSTEM
Caterpillar announced improvements to its Cat MineStar Terrain
system at MINExpo. The upgrades are expected to improve
efficiency and productivity. Terrain combines GNSS guidance with
integrated software that enables remote monitoring and fact-based
decision making. Miners use Terrain to optimize production
efficiency, enhance safety and reduce cost per ton. All Terrain
products (for grading, drilling and loading) have been upgraded.
With the Terrain for grading update, the D10T (pictured) and
D11T dozers can be ordered with factory-installed blade control
capabilities integrated into the machine control system.
LIEBHERR PRESENTS NEW Automating blade movement helps all operators move material
R9200 MINING EXCAVATOR faster and more accurately, with less fuel and rework required.
The newest version of Terrain for grading also includes
Liebherr added a new 200 metric ton superior digging performance and high a feature that tracks machine status (working or inactive), notes
class machine to its mining excavator fill factors, even in the most extreme when a unit is inactive, and prompts the operator to select
product range in the USA, at MINExpo mining conditions. This new excavator a delay code, explaining the inactivity.
The 16.3yd³ (12.5m³) bucket is the is powered by the Cummins QSK38
largest in its class, and offers diesel engine that complies with USA/
sustainable performance while EPA Tier 2 or 4i exhaust emission limits
delivering peak fuel-burn efficiency, and has a rated output of 1,086hp
even in challenging conditions. It is (810kW). The cutting-edge cab of the
designed to match mining trucks with R9200 provides a panoramic view of the
payloads of up to 154 tons (140 tonnes). operation leading to efficient truck
The R 9200 is available in backhoe loading and safe machine positioning.
and face shovel configuration and is The R9200 integrates an advanced
fitted with the Liebherr advanced electronic piloting control system that
bucket and GET solution to deliver is intuitive and versatile.
Rise of the
SAFER AND MORE PRODUCTIVE
machines
14 iVTInternational.com November 2016
MARKET REPORT
34.7%
The share the
Asia-Pacific
region has of
smart mining
turnover,
making it
the world’s
biggest market,
followed by
e
North America
and Western
Europe
KOMATSU BREAKTHROUGH
A driverless autonomous haulage center of gravity in the middle. This mining equipment and promote
vehicle from Komatsu was is designed to enhance weight remote control and unmanned
The mining sector is in the unveiled in September 2016 at distribution across all four tires, machine operation, the company
midst of a technological MINExpo in Las Vegas. The which helps with traction and believes it will be able to help its
revolution, with automation and Innovative Autonomous Haulage braking control. mining customers boost
smart technologies witnessing an Vehicle has a structure without Komatsu says it expects its productivity levels.
uptick. The industry is gradually a cab and was developed as an new autonomous vehicle to Komatsu has yet to announce
recovering from a steep downturn, exclusively autonomous vehicle, substantially improve productivity when and at which mine site the
so mine operators around the world having been designed to fully at mines where existing unmanned new vehicle will first be used.
maximize the advantages of haulage vehicles face challenging
are investing in smart technologies
unmanned operation. conditions, such as slippery
to boost productivity and improve By distributing equal loads to ground and confined spaces for
safety. If automation receives the the four wheels, whether or not loading. Another benefit is that the
right investment, it has the the vehicle is loaded, and by using vehicles will be run according to
potential to surmount the long- four-wheel drive, retarder and their engineering design
standing challenges of precarious steering, the company is aiming guidelines, without the hard
commodity prices, lower-grade ores, for ‘high-performance shuttling’ braking and hard driving that
spiraling operational costs and a lack in both forward and reverse, human drivers can inflict.
of a skilled personnel. thereby eliminating the need for With a gross vehicle weight of
For these reasons automation is three-point turns at loading and 416 tons, it has a nominal payload
unloading sites. of 230 tons. A maximum speed of
being applied to load haul dumps
There is a separate electric 40mph (64km/h) is claimed for the
(LHDs), trucks and even trains. motor in each wheel to give 50ft (15m) long, 27ft (8.5m) wide
Some of the key vehicle independent control of traction and vehicle, which has a turning radius
manufacturers, including Komatsu braking. The engine has been of 52ft (15.9m)
and Caterpillar, are working with moved to the center and lowered By continuing its efforts to On the Web
mining giants, such as Rio Tinto slightly, putting the payload and optimize the performance of Watch a video of the Komatsu hauler at:
www.iVTinternational.com/komatsu
and Barrick Gold, to develop
US$5.8bn
Value of the
global smart
mining market
in 2014
US$13bn
Predicted value
of the global
smart mining
market by 2020
autonomous vehicle technology for class dump trucks – those with a ABOVE: An iron ore mine in largest fleet of AHS trucks in the
Pilbara, Western Australia,
mining applications. capacity of at least 272 tons – to be which accounts for the bulk
world – 69 and counting. The
Vehicles are the latest stage of operated without a driver. Vehicles of the million tons of ore company believes the fleet enables
automation in mining and could fitted with AHS have a wireless hauled by Komatsu using more material to be moved with
its autonomous vehicles
transform conventional mines into network system, high-precision GPS, greater efficiency and safety,
‘smart mines’ that are much more vehicle controllers and obstacle resulting in improved productivity.
competitive and profitable thanks to detectors. Komatsu says trucks using One of the attractions is that
a high level of automation. The AHS can operate safely throughout a driverless vehicles have the potential
global smart mining market is complicated load, haul and dump to operate 24/7 and stops are needed
predicted to grow to revenues worth cycle and can be integrated with only for fuel and maintenance. They
US$13bn by the end of 2020. The other components of an automated have teleoperational functionality,
revenues from automated mining system, including dozers, so they can be monitored and
equipment are forecast to reach loaders and shovels. But, they must controlled from anywhere in the
US$6.2bn by 2017. Mining always be supervised by humans. world. Around 70 such driverless
excavators and LHDs continue to AHS trials began on trucks trucks operate at the Pilbara mines
lead the segment and research through a Komatsu and Rio Tinto of Nammuldi, Yandicoogina and
indicates that autonomous trucks partnership in 2008. Within three Hope Downs 4. They work to
will be adopted extensively in the years Rio Tinto had signed an MoU transport millions of tons of iron ore
next few years. for 150 autonomous trucks. It has and can be supervised by experts
now hauled a billion tons of high- miles from the actual mines. The
Going autonomous grade ore and other material in the first batch of these vehicles has
An autonomous haulage system Pilbara region of Western Australia covered almost two million
(AHS) has been commercialized for and also at mines in Chile. Rio Tinto miles to date. They are capable
mining by Komatsu. It enables ultra- says it now owns and operates the of independently moving around
US$4.2bn
operated dozers are tested at the
Full autonomy company’s proving ground near
Following the success of automated Tucson, Arizona.
