As electrification reaches deeper into off-highway industries like mining and agriculture, many OEMs are confronting a growing gap between the capabilities of traditional equipment and the needs of emerging technologies. One global engineering equipment manufacturer recently encountered this issue while trying to adapt a jib crane to support heavy-duty EV charging cables. The result was an opportunity to re-engineer the process with the help of a systems integrator — bringing ergonomics, safety, and infrastructure into alignment.
The Challenge
The OEM had deployed a standard jib crane system with a manual pulley to lift 120-pound EV charging cables used to charge electric mining trucks. However, the off-the-shelf setup was never intended for such loads or environments.
One significant issue was the uncontrolled swing of the jib crane. As operators moved the cable toward the truck’s charging port, the crane’s movement caused the cable to bend unpredictably, increasing the risk of damage. The trucks themselves added complexity: the charging outlet is located behind a hinged door that lifts into a horizontal shield, making precise alignment of the heavy cable and connector plug difficult.
Beyond operator challenges, the charging system also needed to support auxiliary equipment, including chillers and power distribution units. The OEM required a solution that could be deployed without pouring a foundation, withstand environmental extremes, and scale with future vehicle upgrades. After several successful prior projects, they partnered with a systems integrator to develop a custom crane and support system tailored to these unique requirements.
The Solution
The systems integrator designed and built a custom telescopic crane system to address both the mechanical and operational limitations of the original design.
Unlike a jib crane, which pivots in an arc, the telescopic crane allows for linear, controlled extension and retraction of the charging cable. This motion eliminates the swinging action that previously led to misalignment and cable stress. The crane’s telescoping arm enables operators to reach various charging points directly and with consistent control.
ACS Inc.
A movable cable track system supports the full length of the cable as it extends and retracts. This track holds the cable's weight, limits lateral movement, and ensures the bend radius stays within 40 inches — critical to maintaining cable integrity. By isolating the cable from unnecessary strain and movement, the system protects a key investment while ensuring smoother operation.
To further reduce the physical burden on operators, the plug end of the cable is attached to a tool balancer, effectively making it weightless. Operators use a handlebar to push both the crane arm and track system forward in a synchronized movement. The plug can then be maneuvered with precision into the truck’s charging port, even with the added complexity of the protective door shield.
Auxiliary Engineering and Infrastructure
Supporting systems were designed to match the crane’s performance and meet the OEM’s strict deployment and environmental requirements.
- Dual cable tracks for faster charging — Recognizing the demand for efficiency, the crane features two cable tracks. This allows for faster or redundant charging operations, reducing downtime and increasing throughput on the worksite.
- Steel base plate for stability without concrete — To avoid pouring a foundation, the integrator engineered a heavy-duty steel base plate to stabilize the crane. This solution anchors the system securely — even when the arm is fully extended — while enabling relocation and reassembly in the future if needed.
- Containerized power and cooling equipment — The integrator also designed a weatherproof, containerized enclosure to house the system’s support equipment, including a transformer, cooling fans, and three power panels. The container includes custom internal supports to secure the equipment, ensuring vibration resistance and proper airflow. Electrical components in the enclosure include transformers ranging from 45kVA to 225kVA, and power panels supplying 208V, 440V, and 480V.
ACS Inc.
This containerized solution was critical for environmental protection, especially in the client’s high-temperature, high-dust location. It also allows for simplified installation and serviceability — key factors in off-highway settings where access can be limited.
The Outcome
The custom telescopic crane system significantly improved the safety and efficiency of EV charging operations. Operators can now manage heavy-duty cables with minimal physical effort, thanks to the system’s ergonomic, weight-neutral design. Controlled linear motion eliminated alignment difficulties and the risk of cable damage, improving both the speed and reliability of each charging operation.
The system’s modular and adjustable components support a range of operator heights and future charging hardware. This flexibility ensures that the investment can evolve alongside the OEM’s electric fleet — avoiding obsolescence as equipment requirements change.
By integrating the electrical support systems into a retrofitted shipping container, the solution remains compact, weather-resistant, and easy to deploy. The entire assembly — crane, power distribution, cooling and controls — was delivered as a coordinated system, reducing the need for site-specific construction and minimizing installation time.
For mining OEMs embracing electrification, adapting traditional infrastructure to meet new demands is a growing challenge. This project illustrates how a custom-engineered solution — developed in partnership with a systems integrator — can overcome the limitations of off-the-shelf equipment.
By rethinking the cable handling and support systems from the ground up, the OEM was able to improve operator safety, protect critical components, and streamline charging operations in a rugged environment. As electric fleets grow, mining OEMs will increasingly rely on purpose-built, scalable solutions like this to keep pace with industry transformation and field demands.
