{"id":7295,"date":"2024-06-17T13:04:39","date_gmt":"2024-06-17T13:04:39","guid":{"rendered":"https:\/\/propulsionquebec.com\/?post_type=ressource&p=7295"},"modified":"2025-02-26T21:10:39","modified_gmt":"2025-02-26T21:10:39","slug":"the-challenges-of-designing-a-40-tonne-100-electric-mining-vehicle-for-open-pit-mines","status":"publish","type":"ressource","link":"https:\/\/propulsionquebec.com\/en\/nos-ressources\/the-challenges-of-designing-a-40-tonne-100-electric-mining-vehicle-for-open-pit-mines\/","title":{"rendered":"The challenges of designing a 40-tonne, 100% electric mining vehicle for open-pit mines"},"content":{"rendered":"
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The mining industry is facing growing environmental and economic challenges and it has become necessary to transition to more sustainable solutions. In this context, the electrification of mining vehicles appears to be a promising solution. To evaluate whether this technology is ready for large-scale implementation, we met with three partners closely involved in developing and conducting on-site testing with the first 40-tonne, 100% electric mining vehicle for open-pit mines: Eddy Zuppel, Program Leader, Clean and Energy Efficient Transportation, Guillaume Imbleau-Chagnon, Senior Project Manager, National Research Council Canada (NRC), D\u00e9sir\u00e9e Tremblay, Manager, Innovation and Finance Strategy with Dana TM4 and J\u00e9r\u00e9mi Fournier, President of L. Fournier & Fils.<\/strong><\/p>\n<\/div><\/div>\n<\/div>\n <\/div>\n <\/div>\n\n <\/div>\n<\/div><\/div><\/div>\n\n

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Partnerships and implications<\/strong> <\/h5>\n<\/div><\/div>\n\n
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The partners involved in the development of a 100% electric Quebec mining vehicle were all eager to be involved with the project from the outset, for a variety of reasons. NRC\u2019s Eddy Zuppel explained their contribution: \u201cBefore starting the project, it was important to model and simulate the vehicle\u2019s route in order to understand its energy needs and design the optimum battery pack. We also tested battery modules to ensure their performance and safety, and conducted a life-cycle analysis to evaluate the potential reduction of greenhouse gas emissions (GHG).\u201d  <\/p>\n<\/div><\/div>\n\n

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J\u00e9r\u00e9mi Fournier shared the vision of his company, L. Fournier & Fils: \u201cWe are one of the biggest mining companies in eastern Canada. As a partner, we provided a diesel truck bed for the electric conversion. We also shared past operational data to compare performance data. Our objective is to reduce the carbon footprint of our operations, while increasing efficiency.\u201d  <\/p>\n<\/div><\/div>\n\n

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D\u00e9sir\u00e9e Tremblay explained that Dana TM4, which specializes in manufacturing electric drive systems for a variety of vehicles, including off-road vehicles, provided the project with a high-power electric motor. \u201cWe worked closely with another project partner, the Institut du V\u00e9hicule Innovant (IVI), to integrate the motor into the truck\u2019s existing transmission, making sure that it can withstand the higher vibrations characteristic of mining roads.\u201d  <\/p>\n<\/div><\/div>\n\n

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Interesting perspectives despite challenges<\/strong> <\/h5>\n<\/div><\/div>\n\n
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NRC\u2019s Guillaume Imbleau-Chagnon specified that models and simulations allowed them to establish the correct dimensions for the battery pack. The exact data will be available this summer, which will assist in the development of new electric trucks or help mining operations to meet their energy needs. Across the entire electric mining vehicle development process, the partners said they encountered several challenges when designing and manufacturing the vehicle. NRC\u2019s Eddy Zuppel highlighted the difficulty in finding a supplier for the prototype\u2019s battery cells, which had to be adapted to off-road vehicles, while his colleague, Guillaume Imbleau-Chagnon, mentioned the limitations of the testing sites. \u201cWe were not able to test the high-power charger, which limited our vehicle charging data.\u201d In fact, the charger will be tested at another mine site at a later date. D\u00e9sir\u00e9e Tremblay of Dana TM4 emphasized the importance of a robust bearing system. \u201cWe used ceramic and iron bearings, which can resist partial electric discharge.\u201d The on-site testing is complete, and the conclusions will soon be shared.<\/p>\n<\/div><\/div>\n<\/div>\n <\/div>\n

