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Planning charging for electric mining equipment starts with the machine’s real duty cycle—not a generic runtime estimate. Map travel, gradients, productive work, idle periods, shift schedules and routes; then choose charging or swapping arrangements that meet that work without creating unplanned travel, queues or power constraints.
There is no universal answer to whether a mine should charge batteries on the vehicle or swap them. The right operating system depends on the equipment, mine layout, power supply, production schedule, battery interfaces and safety requirements. This guide focuses mainly on underground battery-electric vehicles; the Oyu Tolgoi example is an aboveground demonstration, not a template for underground production.
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What should a mine plan before choosing charging or battery swapping?
Plan energy as part of the production system. A battery-electric machine needs enough usable energy to complete its assigned work between energy events, while the mine needs a practical way to deliver that energy without compromising output, safety or future development. Battery capacity is central to a vehicle’s operating envelope, particularly for energy-intensive heavy equipment; actual range and runtime depend on the machine and its duty cycle, as the Global Mining Guidelines Group (GMG) recommended practices explain.
Work through the fleet and the infrastructure together: operating cycles, charging windows, station locations, available electrical capacity, spare-pack flow, compatibility, training, emergency response and maintenance. Revisit the plan once the fleet is operating. A machine’s published runtime or a supplier’s swap-time figure describes a particular product or project, not a guarantee for another mine.
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How do I plan charging for electric mining equipment?
Start by documenting what each machine must do in a real shift, including demanding periods and changes as the mine advances. Use that operating picture to estimate when energy is needed, where the machine can receive it and how charging or swapping affects production time.
- Define the work by machine. Record the equipment type, task, loaded and empty travel, route distance, gradients, productive work, idle periods, breaks and shift length. Capture cycle-time variation and peak-duty periods, not just an average shift. A short, steep loaded haul can place different demands on a pack than a longer, less demanding route.
- Map the mine and its changes. Locate active headings, ramps, shafts, service areas, parking and potential charging or swap locations. Include the time and distance to reach each energy point. Account for route changes as development advances; a station that is convenient today may become a detour or a bottleneck later.
- Model the schedule. List how many machines operate at once, when shifts change, where breaks fall and when production peaks. Determine whether energy events can fit into a scheduled pause or would interrupt productive work. Include the time to leave the work area, travel to a station, queue, connect or change a pack, and return.
- Establish the operating requirement. Work with the equipment OEM to determine usable energy, charging limits and expected runtime for the intended duty. Plan against difficult operating periods and the consequences of a depleted machine, rather than sizing only around a favorable average.
- Compare feasible energy strategies. Evaluate onboard charging, off-board charging, opportunity charging, swapping or a combination. Compare the effect on runtime, travel, waiting, availability, power demand, infrastructure and staffing.
- Coordinate with electrical and mine planning. Estimate simultaneous charger use and include other mine loads such as ventilation, pumps and lighting. Check supply routes, transformer capacity, future development and any planned generation or storage with the relevant specialists.
- Set controls and review measures. Define safe work procedures, training, inspection, maintenance, emergency response and the operating data that will show whether the plan is working. Review the arrangement after commissioning and revise it as the fleet or mine changes.
The GMG guideline treats implementation as a connected business-case, mine-design, battery, charging, interface and performance question—not a vehicle-only purchase. Its 2022 Version 3 recommendations are general guidance, not a substitute for local regulations, site standards, OEM instructions or specialist engineering.
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On-vehicle charging can suit a fleet whose machines have useful charging windows and access to appropriate charging points. Swapping can suit work that needs a machine back in service before its pack can recharge, but it replaces charging downtime with a more involved battery logistics, handling and safety system.
Compare the full operating cycle, not just the minutes spent connected to a charger or changing a pack. A fast swap may still add travel, queueing or handling time; charging can be efficient operationally if it takes place during a pause the shift already includes. GMG says the choice of charging method depends on operational needs and notes that where battery runtime is substantially shorter than shift length, swapping, in-shift charging or opportunity charging may be needed.
