Innovation in trucks and loaders has apparently plateaued for the moment. The machines out now represent the fruits of several seasons of research and development, and either have an established reputation or are on the fast-track to it. With a few noteworthy exceptions, the common headlines cover sales and deployments instead of new-release announcements. Even the big acquisitions are increasingly old news. The market for, shall we call it, the ESG-generation of trucks and LHDs is not necessarily mature, but it can buy its own drinks.
Synchronously, lithium-ion batteries and battery-electric technology in the space seems to be having its own peak moment as well. It has now been several quarters since the last major advance that significantly extended range or drastically diminished charge time. Futurists may dabble with the idea of nuclear batteries, but that would be the new horizon, equations in erasable ink on a whiteboard. And Honda’s supposed lithium- and cobalt-free, petrol-powered, closed-loop hybrid solution remains an internet rumor.
It is a similar situation for autonomous-control, remote-control and machine-monitoring technologies in the underground mucking and trucking space. Successive quarters defined by disruption have been followed by successive quarters of near-stasis, as suppliers release only minor updates and share use-case success stories.
Deployment and use-case success stories are typically geared to send newish solutions viral and to turn proven solutions into legends. The emphasis is typically not on new, market-disrupting solutions. Still, suppliers said there is no peak in R&D projects and spending. Endless, continuous development, they said, will bring the next round of updates, technologies, solutions and machines. The question is whether that round will be the first of either the post-ESG or the neo-ESG generation.
Compared to the TH551, the Toro TH551i has a low weight-to-size ratio that translates to significantly higher fuel efficiency. (Photo: Sandvik)
Sandvik Bullish on Toro
The two Toro TH551i trucks on their way to Oyu Tolgoi will be among the growing number operating far from their motherland. Despite the Spanish moniker, the truck can technically claim Australian heritage, being that is basically where it was bred, born and raised.
Legend has it, the original TH551 design was conceived almost 15 years ago in a workshop arranged for Australia-based customers. Initial development was fueled by feedback largely from the same miners. The prototype tested its bullish heft and grit in an Australian mine. Since then, its population in Australia has steadily grown.
And if it thrives there, it dominates elsewhere, said Esa-Pekka Kantola, product line manager, large trucks. “Most Australian mines are located in very harsh conditions, usually in the interior of the country, hundreds of kilometers from major cities,” he said. The first units were ultimately field proven in Australian mines, qualifying the truck for duty almost anywhere, a fact not lost on the market. “The Toro TH551i dump truck is now a legacy leading product throughout the world.”
It earned that accolade because it checks off several boxes. The truck is “designed to be powerful and efficient, while also keeping the total cost of ownership low,” Kantola said.
The TH551i is roughly 11 meters (m) from tip to tip, 3.5 m wide, 3.5 m from top to ground, and weighs about 47 metric tons (mt). The low weight-to-size ratio translates to a significantly lower fuel burn compared to its predecessor, he said.
The Volvo TAD1643VE-B engine provides 565 kilowatts (kW), and delivers 3,200 nanometers (Nm) of torque. It “has, on average, 25% better fuel efficiency than all other OEMs, making it the most efficient on the market,” Kantola said. “Sustainability is further enhanced because the Volvo Penta engines can use traditional diesel fuel, as well as a variety of paraffinic and hydrotreated vegetable oil diesel, which is derived from food and forestry waste materials.”
Part of the i-series, the truck has several integrated technologies that help reduce downtime and increase productivity. Managing those technologies is the Intelligent Control System, which “compiles all diagnostics and alarm log files,” he said. “This can range from identifying the need for a filter change, sensors and transmission self-diagnostics, among other notifications.” Accessible via an in-cab monitor, the system runs all the subsystems.
One is AutoMine, “which allows for remote operation of the equipment,” Kantola said. Available in multiple packages, AutoMine is “installed in the factory during assembly or can be easily added after it is in production.”
Another is the Integrated Weighing System, which calculates the amount of ore in the bucket. “It does this by considering the environmental temperature and the truck’s inclination angle, and it has a three-point measurement system on the dump box,” he said. It alerts the operator when the rated capacity is reached.
The rated capacity “is based on a 90% fill factor, which reflects actual mining conditions to ensure reliable performance expectations,” Kantola said. “While some figures in the market may be based on theoretical 100% fill factors, this is rarely achievable in real-world mining operations,” he said. “Our approach provides a more accurate representation of usable capacity.”