trucks, Rio Tinto has already Caterpillar is also working in
embarked on a trial for robot drill collaboration with Fortescue Metals
Value of the
mining. Unmanned trains are also Group on automated robo-trucks at worldwide market
being trialed, under the company’s
‘Mine of the Future’ program. Yet
the Western Australia-based
Solomon Hub mines. The company
for automated
the ultimate goal of fully has achieved dramatically increased smart mining
autonomous trucks that don’t productivity levels following
require even remote manual implementation of these
equipment in 2014
supervision has not quite been autonomous haulage systems.
US$9.5bn
achieved, despite companies such as Moreover, the Queensland mining
Google showing how they are industry awaits a fleet of driverless
possible on the open road – an trucks for underground mining.
environment that is much less
predictable than a mine or quarry.
In Sweden, Volvo announced
ambitious plans for a flagship
Predicted value
However, they may be on sites soon automation project that could of the worldwide
because Komatsu is already moving
on from AHS, which is designed to
represent the highest possible level
of mining vehicle automation –
market for
be applied to regular ultra-class robot mining trucks or driverless automated smart
trucks. It has just launched a vehicle trucks designed for operating in BELOW: Volvo’s fully
autonomous underground
mining equipment
that has been designed for complete underground mines. Partnered with
autonomy from the start (see Swedish mining group Boliden, the
haul truck is being tested
in Kristineberg mine in
by 2020
Komatsu Breakthrough, p28). company is currently testing Sweden, in collaboration
But Komatsu now has plenty of driverless trucks in the country’s with mining group Boliden,
in what is believed to be a
competition in the race to achieve Kristineberg mine. world first
full autonomy. BHP Billiton has
recently accomplished trials of fully Safely does it 69 days. By using more teleoperated
automated, driverless lorries in a Even more important than or fully autonomous vehicles
Mexican coal mine in collaboration productivity, the greatest reason for underground, the risk to human life
with Caterpillar. Moreover, the vehicle automation in mining is will be reduced.
company has plans to expand its safety. Nobody wants to see again The functionality of automated
existing fleet of driverless trucks and the likes of the Chilean mining vehicle technology continues to
is currently testing unmanned accident at Copiapó in 2010, in improve. Robotic components of
lorries for underground tunnels. which 33 men were trapped 2,300ft fully automated mining vehicles
Caterpillar driverless trucks are (700m) underground, some for up to can handle all functions, from
ignition, acceleration, braking and
transmission to accurate navigation.
Today, obstacle detection and
avoidance, once considered to
be the most novel features for
autonomous vehicles, are highly
sophisticated and reliable.
Out of nearly 50,000 haul trucks
operating in mines across the globe
today, not even 1% are autonomous.
The twin drivers of productivity and
safety are going to boost that figure
in the next five years. It’ll happen
almost automatically. iVT
T236
Generation 2 AC drive system. handling for electricians and
mechanics when servicing the
Built to perform electrical drive. The drive operates
“This revolutionary machine at 690V AC and 900V DC –
provides the industry with a new consequently in most countries
benchmark in the 100 metric ton regular site technicians can carry out
class for off-highway haul trucks, the system maintenance. “An
focusing on top performance, industry first, Liebherr’s Litronic
VITAL STATISTICS
Engine: Cummins QST 30 diesel 895kW
Payload class 100t
Gross vehicle weight (GVW) 180t
Empty vehicle weight (EVW) 80t
Gross HP (SAE J1995) at 1,900rpm 895kW
Emissions (USA/EPA) Tier 2
Drive system: Liebherr Litronic Plus Generation 2 high-efficiency
drive system with integrated active front-end for
engine retarding operation
Max. speed 55km/h (34mph)
ABOVE: With its impressive Plus Isolation system ensures the providing a 690V AC tension level – Billed as an evolution in electric
performance and reliability safety of maintenance personnel below the level that would require drive system design, the Litronic
and low operating costs,
the T236 is intended to set through the elimination of hazards specifically certificated electricians Plus Generation 2 features active
a new benchmark in the by design,” says Scott Bellamy, for maintenance. front-end technology. The drive
100 metric ton class
senior product manager for Liebherr The three frequency converter system is able to deliver controlled
Mining Trucks. modules installed in the rear of the engine speed with almost no fuel
The in-line electrical powertrain machine are also rated to IP68 and consumption by making efficient
layout minimizes cable length, can be easily removed and replaced. use of electrical energy during
while the maintenance-free IP68- retardation. Vertical integration of
rated plug-and-drive power modules Ergonomics inside components ensures that the T236
help provide reliable operation in all Richthammer says Liebherr is powertrain achieves optimal system
weathers. This is combined with committed to designing mining efficiency and performance
extended-life service intervals and trucks that operators want to drive: throughout the full range of
minimal maintenance time provided “The ergonomic T236 cab and the applications. The variable hydraulic
by ground-level service points. superior properties of the front- system lowers machine parasitic
The hydraulics package covers wheel suspension system fulfill this losses (energy loss not contributing
the fan drives, blower and electrical commitment and promote driver to power), maximizing the power
traction motors. The powertrain efficiency with superior comfort, available to the traction wheels,
comprises the diesel engine and safety, acceleration and handling while lowering fuel consumption
remote-mounted alternator for increased performance.” when power is not required.
California-based Artisan
Vehicle Systems has been
fitting its battery-powered electric
powertrains into the mining
vehicles of various OEMs for several
years. But it has changed strategy
with the release of its new 153 LHD
(load haul dump) vehicle. For the
first time, Artisan has produced
every component of the battery-
powered 1.5-yard, 3 metric ton LHD
underground mining vehicle and is
selling it under its own name.
