❱❱ The infinity train is an iron-ore freight train that uses gravity to charge its batteries on return trips down to the mine
E
very three years, suppliers of construction machinery, building material machines, mining machines, construction vehicles and construction equipment head to Munich for the Bauma trade show. At this year’s event, which was held in October, electrification of plant and
machinery was a dominant theme as construction equipment manufacturers strive towards net zero targets similar to other industries with high carbon emissions. Achieving such targets requires large technological gains and
the participation of advanced engineering organisations is vital to the industry. This year, there was no shortage of technology giants at the event, all of whom were demonstrating the advances they’ve made in off-road vehicle technology and striking partnerships with companies that supply the construction and mining sectors. One such company in attendance was Williams Advanced Engineering (WAE). Recently acquired by Fortescue Metals Group, WAE now has a stake in the mining industry and is assisting Fortescue in delivering a zero-emissions mining fleet by the end of the decade. At Bauma 2022, WAE was demonstrating its advanced battery and energy storage technology, which has been specifically developed for the rugged use typical of mining and other off-highway applications. With its expertise in high-performance battery technology
developed originally for motorsport and road vehicles, WAE’s acquisition by Fortescue naturally lead to the company becoming involved in transitioning its established battery technology to the off-highway sector, using its expertise to become a global green renewables and resources company through the decarbonisation of the worldwide off-highway vehicle fleet. Additionally, WAE is working on a world first, zero emission
“infinity train”, a regenerating battery electric train that hauls iron ore and will use gravity to assist in the recharging of its battery electric systems for the return trip to reload. The technology demonstrated by WAE at Bauma included several elements of battery systems and management.
MODULAR BATTERY MANAGEMENT Featuring a scalable, modular design delivering sub-30min pack charge times for maximum performance, WAE’s off-highway battery module boasts laser-welded cell-to-busbar technology for
in-service reliability. It also has a robust alloy frame, which improves durability and extends life in service, as well as optimised cell packaging for maximum energy density. To unlock battery performance through its software architecture,
WAE’s battery management unit is designed for pack architectures of less than 800V. Its advanced state detection algorithms allow for more efficient energy usage. Equipment down-time is also reduced by enabling maximised fast charge rates. In addition, the cell management unit enables real-time telematics to maximise cell performance by enabling high- precision cell voltage and temperature monitoring. Its innovative flexi-interconnects result in enhanced durability, while the system’s design also allows manufacturing complexity to be reduced for high-volume applications. WAE’s DC-DC converter is a 600kW, 1.5kV-1kV stepdown
converter for high-power loads with a rugged design developed for deployment in off-highway applications. Its silicon carbide (SiC) technology delivers exceptional efficiency of 98.5 per cent, while full-power operation takes place at ambient temperature of 50˚C. Additionally, the vehicle control module is a powerful processing platform to unlock performance advantages, featuring a versatile vehicle system controller. Specifically designed for decarbonised powertrains, it has a flexible heterogenous MPSoC processor.
According to Graham Belgum, general manager for Green Fleet,
WAE, high-performance battery and electrification systems are at the core of what WAE does. Over the past two decades, the company has garnered unparalleled experience in the development of cutting-edge technology, which increasingly is being applied to the off-highway sector. “Now that we are part of the Fortescue family, WAE is central to
battery power systems and products capability, supporting the business as it transitions to a clean, green fleet. Our technology has the potential to accelerate the decarbonisation of any off- highway vehicle,” he says.
PARTNERS IN MINING Earlier this year, Fortescue established a partnership with Liebherr centred around the development of green mining haul trucks in which zero emission power system technologies
December 2022 /// Testing & Test Houses /// 13
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