Rewriting the rules

Innovations will allow construction companies to break

free from diesel dependence and focus on energy,
efficiency and the environment.
Table of content
The world’s energy efficient construction machines 03
Construction in cities: finding new energy saving solutions for hybrid engines 04
Bulk fuel filtration: reducing exhaust emissions by facing worldwide fuel quality differences  06

Mining: towards fully electrified and automated machines  07

On the way towards fully electrified mining machines 08

Mining automation: close up on the tomorrow’s smart machines 10

Electrification and automation: the most promising processes 11

Editorial
This white paper centres
around three themes: energy,
electrification and emissions.
Electrification is essential
to attaining the two
goals our clients have
identified as their biggest
challenges when it comes
to construction projects:
energy efficiency and lower
emissions. In today’s increasingly
environmentally conscious world,
it is vital that businesses work to
reduce emissions. Electrification
can help businesses do just that,
ensuring they not only comply
with wide ranging legal standards,
but also boast significant green
credentials. The construction
industry is facing a pivotal
moment when it comes to solving
these challenges. Adapting new
technologies onto old vehicles is
cost-prohibitive and unwieldy.
Thankfully, there are a couple
of alternatives. The first is to
scrap existing fleets and invest
in new-build vehicles that are fit
from the ground up. By doing that,
the industry can work towards
providing mid-term and long-
term solutions to issues such as
noise pollution, diesel fuels and
heavy vehicles. We can also look
to design machines differently. By
rethinking the process, we can
start designing machines with
incremental steps which are based
on existing concepts as well as
new technology.
Parker is working both internally
and has partnered with several
large manufacturing and
construction companies to find
solutions to these challenges
in the short term. Our primary
focus is on heavy-duty equipment
in the mining and construction
industries. Using inspiration from
our like-minded professionals in
the aerospace industry, Parker is
working to break down barriers.
We want to move away from the
way machines have been built for
generations in order to forge a
new path towards a cleaner,
safer and more efficient
tomorrow.
Nils Henriksson
Business Development Manager
Global Mobile Systems

2
THE WORLD’S
ENERGY EFFICIENT
CONSTRUCTION
MACHINES
Our world is constantly under construction.
From sprawling cities to the most remote
corners of the planet, we are building the
future. But as the world’s population swells,
so too must our concern for not just what
we are building, but how we are building it.
The challenges of working safely, working
to limit our impact on the environment and
working more efficiently exist regardless
of the climate, terrain or local politics.
Finding solutions that can be applied
irrespective of the city, country, continent or
climate must be the mission of construction
companies as they transition from not just
doing a good job, but ensuring the energy
and environmental impact of their work is
reduced to a minimum.

3
Construction in cities:
finding new energy saving
solutions for hybrid engines
Blueprints for an office park,
a public garden, a library
or a school are usually met
with enthusiasm at civic
meetings. When it comes to
constructing such properties in
cities however, the reaction is
considerably colder.
Construction sites in urban
locations could also face future
challenges. It is anticipated that
legislations will come into force
to tackle the problems of noise
pollution and exhaust emissions.
To be fully compliant, it is vital
that the construction industry
takes action to address these
issues sooner rather than later.
The answer for many machine
manufacturers has been
electromobility, fully electric or
hybrid implement and traction
systems which utilise electric
prime movers or diesel-electric
hybrids to replace the noisier,
less environmentally friendly
conducive fuel systems.
There have already been great
strides forward with smaller
machines such as readily
available forklifts that are 100%
powered by electricity. What
were once noisy, gas-guzzling
vehicles are now smaller
and operate with zero local
emissions at whisper-quiet
decibel levels.
When we get to heavy-duty
machinery however, there are
still plenty of challenges that
lie ahead. Powered by fossil
fuels which produce carbon
gas emissions, heavy-duty
machinery cannot be powered by
electricity alone because of their
demanding work cycles. That
means hybrid solutions must be
explored and adopted. The good
news is that battery technology
is improving, making it more
likely that even larger machines
will become fully electric. This
challenge runs the breadth of
the industry, beginning with the
machine builders and original
equipment manufacturers
(OEMs). Thankfully, there are
currently three potentially
viable hydraulic solutions
which represent perfect fits for
electromobility.
Solution n°1: power-on-
demand with Electro-
Hydraulic Pumps (EHP)
aka ePumps
The Electro-Hydraulic Pump
(EHP) is very similar to a
conventional system but works
without an internal combustion
Directional valve
system. Instead it uses an
electric motor which is coupled
with a hydraulic pump, controlled
by a high-performance mobile
hardened drive. Designed with
diesel-electric hybrid and all
electric mobile applications in
mind, the most popular EHP
does not recover energy, it saves
expenditures by using power on
demand as well as operating
under variable pump/motor unit
speeds. In typical applications
this allows the EHP to reduce fuel
consumption by 5%-20% when
compared to a standard load-
sensing (LS) system. Additionally,
EHP systems reduce both
emissions and noise level during
use. The greatest contributor to
noise reduction however, is the
power-on-demand feature which
allows the EHP to turn off when it
is not in use.
Depending on the application,
it is also entirely possible to
incorporate recovery in some
EHP systems.
If the system is designed where
the load can back drive the EHP
and work as both a motor and a
generator, it can then charge the
battery itself.
Boom
Arm
Bucket
4
Solution n°2: saving and recycling energy with
Electro-Hydrostatic Actuation (EHA) systems
“It is estimated
Routing manifolds that EHA can
reduce a machine’s
Boom fuel consumption
by up to