“We are looking to have a similar
business model to the global giant
Caterpillar,” says Mike Kasaba, CEO
of Artisan. “They sell their diesel
engines to OEMs, but also make
their own vehicles. Lots of major
mining companies have integrated
our powertrain into scoops and trucks coming transformation from diesel vehicle in place of diesel are huge.
that were originally made for diesel, to zero-emission vehicles.” A major factor is that using battery-
but the new Artisan 1.5-yard LHD powered equipment reduces the
has been designed from the ground Death of diesel requirements for ventilation shafts
up uniquely for our battery system.” The tipping point, when battery- to clear fumes. They can cost
Artisan launched the LHD in powered vehicles outnumber diesels, between US$50m and US$100m
September, and it is already proving has not yet been reached; most each. In most mines, 40% of energy
popular in an industry slowly underground mining vehicles are costs go on ventilation and cooling.
waking up to the benefits of battery still powered by diesel. “We can In ultra-deep mines the figure can
technology. The company has sold make it happen quickly, but only if reach as high as 90%. Diesel
out of the vehicle for the rest of we get the message across about emissions are the major source of
2016 and is taking orders for the their superior performance and lower fumes and some mines have as
second quarter of 2017. “The costs compared with diesel,” Kasaba many as 150 diesel machines
interest is part of the mining says. “If we can do that through working underground.
industry’s move away from diesel publicizing the success stories, then “A new mining project is an
technology,” says Kasaba. “At by 2020 every request for proposal opportunity to save real money. A
MINExpo, executives from every will be for a battery-powered vehicle project using diesel could require
major mining company told us they and diesel will be a thing of the past.” four ventilation shafts, but with
know battery power is the future Kasaba says the cost savings from batteries, two shafts would be
and they have to plan now for the using machines like the Artisan LHD enough,” says Kasaba. “Also, if
a company using diesel finds an belching out fumes and their voices
adjacent ore body, it has to sink are not drowned out by noise.
additional ventilation shafts. But “Diesel machines can be so loud you
that’s not necessary with battery have to scream to be heard, but all
power. The company saves on you can hear with battery machines
capital expenditure and can reach is the hydraulic system running as the
the adjacent ore much more quickly.” motors are essentially silent,” he says.
The improvements in
Improved performance performance have been made
The new Battery-powered machines are by no possible by recent advances in
Artisan 153 means an inferior alternative. On lithium battery technology. Artisan
vehicle has the contrary, their mechanical tested all possible battery
300%
of the horsepower
performance is far superior to diesel,
according to Kasaba. The new
Artisan 153 vehicle has 300% of the
technologies over the years and, in
the end, settled on lithium for hard-
rock environments. In soft-rock
horsepower of a diesel 1.5-yard LHD environments, such as coal, salt and
of a diesel 1.5-yard equivalent. It loads more quickly, potash, lead-acid batteries work fine,
LHD equivalent hauls up steep grades faster and is but hard rock, including copper-,
more precise, he says. gold-, silver- and lead-bearing ores,
“Electric motors are very power demands smaller and more powerful
dense with high torque and they fit machines that are best powered by
into a very small space,” says lithium batteries. The vehicles can
Kasaba. “For conventional diesel be charged in an hour for at least
machines, the OEMs use the four hours’ running time, or the
smallest engines possible that will batteries can be swapped over in
get the job done. That’s because the around 10 minutes.
kW of ventilation required is kN
250 80
amount
LEFT: The Artisan 153 determined by the horsepower. But
200
New factory
70
reduces ventilation and we can put in a high horsepower Artisan 60has built a 60,000ft2 (5,574m2)
cooling expenses for
mining companies and it has150no effect on the battery 50development center and
BELOW: The Artisan 153 ventilation. And because the production facility in Camarillo,
40
outperforms its diesel battery-powered vehicles are smaller, California, to carry out research into
100
competition
they are more maneuverable. They every aspect
30
of the powertrain,
can get in 50and out71.5
of stopes more
214 including20 the battery, electric motor,
70 75
easily and pull the ore out faster.” vehicle 10controls, power electronics
The experience
0
DIESEL
for the and high-powered
0
DIESELchargers. The
underground workers, too, is far facility will also ramp up production
Total power
more agreeable. They don’t have to
Tractive effort
tenfold to cope with anticipated
put up with hot diesel equipment demand. “California is the
kW kN
250
kph kj
80 12 3.5
70 3.0
10
200
60
2.5
8
150 50
2.0
40 6
1.5
6.9 12 3.5x 1x
100
30
4
1.0
50 71.5 214 20
70 75 2
10 0.5
0
DIESEL 0
DIESEL 0
DIESEL 0.0
DIESEL
Total power Tractive effort Loaded speed Heat generation
(on 17% grade) mucking
10
POWERED VEHICLE AND DIESEL WILL BE A THING OF THE PAST”
3.0
2.5
8 MIKE KASABA, CEO, ARTISAN
2.0
6
1.5
2 0.5
0
DIESEL 0.0
DIESEL
OEM PROFILE
home base for Tesla and other local company, RDH Mining ABOVE: Users of electric vehicles necessary to reduce
the Artisan 153 can
manufacturers of electric vehicles, Equipment, of Alban, in Ontario, experience increased high ventilation costs.
so it’s a huge intellectual center for supplied the vehicles, and visibility and better
what we’re trying to achieve,” says incorporated the Artisan powertrain maneuverability than Beating the battery lag
they can with diesel
Kasaba. technology. Kasaba says that KLG’s mining vehicles Considering the potential cost
Artisan offers remote technical stock has quadrupled since 2013 savings, superior performance, and
assistance to any clients who and it has acquired two additional environmental benefits, the mining
own vehicles equipped with its mining companies. He believes the industry’s sluggish embrace of
powertrains, including those sold cost savings and superior battery technology comes as a
under the name of a different performance from battery power surprise to many people. But Kasaba
OEM. Artisan’s California-based have contributed to that success. says there are logical reasons for the
technicians are connected to the “RDH Mining Equipment is a industry’s conservatism.
vehicles through web-based small company and, while we’re “To understand why, you have to
technologies. “They can very happy with the work we did look at the planning and execution
communicate with local technicians with them, we also wanted to work process for major mining companies,”
in remote mining areas. It’s as if we with larger engineering companies, he says. “They invest hundreds of
are sitting right beside them even so we partnered with Atlas Copco, millions of dollars and the payback
though we could be thousands of a giant with access to huge is often not for several years, so they
miles away,” says Kasaba. engineering departments. We knew have to make their investors feel
Whenever a vehicle is connected we could rely on their integrations safe. How do they do that? By doing
to a battery charger, Artisan’s to produce superior performance,” things they know will work for sure.
technicians receive information he says. Mining lags behind in accepting new
about every action it has performed. One of the fruits of the technology because companies don’t
Faults show up on screen in partnership with Atlas Copco is want investors to feel they are taking
California. “We can then talk live the Scooptran ST7 Battery vehicle, risks and, therefore, feel less safe.”
through our system to the which was launched in May. Artisan But Kasaba says that if Artisan can
technician and try to diagnose any provided the battery technology. demonstrate to nervous investors, that
problems. And we can remotely Atlas Copco says it produced the the up-front costs of battery-powered
upgrade our software,” says Kasaba. vehicle to provide the market with vehicles are roughly equivalent to
alternatives to the more common diesel ones, the battle can be won.