A third is the Integrated Jacking System, which helps maximize uptime. “This consists of four remote-controlled hydraulic cylinders on the front and rear frames of the truck, which can lift it even with a full load, on level ground, to quickly change one or more tires,” he said. “This reduces downtime as, usually, the truck would need to be towed to a maintenance bay to change the tire.”
Data captured by the control system can be relayed to MySandvik Digital Services. Among those services is the Knowledge Box, “which organizes the data and gives equipment health for a single machine or for an entire fleet,” Kantola said. The data is arranged as “productivity and utilization information on a dashboard.”
A proximity detection interface is available. It can take “automatic action, which includes slowing down or stopping the equipment,” he said. “It is also compatible with third-party proximity detection systems.”
When the TH551 was upgraded several years ago to the i-series “intelligent version, the overall weight reduction, by using less steel, was also designed into it,” Kantola said. The reduced mass and optional Traction Control technology “helps the customer reduce tire wear and the frequency of needed tire changes,” he said. “Combine that with the control system monitoring a variety of machine functions to alert the operator before damage happens and customers see lower fuel and component costs and better monitoring to keep the equipment in production longer.”
Australia continues to be the seedbed of innovation for Sandvik trucks. The supplier is currently “developing a diesel-electric version of a large dump truck” and Australian customers are again intimately involved, Kantola said. “They have visited our factory in Turku, Finland, quite a few times over the last year and a half, and we will be testing the first prototype in one of their operated mines.”
Among the first of the rebranded GHH machines, the HX45 truck, with a power rating of 460 kW, is ideally paired with the WX15 15-mt LHD for efficient three-pass loading in mid-seam mass-mining, low-profile and industrial-mineral applications. (Photo: Komatsu)
Komatsu Onboards GHH
Komatsu said the acquisition of GHH in 2024 upsized its underground loading and trucking business to the benefit of customers. “We are uniquely positioned to capture new opportunities in the underground hard rock market,” said Jason Smith, vice president, operations and aftermarket, hard rock. The acquisition “enhances our ability to meet the diverse needs of customers worldwide by expanding our product portfolio, geographic footprint and technical expertise.”
GHH’s offerings “coupled with Komatsu’s scale and resources, allow us to accelerate innovation, deliver more value, and further establish Komatsu as a leader in underground mining solutions,” he said. With the acquisition, Komatsu gained “talented people and proven expertise,” positioning it “to deliver greater innovation and local support globally.” GHH facilities around the world “significantly extend” Komatsu’s “reach and service capability.”
Currently, the supplier is focused on “ensuring a seamless transition” and “integrating the GHH product line,” Smith said. “We’re also advancing automation, digital tools and safety-enhancing features across the product line.”
Ultimately, the acquisition will result in “fit-for-purpose products supported by local service teams, while also providing advanced solutions such as remote operation, automation and digital analytics,” he said. “Our focus is on being a long-term partner who can help customers meet today’s operational demands while preparing for the challenges of tomorrow.”
The first fit-for-purpose products are expected to expand “Komatsu’s underground portfolio beyond our historic strength in narrow vein mining, enabling us to serve mid-seam mass mining, low-profile and industrial mineral applications,” Smith said. “With products like the WX15 LHD and the HX20, HX30 and HX45 underground mining trucks, we can now address a broader range of customer needs.”
Komatsu showcased the HX45 at MINExpo 2024, where it garnered the attention it deserves, a Komatsu truck expert said. “Since then, we’ve been preparing to bring the truck into new markets globally, expanding availability beyond its existing footprint in Europe, Southern Africa, India and Latin America,” said Ingo Rath, global product manager, trucks, hard rock, Komatsu. “The HX45 represents one of the first rebranded GHH machines to be integrated into the Komatsu portfolio and will play a central role in our strategy to grow in the mid-seam mass mining and industrial minerals segments.”
The 45-mt truck is “designed for high productivity and durability in tough conditions,” he said. “It delivers a best-in-class power rating of 460 kW, an excellent turning radius for maneuverability in confined underground environments, and an exceptional 68° dumping angle that reduces material carry-back.” The design offers “efficient material movement cycle after cycle.”
That efficiency “translates to less wasted fuel and lower emissions per ton moved,” he said. “Its durable frame and components” ensure uptime and “extend machine life, further supporting both environmental and economic goals.”
