When upgrading makes more sense than buying a new machine
AE60 type locomotives are among the long proven solutions in mining traction. Mechanically robust, structurally stable and adapted to the demanding conditions of underground operation. Their limitation, however, tends to be the original lead battery technology.
As part of the modernization project , we carried out the overhaul of the AE60Pb locomotive, during which the original 332V / 340Ah battery was replaced by VONSCH LV01 147Ah Li-ion modules. The aim was not only to increase the capacity. The aim was to stabilise performance, reduce operational constraints and bring the power architecture of the machine up to current standards.
Limits of the original lead technology
The original lead-acid battery provided a real usable energy of approximately 68 kWh while respecting a safe depth of discharge. In practice, however, typical phenomena characteristic of lead-based systems occurred. Namely, voltage drop at higher loads, higher system weight and the need for regular maintenance.
For longer duty cycles, this meant fluctuations in the performance of the traction converters and a gradual degradation of the parameters. From the operator’s point of view, these are factors that affect both machine availability and the scheduling of service intervals.
New configuration: li-ion system VONSCH LV01 147Ah
The upgrade consisted in the implementation of 15 VONSCH 1P12S147Ah LV01 modules connected in series. With a capacity of 147 Ah and an energy of 6.544 kWh, each module is designed for traction and industrial applications in harsh environments.
Li-ion technology delivers a more stable voltage characteristic throughout the entire working cycle. The traction converters thus operate in the optimum range without significant voltage drops, which is directly reflected in the performance of the locomotive.
The system is integrated with the VONSCH LOKO BMS, which provides charge management, cell monitoring, over-current and short circuit protection and enables remote monitoring of the battery status. Energy management thus moves from a passive mode to a controlled and predictive model.
Energy and operational benefits of modernisation
Switching from lead to Li-ion means approximately 40-45% more usable energy for the same space availability. At the same time, there is a significant reduction in the weight of the battery system and an extended lifetime of over 2,000 charge cycles.
For the operator, this means more stable performance throughout the work shift, lower service interventions and more predictable system behaviour. The modernisation is thus not only technically, but also economically, especially in the long term TCO.
Repas as a comprehensive intervention in energy architecture
The AE60Pb refurbishment project was not limited to the replacement of the battery system. It included modifying the battery tray, implementing a new 24V power supply with UPS to power the BMS, upgrading the instrumentation ranges and updating the locomotive control software.
New DC safety relays and disconnectable connectors for service and charging were fitted. The entire intervention was carried out vertically from the power electronics to the machine control logic.
This approach allows the mechanical robustness of the original locomotive to be preserved, while at the same time significantly upgrading its power core.
Li-ion upgrading in mining traction as a milestone of the decade
Repase AE60Pb with Liion modules VONSCH 147Ah LV01 represents the biggest technological leap in the last decades in the field of mining battery locomotives. It makes the vintage locomotive a modern, powerful and safe machine ready for many more years in demanding service.
Summary of modernisation
- Original battery: 332 V / 340 Ah
- New system: 15× VONSCH LV01 147Ah
- +40-45 % usable energy
- Stable performance throughout the shift
- Lifetime over 2000 cycles
VONSCH – the energy conversion expert
We have been in the power electronics business for more than 30 years. We design solutions for mining traction, Small Hydropower Plants, Battery Storage and specific industrial applications.
The Repas AE60Pb is an example of a complex solution where technical expertise, detailed knowledge of energy processes and the ability to implement a functional unit come together.
We are searching for a technical truth. With enthusiasm. So that the result is not a compromise but a stable solution.
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Are you considering upgrading your traction locomotive?
If you operate a locomotive with lead-acid battery technology and are considering switching to a Li-ion system, we will be happy to assess the technical and economic options for upgrading.
Write to us.
