Engineering an Efficient Solution for an Electric Mining Truck

Beyond Off-the-Shelf: Infrastructure Design for the Electric Mining Truck

As electrification reaches deeper into off-highway industries like mining and agriculture, many OEMs are confronting a growing gap between the capabilities of traditional equipment and the needs of emerging technologies. This challenge is central to mining electrification. One global engineering equipment manufacturer recently encountered this issue while trying to adapt a jib crane to support heavy-duty EV charging cables for an electric mining truck. The result was an opportunity to re-engineer the process with the help of a systems integrator, bringing ergonomics, safety, and infrastructure into alignment for true mining electrification.

In the article “Custom Charging Infrastructure: Engineering a Safer, More Efficient Solution for an Electric Mining Truck,” published in OEM Off-Highway, ACS Lead Mechanical Engineer Drew Heidenreich discusses how ACS designed and built a custom telescopic truck crane system to address both the mechanical and operational limitations of the original design. He addresses:

The Challenge

The OEM used a standard jib crane and manual pulley for the 120-pound EV charging cables of electric mining trucks. This off-the-shelf setup was inadequate for the load and environment, causing an uncontrolled swing that risked cable damage and made precise alignment difficult. The charging port’s hinged door added complexity to the connection. Furthermore, the system needed to support auxiliary equipment (chillers, power units), withstand environmental extremes, and be a foundationless, scalable solution for accelerating mining electrification. The OEM partnered with ACS for a custom design.

The Solution

ACS developed a custom telescopic truck crane system to solve mechanical and operational limits. Unlike the arc of a jib crane, the telescopic system provides linear, controlled extension, eliminating swinging, misalignment, and cable stress.

• A movable cable track system manages the cable’s weight, limits lateral movement, and maintains the critical 40-inch bend radius, protecting the cable investment.
• To improve ergonomics, a tool balancer makes the plug end weightless, letting operators maneuver the connector with precision via a handlebar.
• A containerized enclosure houses power and cooling equipment on a steel base plate, allowing for foundationless deployment, weather protection, and easy relocation.

The Outcome

The custom telescopic truck crane significantly improved safety and efficiency. Its ergonomic, weight-neutral design reduced operator effort. Controlled linear motion eliminated cable damage risks, boosting charging speed and reliability for the electric mining truck fleet. The system’s modular design ensures it can evolve with the OEM’s electric fleet, avoiding obsolescence. Delivering the entire assembly – crane, power, and controls – in a containerized, coordinated system minimized site-specific construction and installation time.

For mining OEMs, adapting infrastructure is key to mining electrification. This project demonstrates how custom-engineered solutions overcome off-the-shelf limitations to improve operator safety, protect critical components, and streamline charging operations in rugged environments.

Read the full article here.