| Approach | Potential fit | Plan for | Key trade-off |
|---|---|---|---|
| Onboard charging | A machine can remain at a suitable charging point during a planned pause or shift transition. | Compatible onboard equipment, connection access, charging window, power supply and protection of connectors and cables. | Charging occupies the machine and may require travel to a fixed point; useful work time depends on when and where charging occurs. |
| Off-board charging | A pack can be charged away from the machine, with a compatible battery-change process. | Chargers, pack inventory, charging locations, handling method, safe staging and clear tracking of pack condition and charge state. | The vehicle may return to work sooner, but the mine must manage the packs, charging capacity and handling workflow. |
| Opportunity charging | Short, planned energy events can be incorporated into the work cycle at accessible locations. | Station placement, charger compatibility, time available at each stop, traffic and simultaneous demand. | Can reduce the need for a single long charging stop, but only if the route and production schedule provide dependable opportunities. |
| Battery swapping | Work requires a machine to resume operation before its removed pack can recharge. | Compatible pack and vehicle integration, spare packs, chargers, handling equipment or an OEM-specific swap mechanism, station space and procedures. | Can reduce the machine’s stationary energy-event time, but adds inventory, power, handling, space and safety requirements. |
| Mixed strategy | Different machine types, routes or schedules have different energy needs. | Separate duty analysis, clear interfaces, coordinated infrastructure, operating rules and workforce training. | Can fit varied work, but introduces more coordination and may complicate common charging or swap arrangements. |
For a long uphill haul, evaluate swapping, charging points along the grade, opportunity charging or energy storage as options. Consider the operational profile and downhill regenerative braking when assessing locations. None is automatically best. In surface operations, investigate whether trolley assist, battery-electric haulage or another approach suits the haul profile and project design; the available guidance does not establish one solution for all pits.
Where should charging stations go in an underground mine?
Place stations where they fit the mine’s current and future routes, power supply and operating schedule—not merely where an excavation is available. Account for access, congestion, personnel movement, parking, cables, maintenance and the time a machine spends travelling to and from the station.
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Assess each candidate location against:
- Operating access: distance from active work and the likely route back into production; ramp and shaft access; traffic conflicts; safe vehicle approach, parking and exit.
- Mine development: planned heading advances, changing routes, station relocation options and whether excavation and access will remain practical.
- Electrical supply: distance and route for power distribution, other connected loads, charger demand and the prospect of future fleet expansion.
- People and equipment: room to work safely, clear visibility, protected access and adequate egress for personnel and service work.
- Environment and upkeep: ventilation or cooling needs, water and mud exposure, level cleanable floors, cable abrasion and connector protection.
- Emergency provisions: suitable fire detection, emergency isolation and other controls determined by the site’s risk assessment and applicable requirements.
These factors reflect GMG’s recommendations for underground charging areas, including ventilation or cooling, separation from hazardous areas, personnel space, fire detection, an emergency off switch, parking, water and mud protection, cable wear, visibility and cleanable floors. The final design must also satisfy the mine’s local rules, technical requirements and site standards.
How many spare batteries and chargers does a mine need?
There is no universal spare-pack ratio or charger count in the available guidance. Calculate the inventory and charging capacity from the fleet schedule, energy demand, charging duration, required availability, maintenance needs and peak operating conditions, using the selected OEM’s specifications.
For each machine or group of compatible machines, map the pack flow through the day: packs in service, packs awaiting charge, packs charging, charged packs ready to deploy and packs unavailable for inspection or maintenance. Check whether that flow can meet production demand when machines operate simultaneously or a pack is delayed. A plan based only on average demand can fail during a peak period or when equipment is unavailable.
Next, match charger capacity and operating windows to the number of packs that need charging and the time required by the specified equipment. Model how chargers overlap with other mine loads. GMG advises accounting for simultaneous equipment operation when selecting transformers and including charger operation in the electrical load plan for an all-electric mine. ABB also recommends coordinating grid infrastructure and battery energy storage planning with production forecasting to manage load peaks and generation volatility; this is supplier guidance, not a universal sizing formula.
For a swap arrangement, also include charging and staging space, delivery of discharged packs, the means of handling packs, safe access and egress, and the procedures that keep packs at the appropriate charge and service status. A compatible crane may be needed in some designs, while some OEM systems use a machine-mounted mechanism or ground-level change and may avoid some station hardware. Let the selected machine’s requirements define the layout; a generic station drawing cannot establish the right inventory or equipment for every fleet.
How do charging and swapping affect mine power requirements?