Golden partnerships tethered electric vehicles. Like “If we look at the cost of the machine
Artisan has been working to develop Kasaba, Atlas Copco believes the without the battery pack there’s a
its powertrain technologies in trend for deeper mines will make slight premium for battery but it’s
partnership with OEMs since 2010. not outrageous. If we look at the cost
LEFT: The Artisan 153
One of the most productive emits zero poisonous of a battery pack over its four-year
partnerships has been with Kirkland diesel emissions life before it has to be remanufactured
Lake Gold (KLG), which relies and compare that to the cost of
heavily on Artisan’s equipment for diesel fuel, it’s also comparable.
its gold mines in Ontario, Canada. “The other benefits of batteries –
At Kirkland Lake Gold’s Macassa lower emissions, lower ventilation
Mine, for example, Artisan’s electric costs, cooler and quieter motors,
powertrains drive 14 underground lower maintenance costs, and
machines, including 3.5-yard scoops superior productivity – go direct to
and 20 metric ton haul trucks. The the bottom line,” he says. iVT
New
webasto.com
New
worlds
order
30 iVTInternational.com November 2016
OFF-WORLD MINING
ABOVE: An AC-3 truck The prospect of extraterrestrial that both operate without requiring in northern Sweden. Torbjörn
that could be converted to mining has been a staple of a full area network. Holmström, a member of the Volvo
use Hitachi’s autonomous
haulage system science fiction for decades, and now Komatsu has developed what it Group Executive Board and Volvo
ABOVE RIGHT: The technology has progressed calls “an innovative autonomous Group chief technology officer,
stockyard at one of Rio sufficiently for us to seriously haulage vehicle” that doesn’t even observes, “This is the world’s first
Tinto’s Pilbara iron
ore mines in Western
examine how this could happen. Are have a cab. At over 400 tons, and fully self-driving truck to operate
Australia, where increased the autonomous mining vehicles of with a top speed of 64km/h it is a under such tough conditions. It
automation has boosted today paving the way for extra- clear indication of the way the is a true challenge to ensure that
production
terrestrial mining in the future? industry is going. everything works with meticulous
Certainly one of the great Hitachi is taking a slightly accuracy more than 1,300m
advances in the mining industry in different view, building in the ability (4,265ft) underground.”
recent years has been the rise of to upgrade at a later date if required. The machine features a battery
automation. For example, Rio Tinto Craig Lamarque, division of onboard sensors and is able to
has claimed that last year at its manager, Hitachi Construction constantly work out the most
Pilbara mine 400 million tons of Machinery (Americas), commented economical routes.
material were moved by recently, “As a fully integrated With all this activity on
autonomous trucks, resulting in a system, our autonomous haulage automation research here on earth,
12% productivity boost. There was system results in a truck that can could this be a template for mining
also a 13% reduction in load and determine the most efficient paths on other planets?
haulage costs due to truck without constant communication The next thoughts to spring to
efficiencies, and from a drilling with traffic control. We’ve also mind must be: How would we know
perspective greater automation has included components that make it where to go? And how would we get
cut costs by 8%. Even the mining possible to convert any Hitachi AC-3 our equipment up there?
cargo trains have benefited, with truck bought today to automated
250 journeys being automated. haulage in the future.” Where do we go?
The industry has not been slow And there are even more NASA’s Origins, Spectral
to recognize this trend. Caterpillar ambitious plans afoot. Volvo is Interpretation, Resource
recently launched an object trialling an automated truck deep Identification, Security-Regolith
detection system and an anti- underground in the harsh Explorer (OSIRIS-REx) project may
collision proximity detection system conditions of the Kristineberg Mine hold clues about answering the first
THEN…
Of course NASA has been here T-shaped manual controller
before when it comes to the positioned between the seats.
subtleties of designing Pulling it back applied the
off-planet off-roaders. brake, with a stick-mounted
The Lunar Roving Vehicle switch to select reverse.
(LRV) used on the Apollo 15, 16 Comfort was not neglected.
and 17 missions is a fascinating There was an armrest between
little machine. On each mission the seats, adjustable footrests
it traveled a variety of distances and even Velcro seatbelts.
over three traverses within its It did end up costing in the
maximum safe range of 3 miles region of US$38m in 1971,
(5km) from the lander. though, which in today’s money
Starting at the bottom, the would be about US$226m.
wheels consisted of a spun Gene Cernan on Apollo 17
aluminum hub with tires made was the last person to drive an
of zinc-coated steel strands. LRV on the moon. In a 2013 visit
The tread is made up of titanium to the Science Museum in
chevrons covering half the London he is reported as having
available surface area. said, “Flying Snoopy (the lunar
Each 0.25hp wheel motor is module) was pretty exciting, but
capable of 10,000rpm, reduced driving a car in one-sixth of
by an 80:1 harmonic drive. Earth’s gravity – if you get the
Power came from two 36V silver chance, try it. It’s a lot of fun. I
zinc potassium hydroxide truly believe we could go back
non-rechargeable batteries. To and drive it again, but you might
steer, the driver used a need to replace the batteries.”
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…AND NOW
In September this year NASA
2016
enable situational awareness.
“A SMALL, 10 METER S-TYPE
ASTEROID CONTAINS ABOUT
650,000KG OF METAL, WITH ABOUT
demonstrated RASSOR 2.0, the Autonomy can be programmed if 50KG IN THE FORM OF RARE METALS
Regolith Advanced Surface
Systems Operations Robot, a
it is required.