50% ”
Arm

Bucket
Bjorn Eriksson
Senior Systems Engineer -
Asymmetric
Global Mobile Systems
cyl. make-up

While EHP can be thought of
as the solution of the present,
Electro-Hydrostatic Actuator
(EHA) systems could be seen
as the answer for tomorrow.
Deciding on the type of application
and duty cycle in use are the
biggest determining factors in
whether to use an EHP or EHA
system. Initially employed in the
aerospace industry, every EHA is
a self-contained hydraulic system
which integrates a single cylinder,
one feedback unit, one variable
speed pump, one servo motor,
one electric drive and the control
electronics into a compact setting
that only requires an electrical
connection to work.
There are no throttling valves
involved in the EHA systems,
meaning every function of the
machine is independent of the
others.
Each function has its own pump
which can also be used as a
motor when recovering energy.
By removing the conventional
valve control, energy losses
dramatically decrease, making
the system much more efficient.
It is estimated that EHA can
reduce a machine’s fuel
consumption by up to 50%.
There is however a downside
to EHA technology. It cannot
be retrofit to any current
construction vehicles; it can
be used only when creating
new machines. Unlike EHP,
EHA represents a huge leap
forward in technology as well
as a complete departure from
the way things have been built
in the construction industry
for decades. That does not
mean it should be ignored, and
as the cost of this technology
decreases, EHA is set to become
much more relevant with new-
build machines coming online.
Solution n°3:
combination of EHA
and EHP
A lot of applications have several
implement functions. With so
many functions within any given
application, the use of power can
fluctuate substantially. When
it comes to these applications,
the best resolution is usually
to create an entirely custom
solution that uses a combination
of EHA and EHP. For example, the
most power consuming functions
with energy recovery utilise EHA
while an EHP system operates
the rest. There are also plenty
of solutions where a cross-talk
between EHA channels are used.