They add electrical loads that must be planned alongside production and essential mine services. Charger and transformer decisions depend on how many machines and chargers may operate simultaneously, the charging philosophy, the equipment’s specified requirements and the mine’s broader power system.
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Build an operating-load picture by time period. Include charging windows and overlap, plus loads such as ventilation, pumping and lighting. Ask whether chargers would coincide with other high-demand work and whether planned fleet growth or mine development will change the load. Do not treat the sum of charger nameplate figures as a complete site power plan or infer a universal kilowatt requirement from an example machine: the mine’s operating schedule and supplier specifications matter.
Where grid capacity, generation variability or future expansion is a concern, assess the supply and any battery energy storage as part of production forecasting. ABB describes coordinating grid infrastructure and storage planning with mine production forecasts; the specific design requires site electrical engineering. If supply is constrained, compare operational changes—such as charging windows, charging locations or a different energy strategy—with any proposed infrastructure investment instead of assuming a single fix.
What safety and maintenance controls does a charging or swap station need?
Charging stations and swap areas need engineered controls, trained personnel and clear operating procedures. Battery and electrical hazards can include fire or explosion, electric shock and arcing faults, so a station plan should address prevention, detection, isolation, emergency response and safe access.
At minimum, develop site-specific procedures and responsibilities for:
- Battery movement and connection: approved handling methods, compatible equipment, inspection before use, safe connection and disconnection, and control of access to the work area.
- Electrical isolation: emergency shutoff, safe maintenance isolation and procedures for responding to faults or damaged equipment.
- Fire and abnormal conditions: detection, alarm escalation, response and any suppression provisions required by the risk assessment, OEM instructions and local requirements.
- Station conditions: ventilation or cooling where required, separation from hazardous areas, suitable parking, protected cables and connectors, cleanable floors and clear egress.
- Training and upkeep: personnel training, inspection schedules, maintenance responsibilities, battery monitoring and records of faults or damage.
For swaps, plan a safe working space around the battery movement and ensure that routes, equipment and staging do not block access or egress. The exact handling system and controls depend on the equipment design. GMG’s guideline discusses fire and explosion, shock and arcing risks, detection, suppression, emergency isolation and swap-space safety; it is general recommended practice and does not replace local law, the site’s risk controls, OEM instructions or qualified engineering advice.
How do equipment compatibility and interfaces affect the plan?
Confirm compatibility with the machine and infrastructure suppliers before committing to a common charging or swapping layout. Electrical connection alone does not make batteries interchangeable: pack dimensions, vehicle integration, controls and handling requirements can also determine whether packs or stations work across equipment.
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Check the intended configuration for voltage, power acceptance, connector and communications, charger output range, charging controls, battery dimensions and form factor, handling method, maintenance and service arrangements. Ask which interfaces are supported by each machine and charger, what operating limits apply and how a mixed fleet will be managed. Record the answers in procurement and commissioning requirements rather than relying on a general statement about standardization.
GMG recommends standardization as far as possible but notes that swap interoperability is complicated by pack form factor and vehicle integration. ABB describes open standards such as CCS and OPPCharge for its charging infrastructure; that supplier description should not be generalized to every mining machine or swap system. Verify the actual interfaces supported by the selected equipment.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.What can published mine electrification examples tell planners?
Examples help define the questions to ask, but their figures belong to their named machine, site and operating context. They are not interchangeable runtime, productivity or swap-time assumptions for a different mine.