The whole thing is scalable, LIKE PLATINUM AND GOLD”
machine with many novel meaning that its size can be Dante Lauretta, principal investigator, OSIRIS-REx mission,
features actually designed to go easily altered to suit the space University of Arizona in Tucson
mining in space. available on board the launcher
There are all sorts of – without a massive redesign.
challenges to be overcome for a Another area of the design that
lunar mining machine. For has received careful attention is
example, where gravity is low, a overall mobility. Even if it
light machine would struggle to overturns, its symmetry allows it
generate enough force to dig to simply carry on reverse digging
through what could be very dense in the new orientation. It can even
material on the surface. To solve stand up to dump its cargo if question. Launched in September you’re mining these asteroids. The
this problem, RASSOR features there isn’t a ramp handy.
2016, its mission is to visit the near- other thing C-type asteroids have is
counter-rotating drums to give In the images shown here
earth asteroid Bennu, make a close- organic material – a lot of organic
near-zero horizontal and minimal RASSOR 2.0 is demonstrating an
vertical net reaction force. in situ resource utilization (ISRU) up study, break off a chunk and carbon, phosphorous and other key
Loading is accomplished by with a simulated propellant bring it home for detailed analysis. elements for fertilizer to grow food.”
scoops on the drums, spinning at production exercise, exactly the In the close-up study, a device With stony S-type asteroids,
around 20rpm. They can be type of task needed for a dubbed the OSIRIS-REx Visible and Lauretta notes, “There is a fair
raised to safely store the regolith successful Mars mining mission. Infrared Spectrometer (OVIRS) will amount of trace elements that are
while the vehicle drives to the NASA has said it is keen to measure visible and near-infrared economically valuable, including
dump site or processing plant. explore whether there is any light reflected and emitted from the gold, platinum and rhodium. A
When there, the bucket drums scope to use a large version of asteroid and split it into its small, 10m S-type asteroid contains
reverse their direction of rotation, the machine on Earth in locations
component wavelengths. Dante about 650,000kg of metal, with
causing the regolith to be tipped that are too difficult or dangerous
Lauretta, principal investigator for about 50kg in the form of rare
out of each scoop. to get to, and the Kennedy Space
This can all be done wirelessly, Center is looking for commercial the OSIRIS-REx mission at the metals like platinum and gold.”
and cameras and telemetry partners to develop it further. University of Arizona in Tucson The rendezvous is expected in
says, “In particular we will rely on it October 2018.
to find the areas of Bennu that are So if a trip like that could identify
rich in organic molecules to identify exactly where to go, now we need to
possible sample sites of high consider how we’ll get our heavy
scientific value, as well as the mining kit up there.
asteroid’s general composition.”
There are numerous types of How do we get there?
asteroid, and with launch costs so One man spending time – and
high, knowing exactly where to get money – doing just that is SpaceX’s
what you want is vital. The other Elon Musk. In a speech he gave in
key ingredient is water, as Lauretta September he outlined his plan to
NASA/Dimitri Gerondidakis
Displacement
Displacement
Angle
Angle
Inclination
Inclination
CHA L L E N G E
SHOOT FOR THE MOON
ALBERTO SECO
Alberto has been involved in design projects from cell
phones to heavy equipment. After a spell at an Italian
design consultancy and as an industrial designer, he
now works in the automotive sector
This concept excavator and dump truck can work together and they are suitable
for moon mining activities.
The materials would need to be of the highest quality aerospace grade so that
they will cope with temperatures that can range from around -200°C out of sight
of the sun, up to nearly 200°C in full sunlight (-328°F to +392°F). This temperature
range requires robust materials whose dimensions have minimal thermal
expansion and contraction properties. The boom and stick on the excavator have
been built by using transversal tubes and structural elements that would offer
both stiffness and flexibility. These cross-elements would create windows on the
boom that will improve right-hand-side visibility for the operator.
To minimize their need for external energy delivery, energy recovery systems
would be fundamental for the operation of both vehicles; electricity would have
to be the base of the drivetrain and the batteries would need to be easily
accessible. For the dump truck, the energy recovery would come from
regenerative braking systems, while in the excavator the energy-storage cylinders
would benefit from the boom and stick being operated by electric motors.
There is no wind or rain on the moon, so every kind of impression left behind
on the surface would last for many thousands of years. Such a fragile environment
calls for the most effective form of compaction reduction. Thus, instead of a
four-wheel driveline, the 40-ton lunar dump truck has been designed with six
wide wheels that will distribute the burden. In order to minimize the dust thrown
up, the wheels are to be made of metal strips, creating a sort of perforated tire.
These flexible wheels, combined with variable suspension, would provide
self-leveling transportation suitable for the moon’s topography.
In the case of the 55-ton lunar front-shovel excavator, four independent
tracks covered with mudguards reduce compaction while controlling dust.
Dividing two conventional tracks would allow a better adaptation to ground
conditions. The width of the lunar dump truck has been enlarged for added
stability. The same principle is adopted for the lunar-shovel undercarriage.
Although both vehicles would be autonomous, big windshield would add
visibility and therefore vehicle control in case of occasional operation
by astronauts. To minimize accidents caused by any clumsy movements
of humans, access to machines and cabs has been eased by means of
parallelogram systems that would place the cabs on the ground. The wide
windshield would act as convenient front doors.
albsec@euskatel.net • www.behance.net/albertoseco
The battery
takes charge
VOLVO’S NEW WORKING CONCEPT HYBRID HAS A DIESEL ENGINE
ONLY FOR CHARGING THE BATTERY, NOT DIRECTLY DRIVING THE
VEHICLE, PLUS AN AUTONOMOUS ‘HELPER’ TO SHARE THE LOADS
ney
Save mo
sting
while re
g
or waitin
cted
is conne
p&Kool
The Sto inal A/C system
rig
to the o
www.kalori.com
RELATED TECHNOLOGIES
ELECTRONIC
CONTROL UNIT
PROPORTIONAL ROLLER
SWITCH WITH PWM DRIVER
tecnord@tecnord.com - www.tecnord.com
VOLVO LX1 CASE STUDY
95%
The cut in carbon
emissions expected
across one work site
if Volvo achieves its
vision of full vehicle
SELF STARTER electrification
This is not the only novel vehicle machine vision of its own, meaning it
Volvo is working on. The LX1 has a follows a programmed GPS path
little helper – the HX1. This 6-ton without actively detecting or seeing
electric machine is fully autonomous obstacles along the way, but in 2018
and Volvo believes this is the way of the next iteration of the project will
the future. Johan Sjöberg, technical see vision sensors/obstacle detection L140 machine, and behind that is a
ABOVE: Volvo’s LX1
specialist in site automation, says, systems installed. Another idea is hybrid wheel loader new, unique single boom.