Safety goals are supported by the cabin design. “Intuitive controls, air conditioning, excellent visibility and an additional trainer seat” can help boost operator vigilance and performance, he said. The “oscillating articulation and suspension system provide smooth maneuverability in challenging conditions, enhancing both operator comfort and machine longevity.”
The cabin design offers “safety and ease of operation, while optional features like data logging, payload weighing and digital analytics enable customers to optimize performance and maintenance,” Rath said. Other safety features include fire suppression, camera systems and “optimized LED lighting.” A proximity detection system is available.
The HX45 is best paired with the WX15 15-mt LHD for three-pass loading.
The truck is “already working successfully in multiple underground operations worldwide, where customers have highlighted its productivity and reliability in challenging applications,” he said. “With the integration into Komatsu’s global network, customer interest has accelerated, and we are seeing strong demand as we prepare to expand into additional markets.”
Future development of the truck will equip it with “advanced digital, automation and sustainability features,” Rath said.
“Customers can expect enhancements such as expanded compatibility with digital analytics platforms, greater automation readiness and alignment with future emissions standards,” he said. “Long term, the HX45 will form part of a broader portfolio of trucks and loaders designed to work seamlessly together, offering customers integrated solutions for productivity, safety and sustainability underground.”
In early 2025, Aramine released the L440B, with 13 mt of breakout lift force. More recently, it announced and its sibling, the L640B, which could complete the B-series of loaders. (Photo: Aramine)
Aramine Adds Sibling B-series Loaders
On the heels of the release of the L440B battery-powered loader, Aramine announced its “big sister,” the L640B, with a 6.2-mt capacity bucket. Leadership at the company said the model is the result of a winning development strategy. “From the very beginning, we made a bold choice that has proven to be the right one,” said Sylvain Reynier, director, engineering and R&D. “Instead of electrifying a diesel machine, we started from scratch to design a true battery-powered machine.”
The design and the philosophy behind the L640B is basically the “same as those of the L440B and L140B,” he said. “Since these machines have been a strong success, we have no doubt the L640B will follow the same path.”
The loader’s capabilities and features answer trending industry challenges, he said. “The L640B provides the ideal solution for mines with larger gallery sections seeking a 6-mt battery-powered LHD.”
The L640B is “equipped with a fully detachable rear energy module, consisting of a 224-kWh battery pack and its onboard charger,” Reynier said. “It offers an autonomy of four to seven hours, depending on the mine’s condition.”
With the Quick Replacement System (QRS), “the energy module can be recharged near any electrical installation in the mine with a simple winch, and swapped in less than 10 minutes,” he said. “With two energy modules, the machine can operate continuously without requiring any fixed infrastructure in the mine.”
Continuous operation and a 3.1-m3 bucket make it “the ideal solution to ensure mine productivity while delivering zero CO2 emissions during operation,” Reynier said. It also offers “greater operator comfort thanks to significantly lower noise levels, reduced ambient temperature and decreased costs of maintenance and costs related to ventilation and diesel supply.”
The model has the chassis, articulation system, energy module and major components of the L440B. Aramine literature said the L440B is 8.7 m from tip to tip, 2.3 m from road to cab top, and 1.7 m wide. Weighing in at 19.2 mt, it offers 4.6 mt of tramming capacity, 12 mt of tractive effort, and 13 mt of breakout lift force. It comes with a 2.4-m3 bucket.
Standard technology includes the “microSD for data collection and analysis of machine functions,” Aramine said. It arrives ready for remote control. Autonomous operation and a personnel detection system are optional.
The release of the L440B and the L640B furthers Aramine’s mission to develop battery-powered equipment for the electrified mines of today and tomorrow, Reynier said. “Overall, they are cost-efficient, sustainable, and future-proof investments.”
Aramine launched the L140B a decade ago. “In 10 years, we have produced 50 units of the L140B, and our machines are operating in a wide range of demanding environments, from 4,000-m altitude to deep and hot underground conditions,” he said.
“We have built on the enthusiastic feedback from our customers, and our QRS system has proven its reliability,” Reynier said. “The evolution of battery capacity in recent years has allowed us to consider offering a larger battery-powered loader, and thus the first models of our L440B loader rolled out of our production center at the beginning of 2025.”
