Predictive Maintenance in Electric Mining
The shift from diesel to 100% battery-electric mining trucks has raised the technical complexity of operations. Ensuring fleet availability and performance now requires advanced strategies, with predictive maintenance standing out as one of the most effective. This approach allows operators to anticipate failures, optimize resources, and protect their investment in fleet electrification.
Monitoring Critical Variables to Prevent Failures
Predictive maintenance relies on continuous monitoring of the key variables that define the condition and performance of each system in the electric truck. Sensors placed in strategic areas send real-time data to analysis platforms.
The main variables monitored include:
- Operating temperatures of electric motors and power electronics
- Vibration levels in axles, gearboxes, and bearings
- Energy consumption and cycle efficiency
- Battery charge and discharge cycles, as well as battery health
- Cell imbalance and internal resistance within battery modules
Real-time monitoring not only detects potential failures but also provides valuable insights into how each component performs under daily operational demands.
Technical Traceability: A Key to Smarter Decision-Making
Traceability is built by recording and storing operational data throughout the truck’s entire lifecycle. Each sensor feeds into a technical history that allows operators to:
- Identify wear patterns or anomalies
- Link failures to specific operating conditions
- Plan interventions based on real-time conditions rather than fixed schedules
For example, if a traction motor shows temperatures above its normal range, the system enables proactive action without waiting for the next scheduled maintenance.
This process improves decision-making, prevents unnecessary downtime, and extends the lifespan of critical assets like batteries.
Impact on Mining Productivity and Operational Costs
Predictive maintenance delivers both technical and financial benefits. Beyond preventing failures, it helps maintain production levels even in demanding environments.
Operational advantages include:
- Detecting efficiency drops in regenerative braking and applying timely adjustments
- Anticipating battery autonomy loss to avoid production stoppages
Additionally, it enables:
- Reducing unnecessary spare parts inventory
- Maximizing truck utilization
As a result, mining operations achieve higher fleet availability, reduced downtime, and better resource allocation—generating savings on maintenance and strengthening production targets.
Extending Component Life through Remanufacturing
Accurate wear monitoring also opens the door for controlled remanufacturing. By accessing each component’s history, it becomes possible to decide which parts can be safely refurbished and reused.
For example, battery modules with manageable degradation can be reconfigured for further use, while others are retired as planned. This not only reduces replacement costs but also minimizes waste—supporting the operation’s sustainability goals.
Many mining companies already apply these strategies, as explored in our article on remanufacturing in mining.
Maximizing the Availability of 100% Battery-Electric Fleets
For fully battery-electric fleets, predictive maintenance is even more critical. Unlike diesel equipment, electric trucks lack auxiliary systems that allow them to keep running during major failures. Every stop impacts production and mine planning.
Applying predictive maintenance helps to:
- Ensure continuous operation, even during extended shifts
- Prevent electrical overloads and system failures
- Extend battery life and maintain efficiency
At NewSteel, we lead the conversion of diesel trucks to 100% battery-electric fleets in Latin America, providing mining companies with the tools to operate safer, more efficient fleets ready for the industry’s evolving challenges.
Ready to Improve Your Fleet’s Availability?
If your operation is ready to improve fleet availability and reduce downtime, NewSteel is your partner in driving this change. Our team is ready to guide you through the benefits of predictive maintenance and battery-electric truck conversions tailored for mining.
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