Charging solutions for the mining industry

Big and heavy mining vehicles require high charging power to charge their large capacity batteries. Stäubli understands these requirements and has invested heaviliy into developing a solution that can match the needs of the mining industry.

The QCC-5000 system delivers class-leading 7.5 MW of charging power, all packaged within a robust, reliable and easy to automate package. Higher charging power is all about properly managing heat. By heavily focusing on cooled cables and conducting extensive test sessions, currents up 4250 A continuous and 5000 A peak could be achieved.

Due to the nature of the charging system, only the charging pin needs cooling, while the socked inside the vehicle remains uncooled.  

To achieve interoperability within the mining fleet, having a charging solution that follows an international standard is key. Stäubli champions compliance with these standards, and the Quick Charging Connector System (QCC-5000) for the mining industry aligns with SAE J3105/3. This open standard, encompassing the design of charging pins and sockets, paves the way for various suppliers to provide compatible solutions.

While the SAE J3105/3 based QCC system has been around for years and has proven itself in many demanding environments, Stäubli has undertaken extensive developments on the system to adapt to the ever-growing charging-power needs of the mining industry. 

Overall the QCC-5000 system is designed according to the following standards: SAE J3105, SAE J3105/3, IEC 63407, IEC 61851-23-1

Learn more about SAE J3105/3

One of the key elements that makes the QCC-5000 stand out is how it combines charging power, safety and automation possibilites. Using an automated connection device increases operational safety in mines and means that drivers do no longer have to get out of their vehicle to initiate the charging process. Depending on the application, vehicle type and general customer needs, the QCC-5000 system offers a variety of integration possibilities:

• Standard Stäubli guiding system
• Mounted to a robot arm
• Fully customized solutions.

Furthermore, the system is fully mating compatible with the already existing, tried and tested QCC-1500.

Following Stäubli's vision of making work easy and safe, the QCC-5000 automatic charging connector was designed with highest safety measures in mind. The complete connector is IP56 protected in unmated start, with the charging contacts only being revealed at the end of the connection process, when full pin and socket are fully connected. Current manual systems feature unprotected contacts making them more prone to failure in demanding mining application while also exposing workforce to higher risks.

The Stäubli system allows vehicles to mate with a charger automatically, without the driver leaving the cab, which enables fastest connection times and avoids the necessasity of the operator to come near the high current.

QCC-5000 leaves different possibilities for integration and automation whereby additional enclosures and safety procautions can further increase the operational safety of this automatic connection system.

As a charging solution that places a big focus of robustness and reliability, the quick charging connector QCC was specifically designed to be used in harsh environments. This makes QCC a favoured charging solution in many industries such like the port industry, where our system has proven itself for 6+ years and established itself as the market leader.

The QCC-5000 features a ruggedized cunstruction and highest protection of its critical components. To guarantee uninterrupted charging cycles, seals and touch protection keep the contacts clean from water and dust, despite the harsh surroundings.