As those models are deployed, the supplier is growing its production capacity. “The goal is to continue expanding our range of battery-powered machines, in particular by developing battery-powered trucks that match our L440B and L640B loaders,” he said. To achieve that goal, the company is building new facilities “not far from our existing production workshop, mainly to increase our production capacity for battery-powered equipment.”
Aramine hopes to “offer a complete range of battery-powered machines,” Reynier said. “We have long believed in the decarbonization of mining, all the more so since the health and safety of miners has always been the top priority in the design of all our machines.”
Above, the crew that installed AutoNav on a Cat R2900 XE Hybrid loader for AIC Mines at the Eloise copper mine in Northwest Queensland. The announcement for the installation was the third in one quarter. (Photo: RCT)
RCT Reports Regular Deployments
Recently, RCT reported Stawell Gold mine in Australia automated two new Cat 2900XE diesel-electric loaders with AutoNav. The loaders join a fleet of Epiroc ST18S loaders with AutoNav that are managed remotely from control centers in the mine and on the surface.
The miner wanted the entire loader fleet on AutoNav to eliminate the costs “and the complexity of running parallel systems,” said Owen Perrott, branch manager, Brisbane, RCT. “No need for duplicate operator stations or double the support resources, just one unified, streamlined setup.”
The mixed fleet on AutoNav “makes this project unique,” he said. The site can seamlessly rotate in and out Cat and Epiroc loaders “with zero system modifications.” The capability delivers optionality and uptime.
“This approach future-proofs Stawell’s operations by eliminating vendor lock-in and empowering the team to integrate machines from any OEM without disrupting their automation framework,” Perrott said. “It’s a smart, scalable solution built for today, and ready for tomorrow.”
The installation and transition went smoothly due in part to “the fact that today’s hybrid and diesel systems are quite similar in terms of setup and functionality,” he said. “For the operators, they were already familiar with the AutoNav system.” They required no retraining. The “consistency also reduces operator fatigue and confusion, promoting wellbeing and safer operation.”
AutoNav enables “five scalable tiers of automation, from line-of-sight to fleet automation,” said Hari Prakash, product manager, automation and control, RCT. It allows a mine to incrementally “adopt automation at a pace that matches their capability and infrastructure.”
It offers useful data and real-time analytics. And, critically, it is OEM-agnostic and compatible with “any make or model of machine,” he said. “Its modular, scalable design effectively reduces barriers when integrating with legacy fleets and infrastructure.”
Machines on AutoNav are controlled by the AutoNav Center, which can be located almost anywhere. In it, “operators are removed from hazardous areas and work from secure, ergonomic stations,” Prakash said. Hardware includes a “purpose-built operator chair designed for advanced automation, unlocking autonomous functions while giving operators complete, real-time visibility of the work area.”
AutoNav features several key functions that “address trending industry challenges,” he said.
With the multi-machine select function, “an operator can switch between machines of the same type, across different work areas or levels,” Prakash said. “Only one machine is actively controlled at a time.” With the multi-machine control function, “an operator can simultaneously control multiple machines of the same type, improving productivity and optimizing machine utilization per operator.”
The autonomous tramming function “uses advanced algorithms to continuously map the machine’s position in the drive, extending autonomous tramming runtime and boosting productivity,” he said. “Automated tramming and dumping improve cycle consistency and reduce delays, meaning more metric tons moved per shift.” Improved consistency reduces “unnecessary fuel burn and wear, cutting emissions and extending machine life.”
The machine containment system “maintains safety by ensuring remote or autonomous machines stay within designated operating zones and by keeping personnel out of restricted or hazardous areas,” Prakash said. It reduces the risk of incidents, and “also supports compliance with safety standards and reduces downtime from accidents.”
The G-Data function captures and displays diagnostic and performance data to support “informed decisions,” he said. “Centralized diagnostics like the G-Data feature help predict maintenance needs, reducing waste and unplanned stoppages.”
AutoNav launched in 2009 and was incrementally updated with new capabilities over the years. By 2022, machines on AutoNav tallied a combined total of 8 million automation hours, Prakash said.
More recently, in early 2024, the supplier announced AutoNav was installed on loaders at IGO Ltd.’s Nova mine in Western Australia. The mine adopted both underground and surface control centers. It was the latest in a series of installations at operations in the region.
Subsequently, the supplier said the solution was installed on two Cat 2900 loaders at Hillgrove Resources Kanmantoo copper mine. The AutoNav center was located “away from the active mining area,” RCT said.