“By using electricity instead of diesel that they will eventually be able to fills the battery-electric
to power construction equipment in give each other instructions on where autonomous HX1 load Hjertström explains, “Due to the use
a quarry we have the potential to and when to tip. carrier prototype of hub units we are able to pull the
deliver major reductions in fuel As with the LX1, energy recovery is loading nearer to the center of the
consumption, carbon dioxide vital to the success of this machine. machine, enabling us to lift more
emissions, the environmental impact Volvo says that in a typical application than if we had a front axle.”
and cost-per-ton. The electrification transporting material uphill, an HX1 Hjertström sees increasing
of construction equipment will has more than five times the energy interest in hybrid technology across
produce cleaner, quieter and more of a conventional rigid dump truck. In the industrial spectrum. “Of course
efficient machines.” a downhill application the machine it depends a lot on the application,”
Volvo envisages a fleet of these could even be energy neutral (no
he observes. “One of the keys to
small haulers following a pre- need for charging at all) over the
determined path around a quarry. complete work cycle, due to electric
success is with regeneration from,
Currently this example has no energy recovery when going downhill. for instance, braking or lowering a
bucket. An agricultural vehicle, such
as a tractor doing lots of towing on
flat ground, may not benefit as
much as one that spends all day
shoveling. Looking further, I predict
further electrification in all areas.”
The business case for automation
is compelling, especially when
considering the labor costs in the
developed world. As our natural
resources become increasingly
scarce, automation could one day
open up quarries that had previously
been seen as uneconomical. iVT
INCLUDING
strial Vehi
rains
c powert
All-electri us haulers
6
Autonomo ortunities
201
cle Tech
opp
Off-world st
NOVEMBER
ge V late
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MINING
rk
new a iss ou t on
Don’t m for OEMs as
th
mines
portuniti
es being
e huge op expand rapidl
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Front fascia design: Custom in colour, form, design
Bauser Zeitungsanzeige IVT mit Hinweis Agritechnica 2015 90x250 EN v1.3.indd 1 22.09.15 07:46
MARK HALL IVT INTERNATIONAL
Clean up
your act HOW THE MOVE FROM STAGE IV TO STAGE V EMISSIONS
STANDARDS, TABLED FOR 2019-2020, WILL POSE
FURTHER CHALLENGES FOR VEHICLE MANUFACTURERS
19kw
46 iVTInternational.com November 2016
EMISSIONS REPORT
560kw
iVTInternational.com November 2016 47
POWER FACTS
275–770 hp
5, 6 and 8 cylinders
Stage V
Meet us at ConExpo in Las Vegas 7–11 March. South Hall booth S85629. www.scania.com
Go large
For bigger engines the challenges
are slightly different. Although
packaging always remains an issue,
fuel consumption and the question
of how it is best to administer
AdBlue to cut the NOX become
more important factors.
This is one area where there is
little technology transfer from on-
road applications, as Laing notes,
“Typically the larger engines we
work on are either medium speed
LEFT: Fuel injector
(300-1,000rpm) or slow speed (less
durability test. than 300rpm), and the slow speed
Operators do not want engines are typically two stroke.
high running costs to
be the trade-off for Drive cycles for these engines are
Stage V compliance very different from those observed
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EMISSIONS REPORT
with on-road vehicles. Here the use the need to provide a value-for- need to be considered, including the
of high-flow injectors is necessary to money exhaust aftertreatment impact on engine subsystems such
spray the AdBlue into the SCR system. This is brought into as the fuel and air intake system
system. Specific attention needs to perspective when considering the with changes potentially extending
be given to tuning the spray pattern, potential cost of developing a as far as inlet manifold, piston bowl
ensuring fine atomization for better Stage V compliant solution for and exhaust manifold redesign.
mixing, minimizing wall wetting a 19kW engine from scratch, which “Second, much depends on the
and eliminating crystallization of OEMs in the new engine size space constraints of the particular
urea on the injector nozzle.” bandings are potentially facing. installation. If the OEM had to
Where space is an issue, Eminox “Our advice to the OEM is that redesign a machine for Stage IV,
combines SCR and DPF technology there are obvious timescale and then repeating the exercise at Stage
into a single filter substrate. Laing value engineering advantages to V may not be an option.”
feels fortunate to have all the tools evolving a solution from technology
necessary to do this complex kind and components that already exist,” Technological evolution
of design work: “Our ongoing says Laing. “Creating it from a blank Observing the evolution of the
investment in 3D scanning and sheet of paper and apportioning technology, from Stage 3b onward
MAIN IMAGE: A technician
modeling tools to design compact these development and tooling works on an emission a diesel oxidation catalyst (DOC)
systems that use high-performance costs to the finished product would control system with a platinum-group metal (PGM)
catalysts helps here. Furthermore, potentially price the engine – and INSET: Eminox Stage V 1958. washcoat to supply NO2 for either
our computational fluid dynamics product – out of the market.” Stage V effectively mandates passive DPF regeneration or to
the use of a DPF in the
enables us to fine-tune close For those who have no choice aftertreatment system support SCR was in vogue. Stage
proximity mixing solutions. Having but to start from scratch, Laing IV bought further application
this level of in-house capability is offers two pieces of advice. of SCR whether a DPF was
still unusual in the industry.” “First, engine-out used or not.
emissions. What changes With Stage V, Laing
Cost considerations are required to achieve notes, “In all likelihood
If designing an aftertreatment the next level of the proven DOC/DPF
system, there is a need to balance emissions legislation? recipe, applied by
the many technical demands against All the trade-offs will many OEMs on
engines over 56kW at Stage 3b, will solution with the diesel the NO2, may need a control system
be the technology of choice for oxidation catalyst canned so complicated as to send the whole
manufacturers of 19-56kW engines. independently and close thing back to the drawing board.
