The Challenge
A global engineering equipment manufacturer struggled with an off-the-shelf jib crane system and the manual pulley mechanism it used to lift 120-pound cables to charge electric mining trucks at their facility.
The jib crane system swinging motion would bend the cable, risking damage to it and making alignment with the truck’s charging port difficult. The trucks’ charging outlet features a hinged door that lifts into a horizontal shield, further complicating operators’ attempts to align the jib crane-maneuvered cable and connect the plug. Besides operator challenges, the charging system also needed to support the charging equipment and auxiliary chillers.
Based on previous successful collaborations with ACS, the company requested it design and build a customized crane system that was ergonomic and adjustable to meet the fleet and worksite demands and house a chiller system.
The Solution
ACS engineers designed a telescopic crane system to address the ergonomic and operational challenges of lifting and positioning heavy EV charging cables to the electric mining trucks. With the telescopic crane, the operator can extend and retract the charging cable to different distances in a controlled, linear motion.
The telescopic design eliminates direct handling of the cables by the operators. Instead, a movable track holds the cable, supporting the cable’s weight, preventing lateral movement, and keeping the curve of the cable within a controlled 40-inch radius. The operator uses a handlebar to push the crane arm and cable track outward toward the truck simultaneously. The cable plug end attaches to a tool balancer, making it effectively weightless and easy for the operator to maneuver into the truck’s charging port.
Auxiliary Engineering and Infrastructure
- Power capacity: The telescopic crane has two cable tracks to enable the faster charging of the electric mining trucks.
- Crane stability: The ACS team also designed and fabricated a heavy steel base plate as the client didn’t want to pour concrete. The base plate stabilizes the telescopic crane, even with its arm fully extended. The crane is bolted down and can be disassembled for transport.
- Weatherproof container: The client also requested a containerized weatherproof housing for a chiller system transformer, and three power panels. ACS designed the layout and fabricated custom supports to secure the equipment, ensuring optimal cooling performance and protection from the harsh environment.
The Outcome
The custom telescopic crane system greatly improves the charging operation’s safety and efficiency. Operators can now manage the heavy EV charging cables without physical strain, due to ACS’ ergonomic design. The system’s controlled linear motion eliminates the risk of cable damage while ensuring precise alignment with the truck’s charging port.
The design’s adaptability proved especially valuable, with adjustable components that accommodate different operator heights and potential changes in equipment specifications. This forward-compatible approach protects the client’s investment as their electric vehicle fleet grows.
By housing the transformers, and power panels in a retrofitted shipping container, ACS delivered a weatherproof, turnkey solution ideal for the desert environment.
Through custom equipment design and precise containerization, the ACS engineering and fabrication teams transformed standard components to become exactly what the client needed – equipment tailored to its specific operational requirements and environment.
Key Features
- Jib crane system was replaced by a telescopic crane system with dual cable tracks that handles 120-pound EV charging cables with ergonomic ease
- Heavy steel base plate stabilizes the crane without requiring concrete
- Weatherproof retrofitted container houses transformers (45KVA to 225KVA), cooling fans, and power panels (208V, 440V, and 480V)
ACS Services
- Design and fabrication of customized equipment
- Integration of auxiliary equipment and systems
- Containerization of protected equipment
