Caterpillar Mining Trucks

Ed McCord
Product Manager
Caterpillar Global Mining
March 30, 2006
Discussion Points

• Our current situation

• Mining truck propulsion
• Electric drive history
at Caterpillar
• New Caterpillar engine
• Electric drive development
at Caterpillar
• Our future

2
Caterpillar Off-Highway Trucks

Comprehensive Product Line

• Nine models, 40 to 400 ton payload,
all mechanical drive

Market Leader
Mining Trucks
• Four models, 150 ton+ payload
• 785 introduced in 1985
• Two out of every three mining trucks
sold are Caterpillar
• More than 6,000 mining trucks sold
since 1985
• Integrated truck system, best-in-class
design and manufacturing
• Global dealer network support

3
Mining Truck Product Development

Best solutions For miners

Record investments in mining trucks
New products
• Safety, serviceability and performance
• New ergonomic operator station
• Higher reliability… greater availability
• Lower cost per ton

Expand the product line

• New class size
• Mechanical drive and electric drive options

4
Mining Trucks: Strategy

Product
• Industry’s most comprehensive line
Cat Truck for
• Enhanced mechanical drive performance
• Totally integrated electric drive Every Application
• Reliable, durable technology that works

Support
• Industry’s best dealer network Quantum Leap in
• Bumper-to-bumper servicing Electric Drive Support
• Unprecedented on-site services

5
Discussion Points

• Our current situation

• Mining truck propulsion
• Electric drive history
at Caterpillar
• New Caterpillar engine
• Electric drive development
at Caterpillar
• Our future

6
Typical Mining Truck Propulsion

Mechanical Drive System Electric Drive System

Engine Engine

Torque Converter Alternator

Grids

Power
Converter
Transmission

Gear Gear Gear Elect Elect Gear

Differential
Box Box Box Motor Motor Box

7
Discussion Points

• Our current situation

• Mining truck propulsion
• Electric drive history
at Caterpillar
• New Caterpillar engine
• Electric drive development
at Caterpillar
• Our future

8
History of Caterpillar Electric Drive

• Electric Drive mining

products in the 1960’s
• 779 Truck (1966 –1969)
• 75 Ton, 960 HP
• 240 ton Coal Hauler
• Direct Current (DC)
technology
• Mechanical drive proved
to be best value

9
Electric Power

Caterpillar: Leadership in electric power generation

10
Electric Drive in Mining Trucks

Trend to Alternating
Current (AC) technology
High speed coal hauls
Extreme downhill
loaded hauls
Potential for trolley
operation

11
Discussion Points

• Our current situation

• Mining truck propulsion
• Electric drive history
at Caterpillar
• New Caterpillar engine
• Electric drive development
at Caterpillar
• Our future

12
New Caterpillar C175 Engine

New Engine Family

• 12, 16 and 20 cylinders
• 5.3 liters displacement per cylinder:
64L, 85L, 106L
• Weighs 18,000 to 27,000 lbs (8,200 to
12,300 Kg)

ACERT Technology

• Sustainable development enabler

• Tier 2 EPA emissions compliant
• Platform for Tier 3 and 4

2,000 to 4,400 HP in Mining Trucks

13
New Caterpillar C175 Engine

C175 3500B Compared to the 3500 Series

• Higher power density

• Greater displacement/cylinder
• Longer engine rebuild life
• Lower noise levels
• Improved altitude capability
• Improved fuel consumption

14
Discussion Points

• Our current situation

• Mining truck propulsion
• Electric drive history
at Caterpillar
• New Caterpillar engine
• Electric drive
development
at Caterpillar
• Our future

15
Cat Electric Drive
Truck Development

Fundamental Principles
• Mechanical drive chassis:
foundation for new electric
drive trucks
• High product integration
with particular emphasis on
power train
• “Bumper to bumper” support
from Cat dealer network

16
Caterpillar Proprietary Drive System

Alternator: Power inverter:

Capitalize on Cat’s leadership in Collaboration with Mitsubishi Electric
electric power generation
Caterpillar
integration

Controls and Hardware: Motors:

Cat designed and developed Designed and built to Cat’s
specifications

17
Mitsubishi Electric Co.

• World’s largest supplier of IGBTs

(Insulated Gate Bipolar Transistor)
and power inverter devices
• $32 billion sales
• Leading supplier for automotive
hybrid systems
• Extensive experience in rail
applications of AC technology

18
Caterpillar Mitsubishi Collaboration
Caterpillar Contribution
• Systems integration expertise
• Application experience and know-how
• Cat control system
• Hardware/ECMs
• Software
19
Mitsubishi Electric Contribution
• Core knowledge of AC technology
• Extensive AC drive experience in
transportation and rail applications
• Supply of power semi-conductors and
other inverter components
Caterpillar AC Integrated Drive Train

Caterpillar
Caterpillar & Mitsubishi Grids Planetary
Inverter
AC Motor Supplier
AC Motor

MP – Inverter Speed Sensor

Control Temperature
Engine Alternator Rectifier

MP – Engine Voltage Speed Sensor

Control Regulator Temperature
Inverter
Grids AC Motor
Truck MP – Inverter
Controls Planetary
Control

Machine
Control
Software
20
Typical Competitive Electric Drive System

Truck Manufacturer
Engine Supplier Grids AC Motor
Inverter
AC System Supplier & Planetary

MP – Inverter Speed Sensor

Control Temperature
Engine Alternator Rectifier

MP – Engine Voltage
Control Regulator AC Motor
Inverter
& Planetary
Grids
Truck MP – Inverter Speed Sensor
Controls Control Temperature

Machine
Control
Software
21
Caterpillar Electric Drive

Mobile Test Bed

Design: 2004
22
Caterpillar Electric Drive

Ideas into iron…

Build: 2005

23
Caterpillar Electric Drive

…and it becomes a reality

May 26, 2005
• Assembly and start-up
completed per plan

• Cat’s first AC drive system

• Industry record for time

between engine start and
first propel

24
What Have We Achieved So Far?

• Tested components
• Tested software
• Developed control, braking
and cooling strategy
• Developed system integration
• Studied vehicle configuration
• Measured and evaluated
performance and efficiency

25
Discussion Points

• Our current situation

• Mining truck propulsion
• Electric drive history
at Caterpillar
• New Caterpillar engine
• Electric drive development
at Caterpillar
• Our future

26
Next Generation

• Mining truck safety: our #1 priority

• Substantial upgrade to all mechanical
drive products: 785C, 789C, 793D & 797B
• Electric drive will be released for two
models over 200 tons
• Gap between the 793D and the 797B will be addressed
• State of the art C175 engine
• Lowest cost per ton

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New Model Availability

Come see us at MINExpo in September 2008

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Caterpillar Mining Trucks

Hauling Towards The Future

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Caterpillar Mining Trucks

Ed McCord
Product Manager
Caterpillar Global Mining
March 30, 2006