The main questions remaining coupled to the turbo to Also optimization of filter porosity
surround the strategy for DPF use all the space and washcoat application to balance
regeneration. The trade-off between available,” says Laing. the backpressure, soot filtration
population risk and system cost is “However, this solution efficiency and SCR could result in
important to understand in this will likely carry a significant a lengthy development process.
power range.” cost penalty due to the But for Eminox, Stage V is
additional canning requirements. just another step forward. Laing
Regeneration conversation Another option available is to concludes, “The journey to Stage V
The most common aftertreatment downsize the DPF and mandate compliance should be an evolution
arrangement for Stage V, 56-560kW, a filter service interval, usually half of existing technology, not a
is likely to be a DOC upstream of way through the emissions life of revolution. Many OEMs exploit
a DPF followed by an SCR and the system.” recent experience and, where
ammonia slip catalyst (ASC). Even possible, leverage knowledge
after the system layout has been A step forward from other divisions in their
confirmed there are still a number of ABOVE: Engine with A final note of caution. When organization. On the other hand,
questions to be answered, such as Eminox SRC1. Stage V designing a system where the some manufacturers of smaller
will be influenced by
what is the regeneration strategy? the technology used on
DPF and SCR functions engines without much
How should the platinum-group Stage IV – an evolution are combined into previous experience of
metal be distributed? of existing technology, one substrate, the aftertreatment will rely
“In order to facilitate package
constraints, some OEMs may
not a revolution
BELOW: Buses are tested
at Millbrook Proving
additional chemistry
created, as soot and
98.8% more on specialist
exhaust system
consider implementing a three-can Ground in Bedfordshire, UK ammonia fight for The reduction in particulate integrators.” iVT
matter (PM) recorded at
Millbrook Proving Ground
when buses were fitted with
SCR and CRT technology
on a simulated
urban cycle
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Image © Hitachi
E THE
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T E ST FORE
LA KS BE OPY
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THE MAGAZINE FOR INDUSTRIAL VEHICLE TECHNOLOGY, DESIGN & ENGINEERING
E
WE HARD BLE
iVT Industrial Vehicle Technology International
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THE AVAIL
O
NOVEMBER 2016
IS
N
INCLUDING
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Autonomous haulers
D
Off-world opportunities
PLUS Stage V latest
A
NOVEMBER 2016
L O
VOL 24 No. 4
N
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D
AN EAD
YW
new markets WIT HER
HO E,
U
Published by UKIP Media & Events Ltd
PLUS
Plant transplant
WHAT’S THE BEST WAY TO INCREASE THE CAPACITY OF A HIGH-QUALITY
ENGINE FACTORY? THE SIMPLE, STRAIGHTFORWARD SOLUTION IS TO
DUPLICATE IT
Sample inspection
Furthermore, Qingdao uses the latest measuring
instruments to inspect specific samples. Only the
highest-quality parts that meet Yanmar’s strict
standards are used.
All engines go through the dyno testing cell to
guarantee the prescribed performance. The Qingdao
plant also has an emissions measuring room to
ensure that each country’s emissions regulations
are met.
Yanmar’s approach to its staff is the secret of
the rapid success in Qingdao. There is a two-year
training program, with time spent at both plants. In
the first year, health and safety, engine knowledge
and the production system are covered, while year
two features more direct on-the-job training. The TOP: In 2013, Yanmar duplicated its Biwa diesel already been passed fit by being emissions tested
teachers are all long-time Yanmar employees who, engine factory in Qingdao to meet sales demands and checked on a dyno.
of course, were also taught in this way in the past. ABOVE: Qingdao, China Production capacity in Qingdao is 60,000 units
Quality improvements and work efficiency are per year. From agriculture to zoology, these engines
regularly discussed in small groups. This can increase are working in a huge variety of industries. Some are
motivation and encourage more rapid personal stationary, such as generators and pumps, and many
growth. It’s a lot of effort and attention to detail, are mobile such as mini-excavators, wheeled loaders,
but that’s what customers need. When they take small tractors and forklifts. All are made to the same
the engine out of the box they need to know it’s exacting quality as at the Biwa plant. iVT
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were able to cascade this simpler approach down wireless connectivity, ready to deliver instant engine DPF, SCR and urea-dosing technologies in one
through the power range. No EGR also means there diagnostics over the air so that operators can module, providing an up to 50% reduction in
is less to cool, which will help lower the cost of maximize the uptime availability of their equipment. envelope size and a 30% reduction in weight
compared with those of Stage IV exhaust engines will continue to bring proven, premium platform. That offers OEMs the prospect of using
aftertreatment. performance ideally suited for the toughest duty the same Cummins Stage V engine in their
The Single Module is essentially a fit-and-forget cycles. The EGR-free X12 lowers heat rejection by equipment worldwide, overcoming the complexity
system, capable of removing emissions almost over 40% compared with that of engines using of multiple emissions regulations in effect. For each
entirely by passive regeneration, with no impact on cooled EGR. machine, that will bring a common engine
equipment operation and requiring no operator installation, with the same electronic integration
intervention. The service cleaning interval is No torque loss and mechanical hookups, with or without exhaust
expected to extend well beyond the 5,000 hours of At the other end of the Stage V engine range, the aftertreatment, depending on the emissions levels.
today’s systems. The modular design of the Single four-cylinder F3.8 will be available at a 74hp (55kW) While meeting the more stringent Stage V
Module allows for varying diameters and lengths, rating, allowing the opportunity for machines to regulations in 2019, the new engines will also be
to efficiently match catalyst capacity to the power downsize their engine installation without any loss of co-certified to meet US Environmental Protection
output of the engine. torque performance. The F3.8 will offer the benefit Agency Tier 4 Final and equivalent emissions
The Cummins heavy-duty duo, renamed the X12 of a highly compact, engine-mounted Cummins DPF regulations in Japan and South Korea. That will make
and X15 for Stage V applications, will retain the without the need for SCR, making that rating the benefits of the EGR-free engines available to
same DPF-SCR aftertreatment system in order to particularly suitable for rental equipment. OEMs for reducing the complexity involved with
provide ongoing installation continuity for OEMs Cummins Stage V engines come with an powering their global equipment platforms. iVT
in higher-output, more specialized machines. With inherently high degree of tolerance to sulfur in fuel
an impressive 512hp (382kW) top rating for the – up to 5,000 parts per million – removing a major Naomi Buckland is senior off-highway communications
12-liter and 675hp (503kW) for the 15-liter, the two barrier in reaching the goal of a universal engine specialist at Cummins
Coordinated power
A FULLY INTEGRATED ELECTRIC HYBRID DRIVETRAIN SYSTEM FOR
DEMANDING OFF-HIGHWAY APPLICATIONS CUTS EMISSIONS AND OFFERS
OEMS A NEW ALTERNATIVE
The latest addition to Scania’s wide range “The offering is a part of Scania Engines’ is readily available and power is needed. Thanks to
of engines for industrial applications is a sustainability goals,” says Andreas Stenemyr, Scania’s modular system, the gas-fueled engine
gas-fueled version of its well-proven 16.4-liter V8 director, product support at Scania Engines. “We shares many components with the diesel V8 engine.
