Mining giant Fortescue is deploying specially modified KUKA industrial assembly-line robots to manage massive, liquid-cooled copper cables capable of delivering a 6-megawatt charge to its electric haul trucks in Western Australia’s Pilbara region, Electrek reported.
Developing a 6-Megawatt Charging System for the Pilbara Desert
Fortescue and Liebherr have been collaborating since 2024 on a 6-megawatt charging system designed for ultra-heavy-duty mining rigs. Because commercial chargers of this scale do not exist, Fortescue adapted industrial robots normally used for welding applications inside automotive manufacturing plants. The company shared details of the setup in a video released earlier this month, demonstrating how the system interfaces with its 264-short-ton Liebherr T264E electric haul truck.
Operating conditions in the Pilbara desert present severe environmental challenges. Summer temperatures regularly exceed 40 degrees Celsius, while winter nights can drop below freezing amid dusty and windy surroundings. To withstand these conditions, the charging infrastructure incorporates liquid-cooled direct current cables, earthing systems, lightning protection, impact barriers, and safety fencing, according to reporting by The Driven.
Fortescue is using KUKA welding robots to handle 6 MW charging cables https://t.co/zBJN9LX0l2 by @volvojo1
Automating the High-Voltage Connection Process
The liquid-cooled copper cables required to deliver the 6-megawatt power load are too large, heavy, and dangerous for human workers to handle safely. Fortescue engineered an automated connection sequence to manage the transfer without manual intervention.
Your truck will come into the charger bay. It’ll then be handed over to the charger. The charger robot will come out. It’ll take the images of the connection box. Then the robot will connect to the truck, where a handshake will be done with the truck, and the two systems will sync up, and then the charge process will commence,
Fortescue stated in its promotional video, as noted by The Driven.
The charging units must also coordinate with the local power grid stability. Fortescue is building a dedicated renewable energy grid supported by more than 2 gigawatts of new solar capacity and over 4 gigawatt-hours of battery storage. The charging technology uses an integrated communication system to alert the green power network before introducing the 6-megawatt load.
ARENA Grant Funds Fortescue Fast-Charger Development
The development of the 6-megawatt fast-charger test unit received a $10 million Australian dollar grant from the Australian Renewable Energy Agency (ARENA). The initiative supports Fortescue’s corporate target of achieving net-zero operations by 2030.
Fortescue is using car-factory welding robots to plug in its 6 MW haul truck chargers. The plug's too big for a person.- About 24 Tesla Superchargers' worth- Rolling out at its Eliwana mine- 20-30 min top-ups while trucks wait on the digger- A full charge lasts 4-5 hours… pic.twitter.com/wetcVA4tIN
Leveraging our world-class capability in battery and charging solutions from motorsport, the fast chargers have been developed for the challenging conditions of the Pilbara,
Ellie Coates, then-Chief Executive Officer of Fortescue Zero, said when the grant was announced in 2024, as reported by Electrek. Equipped with robotic connection options, they will be able to power Fortescue’s future 240-tonne Liebherr T 264 battery electric trucks in just 30 minutes.
The Liebherr T264E features a 3.2-megawatt-hour battery pack, equivalent to the energy storage capacity of roughly 40 road-going Tesla Model Y crossovers. Fortescue plans to connect its first Liebherr electric haul trucks upon their arrival on site later this year, followed by subsequent integration with models built by XCMG next year.
Frequently Asked Questions About the Pilbara Haul Truck Chargers
Why are industrial automotive robots used instead of human operators?
The liquid-cooled copper cables and plugs required to transmit 6 megawats of power are too heavy, large, and hazardous for human workers to manage. Fortescue adapted KUKA car-welding robots to capture images of the truck connection box, align the plug, and execute the automated handshake safely.
How long does it take to fully charge a 240-tonne Liebherr truck?
Fortescue designed the charging sessions to last between 20 and 30 minutes, capitalizing on recurring downtime moments such as waiting for excavators. A complete charge can power the vehicle for four to five hours depending on operating conditions.
Mining giant Fortescue has revealed some key details of the 6 megawatt (MW) electric truck chargers that it is building itself in order to boost its chances of eliminating fossil fuels from its massive iron ore operations in the Pilbarahttps://t.co/xB5vylLlHL
What financial and institutional backing supports the project?
The Australian Renewable Energy Agency provided a $10 million AUD grant to help Fortescue develop and test the 6-megawatt fast-charger unit as part of the company’s transition toward net-zero operations by 2030.
Related reading