MOTORS & DRIVES
Masters of momentum
From mill drives to large haul truck wheel motors – power delivery is a critical aspect of operational mining – Paul Moore looks at some new solutions & real applications
Drive and motor power is delivered in a myriad of ways in mining – dependent on the power, torque and speed requirements. Motors, whether mechanical( geared) or electric, provide the rotational or linear force used to power the equipment in the mining application. Drives strictly speaking are the electronic devices that manage the electrical energy delivered to the motor but the term drive is often used for the overall combined drive and motor system.
Gearless direct hydraulic motor and drive solutions from Hägglunds, part of Bosch Rexroth, are well known in mining for their high torque and utter reliability, but also their flexibility in applications such as apron feeders, belt conveyors, in-pit crushers & sizers, and bucketwheel miners or stackerreclaimers. But with the introduction of its new Hägglunds Thunder motor, it says the route to those advantages is flexible.
The new solution is based on permanent magnet( PM) synchronous motor technology. A PM synchronous torque motor is a type of multi-pole electric motor, capable of delivering high torque that fits well alongside that of existing Hägglunds motors. By enabling a fully electric, frequency-controlled drive solution from low to megawatt levels of power, the new Hägglunds Thunder creates an additional path to familiar Hägglunds benefits.
“ PM synchronous motors are a wellknown technology with untapped potential in heavy-duty industrial applications,” says Tor Jensen, Vice President Hägglunds Global Sales.“ Our focus on dependable and versatile direct drive solutions hasn’ t changed, nor will it. But with Hägglunds Thunder as a complement to our electrohydraulic portfolio, we can offer a true Hägglunds solution with somewhat different drive characteristics. That provides new answers to specific customer challenges.”
While the specifications for Hägglunds Thunder fit neatly within the Hägglunds portfolio, they create a distinct performance envelope. The Hägglunds Thunder motor range has a nominal torque of up to 200 kNm, and it provides fully variable speed from standstill. Nominal operating speed begins at 30 rpm, which is slightly higher than solutions based on the existing Hägglunds portfolio. Yet the Hägglunds Thunder range opens up to a remarkable 300 rpm – and provides constant high efficiency at nearly any speed within its range.
“ Customers who require high, or extremely high, torque at speeds close to zero will be better served by Hägglunds electrohydraulic solutions,” says Uno Sundelin, Project Manager for Hägglunds Thunder.“ But where the requirements for torque and speed are a good fit, we can use Hägglunds Thunder to supply excellent
The new Hägglunds Thunder is a fully electric, frequency-controlled drive solution with the proven advantages of Hägglunds drive technology
direct drive solutions for up to 4300 kW of power. That’ s a bold new peak, even for Hägglunds.”
Besides such efficient power, Hägglunds Thunder offers solid protection, sustaining a 200 % overload for up to 60 seconds.“ Reliability in unpredictable applications is what customers have come to expect from Hägglunds,” says Sundelin.“ They’ ll find that Hägglunds Thunder sacrifices nothing in that regard.”
Uno Sundelin, Project Manager for Hägglunds Thunder told IM:“ In the mining industry, we see that Hägglunds Thunder will bring high customer value into several applications. Those include belt conveyors and ball mills, for example, which can benefit from its approach to speed control. The latter can mean optimized productivity and more precise inching for inspection and maintenance work, delivered with high efficiency by this new direct drive solution from Hägglunds.”
WEG’ s monitoring solutions deliver in WA and Brazil
In a remote copper mining operation in Western Australia’ s mid-west region, WEG’ s IoT-based monitoring technology, deployed in partnership with WEG’ s service partner and IoT provider, Electro Mechanical Repair WA, played a key role in preventing a major equipment failure. The case highlights the growing importance of predictive maintenance in the mining sector and the value of strong local partnerships.
Using the WEG Motion Fleet Management platform and WEGscan100 smart sensors, the system detected abnormal vibration patterns in a SAG mill motor, well before the issue could be identified by conventional maintenance methods. The real-time data pointed to dislodged magnetic wedges in the stator, which were creating friction and approaching critical vibration thresholds.
Thanks to early detection, the mine carried out a planned shutdown and replaced the motor with a pre-serviced unit, minimising production impact. The faulty motor was sent for repair and analysis by Electro Mechanical Repair WA.
WEG:“ More than resolving a single incident, the adoption of IoT technology and collaboration with a trusted local partner have redefined the mine’ s approach to maintenance. Continuous monitoring now enables teams to predict wear trends, optimise service schedules, and extend equipment lifespan, resulting in improved safety, reduced maintenance costs, and minimised unplanned downtime.”
44 International Mining | NOVEMBER / DECEMBER 2025