engine. The solution is specifically adapted for see an increased interest in gas engines across the This gives customers global access to parts, as well
single-speed power generation. world, specifically in Brazil and Russia. ”In São Paulo, as fast, reliable service.
Its introduction follows growing global interest in for example, the power generators that are used in “If trained service technicians are used to Scania
replacing diesel with natural gas and biogas, reducing power plants to handle energy supply shortages engines in general, and V8 engines in particular,
both carbon dioxide emissions and noise. With must be fueled by gas. they can also work on the gas version,” he says.
natural gas, CO2 emissions are reduced by as much In addition, Stenemyr points out, the engines are Some components of Scania’s basic diesel engine
as 20%; with biogas, reductions can be up to 90%. a perfect fit for remotely located oil fields where gas need to be adapted for use with biogas or natural
gas. For example, with the combustion chamber,
the piston head is shaped differently to reduce the
compression ratio to 12.2:1, compared with a
compression ratio of between 16:1 and 20:1 for
diesel engines. As for the cylinder heads, the diesel
injection technology is replaced with spark plugs.
There are also modifications to the air inlet system
and the fuel injection system.
Field proven
Stenemyr adds that the new engine has also
performed well in recent field tests. “It has been
running for 500 hours and we haven’t experienced
any problems,” he says.
The engine platform is single-speed, PRP
(prime power) with a maximum power output of
364-477 kVA at 1,500-1,800rpm and a
displacement of 16.4 liters in the V8 configuration.
It is four-stroke, spark ignited, and fueled by natural
gas or biogas. Including the cooling package, it
measures 2,021 x 1,316 x 1,754mm (L x W x H).
Scania’s modular system allows the company’s
diesel engine to be adapted to a wide range of fuels.
Compression and spark ignition are the two basic
principles by which combustion engines operate. In
compression engines, the fuel mixture is ignited
when extreme compression raises its temperature.
Scania’s diesel and ethanol engines both work
according to this principle.
In contrast, Scania’s gas engines rely on spark
ignition technology, with a spark plug igniting the
fuel mixture and starting the combustion process.
Scania offers gas engines for both biogas and
natural gas. iVT
High-performance plating
FOR’s portfolio covers a wide range of standard connections that
comply with JIC, ORFS, DIN, BSP, NPT and JIS standards. The
company provides catalog parts and tailored-made solutions made
according to customer demand.
The off-highway market is increasingly demanding clean, reliable products
that offer high resistance to corrosion at a very competitive price. FOR achieves
this with state-of-the-art machining, high automation, robots, and keeping its
facilities immaculately clean.
FOR’s production flow, from machining right through to assembly, is
performed in-house, including zinc plating. Carrying out this treatment
in-house has enabled FOR to be flexible in the process, as well as taking full
control of the quality. For instance, the company’s zinc-plating plants include a
variety of steps in which the components are flushed to remove any
contaminant particles.
FOR recently improved the performance of its ISO 9227 salt spray test. The
company now uses FeZn 12 IV S plating, with 12µ thickness, chrome
passivation, and the latest generation of top sealer, to achieve the highest
standard of plating.
FOR has also released a new grease check valve – a niche product that can
be used in a range of applications. The valve ensures the idler is greased and
can withstand pressure up to 1,000 bar.
INDEX TO ADVERTISERS
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ASM GmbH.................................................................................. 37
Bauser GmbH & Co KG............................................................... 45
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CONEXPO-CON/AGG – IFPE 2017.....................Inside Back Cover
Cummins Engines Ltd.................................................................. 7
Dana Off Highway Systems Group.................... Inside Front Cover
Electric & Hybrid Industrial Vehicle Symposium....................... 56 ABOUT OUR
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Electric & Hybrid Vehicle Technology Expo North America....... 53
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Faster SpA................................................................................... 37
FPT Industrial SpA...................................................................... 19
HydraForce Inc............................................................................ 62
Hyundai Heavy Industries Co Ltd................................................. 9
Industrial Vehicle Technology International
Online Reader Inquiry Service ......................................... 45, 71
John Deere Power Systems.......................................................... 3
Kalori SA..................................................................................... 42 Visit: www.ukipme.com/info/ivm to
Multi-Wing International A/S...................................................... 50 request exclusive and rapid information
Penny & Giles Controls Ltd........................................................ 34 about the latest technologies and
Scania Engines AB...................................................................... 48 services featured in this issue
SIKO GmbH................................................................................. 50
Tecnord srl.................................................................................. 42
Thermamax Hoch-Temperaturdammungen GmbH................... 48
Webasto AG................................................................................. 29
www.ivtinternational.com........................................................... 34
Yanmar Europe BV...................................................................... 13
HALDEX
JOHN S. BARNES
CONCENTRIC
A LEGACY OF
H Y D R AU L I C I N N OVAT I O N
From our origins as the John S. Barnes Company in 1929 through today, we've been
the recognized global leader in the development of innovative hydraulic gear pumps,
fluid motors and power units. No matter what name you may have known us by,
the one constant for more than 86 years has been our commitment to offer our
customers the latest hydraulic technology that meets their unique vehicle application
requirements. Our wide range of products combined with our extensive application
expertise, engineering support, testing capabilities and state-of-the-art manufacturing
facilities allow us to provide value-added, sustainable solutions that consistently
exceed our customers' performance expectations, worldwide.
www.concentricAB.com