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Perspectives and innovations<\/strong> <\/h5>\n<\/div><\/div>\n\n
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Electric mining vehicles show a promising perspective. J\u00e9r\u00e9mi Fournier is optimistic: \u201cIf tests confirm that the charge and range cycles meet needs, this technology represents the future of the mining industry.\u201d  D\u00e9sir\u00e9e Tremblay and Eddy Zuppel insist on the importance of technological adaptation. \u201cEach mine site is unique, so the vehicles must be specifically adapted to the conditions in which they are being used,\u201d  explains D\u00e9sir\u00e9e. Eddy adds that operational advantages, like a reduction in vibrations and noise, can improve operator safety and satisfaction. <\/p>\n<\/div><\/div>\n\n

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Nonetheless, experts are expecting continued improvements. \u201cBattery costs continue to drop, they are becoming safer, and the efficiency of these systems is improving. These developments will make electric vehicles increasingly attractive,\u201d states Eddy Zuppel. The transition to more sustainable solutions requires in-depth planning. J\u00e9r\u00e9mi Fournier emphasizes the need to standardize certain aspects to lower costs and simplify logistics, such as battery packs and charging infrastructure. Guillaume Imbleau-Chagnon envisions modular platforms, allowing for the flexibility of adapting to the specific needs of each mining operation. <\/p>\n<\/div><\/div>\n\n

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In conclusion, while there are still challenges to overcome, the partners are convinced that the technology for electric mining vehicles is on track to transform the industry. Current tests and future innovations will play a key role in this transition. Preliminary results show that these vehicles not only meet operational requirements, they also offer significant advantages in terms of durability and performance. The future of electrified mines seems promising, with the potential to reduce costs, improve safety and reduce GHG emissions. <\/p>\n<\/div><\/div>\n\n

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About the partners<\/strong> <\/h5>\n<\/div><\/div>\n\n
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National Research Council of Canada (NRC)<\/strong> <\/h6>\n<\/div><\/div>\n\n
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The NRC<\/a> partners with Canadian industry to take research impacts from the lab to the marketplace, where people can experience the benefits.\u00a0\u00a0<\/p>\n<\/div><\/div>\n\n

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Dana TM4<\/strong> <\/h6>\n<\/div><\/div>\n\n
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Dana TM4<\/a> is a joint venture between Dana Incorporated and Hydro-Qu\u00e9bec. Dana TM4 develops and manufactures low- and high-voltage electric motors, generators, power electronics and control systems for the automotive, commercial, off-highway, marine, rail, motorsports, and recreational vehicle markets.\u00a0<\/p>\n<\/div><\/div>\n\n

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Dana TM4 contributes to the highest possible energy conversion efficiencies through its expertise in permanent magnet and induction motors, power electronics, thermal management, coil winding, outer-rotor topology, and motor and inverter control algorithms. <\/p>\n<\/div><\/div>\n\n

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L. Fournier & Fils<\/strong> <\/h6>\n<\/div><\/div>\n\n
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As a major mining contractor in Eastern Canada, Fournier<\/a> offers an integrated range of high quality products and services to efficiently meet the evolving needs of its customers. Its activities focus on surface mining, particularly in the areas of mass excavation, formwork and concreting, crushing, and transportation.\u00a0<\/p>\n<\/div><\/div>\n\n

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This project is an initiative of the Institut du v\u00e9hicule innovant<\/a>, carried out with Propulsion Qu\u00e9bec, involving Adria Power Systems<\/a>, Dana TM4<\/a>, Fournier & Fils<\/a> and Nouveau Monde Graphite<\/a> as industrial partners, and the National Research Council Canada (NRC)<\/a> and CANMETMines<\/a> as research partners. The project is being carried out with financial support from the Natural Resources Sector Innovation and Clean Growth Program, the Innov-R program and the Mining Research and Innovation Support Program (PARIDM). The project also receives financial support from the Fonds d’initiatives du Plan Nord and the Industrial Research Assistance Program (IRAP).<\/p>\n<\/div><\/div>\n\n

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We would also like to thank Uniroc<\/a> for hosting our field trials.<\/p>\n<\/div><\/div>\n\n

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Photo credits: Sylvie Tr\u00e9panier<\/a>.<\/p>\n<\/div><\/div>","protected":false},"excerpt":{"rendered":"Partnerships and implications  The partners involved in the development of a 100% electric Quebec mining vehicle were all eager to be involved with the project from the outset, for a variety of reasons. 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