Reference · Traction drives · Mining
40–45% more usable energy per charge:Refurbishment of the AE60Pb mining locomotive – from lead-acid to Li-ion LV01
Modernizing the energy core of a proven machine – battery, BMS, protections and control software
Customer challenge
VONSCH solution - turnkey
The AE60 locomotives are mechanically robust and proven underground – their limit was the original lead-acid battery, 332 V / 340 Ah (≈68 kWh usable): voltage drop under load, high weight and regular maintenance.
This was not just a battery swap – the work ran vertically from power electronics to control logic. The lead-acid battery was replaced by 15 VONSCH LV01 modules (1P12S, 147 Ah, 6.544 kWh) in series, integrated with the VONSCH LOKO BMS.
Li-ion delivers a stable voltage characteristic across the whole cycle – the traction converters stay in their optimal range and the locomotive holds full power through the entire shift. We kept the proven mechanics and modernized only what limited operation. The LV01 modules are Li-ion NMC (CALB cells, developed with LYTH), certified to UN38.3 and EMC 2014/30/EU.
Scope of delivery (technical specification)
- 15× Li-ion module VONSCH 1P12S-147Ah LV01 (6.544 kWh/module, 44.5 V) in series
- VONSCH LOKO BMS – charge control, cell monitoring, protections, remote supervision
- New 24 V supply with UPS for the BMS
- New safety DC relays, disconnectable connectors for service and charging
- Battery tray modification
- Updated measuring ranges and locomotive control-software update
Project in numbers
What the customer gained
- Longer runtime per charge – 40–45% more usable energy in the same space
- Full power throughout the shift – stable voltage, no drops
- Lower system weight and battery life beyond 2000 charge cycles
- Fewer service interventions – no electrolyte maintenance or hydrogen venting; predictive LOKO BMS
- Preserved investment in proven mechanics – only the limiting part was modernized
Why VONSCH
We reduce the risk of a wrong decision - from design to service you deal with a single partner who stands behind the solution.
- A manufacturer, not a reseller - we develop and build power electronics in Brezno, Slovakia.
- A turnkey solution - one responsibility from design through installation to commissioning.
- Service and spare parts from Slovakia throughout the entire lifetime of the equipment.