| Reported example | What the source says | How to use it |
|---|---|---|
| Epiroc fleet and customer figures, 2025 | Epiroc reported more than 600 electric drill rigs, loaders and mining trucks at year-end 2025; 40 mine sites had ordered BEV equipment, and more than 40% of operating sites had placed repeat orders. | These are company-reported fleet and customer figures. They indicate adoption reported by the supplier, not a performance guarantee for a particular project. |
| Boliden Kristineberg trolley comparison, 2025 | Epiroc reported 23% higher productivity for its electrified ramp-haulage trolley solution at Boliden’s Kristineberg mine versus a diesel-driven equivalent. | Keep the named mine, trolley solution and diesel comparison attached to the figure. It is not a general productivity estimate for battery-electric vehicles. |
| Oyu Tolgoi truck demonstration announcement, 2024 | Rio Tinto announced a two-year demonstration in aboveground, non-production work involving eight trucks with 91-tonne payloads, 13 batteries of 800 kWh and a robotic swapping and charging station. The announcement said each battery was expected to last up to eight hours depending on work and a swap was expected to take around seven minutes. | These were announced project specifications and expectations, not independently measured results. The announcement does not confirm the demonstration’s present completion status, and the aboveground setting differs from underground production. |
| Komatsu WX04B underground LHD, 2024 | Komatsu reported four hours of runtime and approximately two hours to recharge for its 4-tonne WX04B underground LHD and associated charging offer. It also described a ground-level swap process and an OEM-agnostic 150 kW charger for underground hard-rock mining. | These are supplier-reported product figures and descriptions. Confirm the specifications, charging arrangement and compatibility for the machine and site being considered. |
| Sandvik loader and truck battery systems, 2025 | Sandvik reported 410 kWh battery systems and three to five hours per charge for its loader and truck systems at the time of publication. It reported about three minutes per battery change for its underground charging station with AutoSwap and AutoConnect. | These are product-specific supplier figures. Compare with another system only after matching equipment, duty and operating conditions. |
The examples show why figures should be treated as inputs to questions rather than planning defaults. Ask what task, route, payload, charging setup and conditions underlie a runtime or productivity claim; then obtain the selected OEM’s data for the proposed duty and validate it against site operations.
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After commissioning, compare actual operation with the assumptions used to plan the system. Track production and energy events together so the mine can distinguish a battery limitation from travel, queueing, charger use, maintenance or schedule effects.
Useful measures include machine output and cycle time; charging and swap duration; energy use; charger utilization; battery state and health; equipment availability and utilization; downtime causes; and electrical demand peaks. Review whether machines reach energy points as expected, whether stations are accessible as routes change, whether charger demand coincides with other loads and whether the pack inventory covers peaks and maintenance.
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Use the findings to revise charging windows, station placement, battery inventory, power management, operating procedures or the fleet plan. GMG recommends collecting and analyzing operational data because charging and swapping complicate the BEV duty cycle. Set review intervals and ownership before deployment, so decisions are based on recorded operating evidence rather than a single headline runtime or a short observation period.
What mistakes make charging plans unreliable?
The most common planning weakness is treating energy delivery as an equipment specification instead of a mine-wide operating system. Avoid these failure modes:
- Using a generic runtime: published hours do not establish performance under the mine’s payload, gradient, travel, work pattern or temperature and operating conditions. Obtain duty-specific OEM guidance.
- Counting only plug-in or swap time: include detours, queuing, parking, connection or handling, return travel and schedule disruption.
- Sizing around average work: peak periods, simultaneous machine use and pack maintenance can drive the actual requirement.
- Placing a station without a development plan: route changes can make a convenient location costly in travel or inaccessible to future work.
- Choosing chargers before modeling the load: charger and transformer requirements depend on charging philosophy and simultaneous loads, including non-vehicle mine services.
- Assuming packs are interchangeable: confirm form factor, integration, controls, connections and handling compatibility across the specific equipment.
- Treating a swap station as just a fast machine change: it also needs pack inventory, chargers, staging, handling, space, procedures, maintenance and safe egress.
- Leaving safety for commissioning: fire and electrical risk controls, training, isolation and emergency response belong in design and operating procedures from the outset.
- Applying a project example universally: keep supplier-reported claims attached to the named site, machine, year and context; do not assume another mine will reproduce them.
Frequently Asked Questions
Can an underground mine use the same charging station as a surface mine?
Not automatically. Underground stations must fit mine access, ventilation or cooling needs, hazardous-area separation, underground power distribution and egress; equipment interfaces and handling requirements also need to match. A surface project example does not establish an underground design.
Does regenerative braking eliminate the need for charging on a downhill haul?
No universal energy balance can be inferred from the route alone. Regenerative braking is a factor to include when evaluating the operating profile and station locations, but the machine’s duty, usable battery energy and energy demand still need to be assessed for the specific route.
Are battery swap times comparable between mining machines?
Only with substantial context. A reported change time is tied to a particular machine, battery system, swap station and method; compare total downtime and operating conditions, not the change-time figure in isolation.
Who should approve an underground battery charging station design?
The design should be reviewed by qualified mine electrical and engineering personnel alongside the equipment OEM and the site’s safety and operations leads. It must meet applicable local regulations and site standards; general industry guidance does not replace those approvals.
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