In early 2025, RCT reported AutoNav was installed on Cat 349D excavators at a mine in Western Australia’s Pilbara region. It was the first time the system was used on that excavator model.
In August, RCT reported the solution was installed on a fleet of Sandvik LH517i loaders at two Goldfields sites. AutoNav Centers were located both on the surface and underground.
In September, RCT reported it installed AutoNav on a Cat R2900 XE Hybrid loader for AIC Mines at the Eloise copper mine in Northwest Queensland. The development means the miner “is operating with our automation technology across most of its fleet,” RCT said. Operators work from “cabins located underground.” The mine reportedly plans to build a surface control center. The deployment is also the first time AutoNav has been installed on a Cat Hybrid model loader.
These miners and others reported they relish the increased production and improved safety, Perrott said. “AutoNav enables loaders to operate at higher tram speeds (6 to 12 km/h), streamlines operator performance across the fleet and boosts overall productivity,” he said. “In essence, it gives mines safer operations, higher output, and better asset utilization.”
Prakash said future updates to AutoNav will include the integration of ultra-wideband technology, artificial intelligence-powered decision support, sensor optimization, optimized automation, improved controls with new features, a stope scanner “to assess the stability of the stope” and a more advanced machine containment system.
Hovermap LHD Delivers Survey-grade Assessments
By Jesse Morton, Technical Writer
Emesent said Hovermap LHD is in high demand because it offers fast survey-grade volume assessments. It can also map possible emergent hazards in mere minutes, preventing downtime and safety incidents.
Mounted by magnetic feet to the cab or bucket of an LHD, the system “uses advanced SLAM-based LiDAR-scanning technology, offering a 300-m range and a 360° field of view to capture and visualize survey-grade point clouds in the field,” the company said in a use-case study. It “connects to the mine’s network via the machine’s onboard Wi-Fi.” It can also be operated by hand, installed “on a backpack, mounted on a drone, vehicle, ground robot, CMS boom, or lowered into shafts in a cage.”
It can “continuously scan and visualize a comprehensive 360° point cloud of the entire stope, even in zero-light conditions, using a dedicated tablet,” Emesent said.
Hovermap LHD usage requires no technical training. That translates to survey-grade accuracy without surveyor dependency, the company said. It delivers “quick identification of remaining stope volume” for “more effective planning of equipment allocation, significantly boosting productivity.” Productivity grains can mean increased stope turnover.
The system can also be used to rapidly map emergent hazards, Emesent said. “The same Hovermap unit as deployed via LHD can also operate without direct human presence in hazardous areas via drone or robot,” said Dr. Stefan Hrabar, co-founder and chief strategy officer. It can identify “loose rocks, overhangs, steep rill angles and oversize material.” And it does it quickly, reducing from days to minutes the time it takes to assess a possible hazard, he said.
Quick, accurate hazard assessment can prevent incidents. By that alone, the system pays “for itself with just 2 or 3 hours of downtime prevention, with the return on investment increasing over time,” Emesent said.
It also pays for itself by delivering information that can be used in optimizing operations to reduce fuel consumption, Hrabar said.
These benefits have been proven on mine sites.
Contract miner Byrnecut was in search of a stope-assessment solution that offered more detail than do 2D cameras and that could generate results quicker than do traditional cavity monitoring systems. The miner basically wanted “24/7 scanning capability for crews,” Hrabar said.
The miner deployed Hovermap LHD. The solution “dramatically reduced the time needed to identify hazards such as steep rill angles, oversize material; and it confirmed the stability of brows, walls and crowns during remote bogging operations,” Emesent said. “Areas that once took up to two days to scan and process can now be captured and visualized in just 10 minutes.”
Based on those results, “Byrnecut decided to roll out Hovermap LHD to additional mine sites, further advancing their commitment to safety and productivity,” the supplier said. Currently, Hovermap LHD is also being deployed by Northern Star. The solution is seeing “growing interest” from operations in Africa and the Americas, Hrabar said. The deployments and interest reflect Emesent’s continuous growth in the underground remote monitoring and mapping space.
The original Hovermap for drones launched roughly a half decade ago. Over the years, it evolved to operate on a range of platforms and to integrate into existing networks. Its population ultimately grew to more than 1,500 units to be deployed around the world. Hrabar said the success has made Hovermap the “world leader in drone autonomy, LiDAR mapping and data analytics.”