5
Bulk fuel filtration: reducing
exhaust emissions by facing
worldwide fuel quality differences
Fuel quality is one of the
toughest variables to gauge.
Just like no two jobs are ever the
same, neither is the quality of
fuel available from site to site.
This becomes more distinctly
obvious from region to region,
as projects are undertaken in
more remote areas or in less-
developed countries which do not
have the same standards of fuel
quality.
When used on construction
sites, the fuel quality levels
can have far-reaching effects.
When a construction machine
is loaded with low-quality fuel,
it will perform below factory
expectations. That means:
• A shorter active life
• A shorter work cycle
• More fuel is required to
complete a job
• More exhaust emissions are
released
In order to reduce emissions,
a better quality of fuel must
enter the engine. The more
contaminants that enter an
engine via its fuel, the more exit
through its exhaust. All engines
already have some sort of fuel
filter in place, but they are not all
equal in their ability to remove
contaminants. Holding fuel to
one universal standard is not a
reasonable solution. Applying
bulk fuel filtration to the fuel
tanks stored at construction sites
however, could well be.
Filters to avoid water, dirt
and biological contamination
Beyond the pre-loaded quality
of fuel on a construction site,
there are three major threats
to the quality of fuel born from
environmental contamination.
1. B
 iological contamination:
Most commonly as a result
of water contamination,
contaminants often enter the
fuel from rarely-used fuel
tanks such as ones connected
to emergency power sources.
2. Dirt contamination:
Dirt is a fact of life on just
about every construction
site. If fuel tanks are not
regularly emptied and cleaned,
substantial quantities of dirt
are likely to get mixed in with
the fuel.
3. Water contamination:
It does not take actual liquid
water for this to occur. When
fuel tanks are filled up with
reserves or emptied to put gas
into a machine, air in and air
out is a part of the process.
Based on the temperature and
relative humidity of the air at a
particular job site, there may
be more moisture on hand to
mix with the fuel.
Regardless of the safeguards put
in place, these three threats can
never be completely avoided.
The only way around it is to look
at the problem from a different
angle: filtering the fuel as it
leaves the on-site tank and is
transported into the construction
machines. In order to do this
effectively, there are two options
available:
• Installing a water separator
filter on the tank exit pipeline of
regularly used fuel tanks.
• Installing a kidney loop filter
on fuel tanks connected to
emergency power generators.
This would work by continuously
filtering the fuel, helping to
avoid biological contamination.
Solutions to prevent water
contamination induced by
fuel theft
Environmental processes
are not the only reason
water contamination occurs.
Construction companies face the
additional problem of fuel theft.
Thieves steal fuel from tanks or
vehicles when the site is inactive
and replace it with water. In this
instance, a water separator filter,
as mentioned above, would not be
useful, as they can only work up
to the point of a ratio of 80%-90%
fuel to 10%-20% water.
A better solution would be a
smart filter, complete with a
sensor built into the tank that
can measure the fuel quality and
automatically send important data
to the machine’s operator. This
device, a part of the Internet of
Things (IoT), will allow operators
to identify fuel theft instantly.
In turn, it allows workers to
avoid damaging equipment and
reducing efficiency as a result
of running a damaging mixture
through the machines.
6
MINING:
TOWARDS FULLY
ELECTRIFIED
AND AUTOMATED
MACHINES
There is virtually no room for error when
it comes to mining construction machines.
Used almost exclusively underground, often
in a highly compacted area, the machines
and their exhaust emissions will directly
impact construction workers. For health
and safety reasons, these machines must
produce as little emissions as possible.
Any solution to reduce emissions must
also require as little human intervention as
possible due to the harsh conditions.
As has been proven by countless studies, the
more time humans spend working in mining
conditions, and in close proximity to mining
vehicles, the more they are injured, contract
illness and die in accidents. According to
the UN’s International Labor Organisation,
the mining industry employs 1% of the
world’s workforce but produces 8% of fatal
accidents in the workplace.

7
On the way towards fully
electrified mining machines
Recent studies have made it
obvious just how much risk
underground miners are taking
when they are exposed to diesel
emissions. A study published by
Occupational and Environmental
Medicine in 2016 found that
diesel emissions can cause
fatal lung cancer at a rate up
to 38 times what is accepted as
the normal occupational risk.
With this in mind, construction
machine builders are actively
searching for solutions to reduce
emissions immediately with
the greater goal of automating
their machines so that humans
are entirely removed from
the process. Not only will this
automation save lives, but it will
greatly reduce the cost of the
average underground mining
worksite. At present, up to 50%
of the cost of mining sites is
spent on air filtration to ensure
worker safety.
Current state of mining
machines
The revolution toward worker
safety is already underway, but
it is taking time. Using complex
cable infrastructure, mining
machines are already electrified
from the grid. The new challenge
is to give them more mobility, as
well as enabling them to travel
longer distances by carrying their
own energy storage. The more
powerful the machine is the less
energy efficient it is. The cost
of the battery (energy storage)
and the weight are a limiting
factor. The travelling distance
and charging infrastructure will
be another challenge whether
they are returning to the surface
or moving from one location to
another inside the mine before
the actual work is performed.
In fact, if you look at the overall
costs of a mining machine, the
lowest budgeted item in its
life cycle is the original cost.
Maintenance is the second
lowest, while the most expensive
components are ventilation and
travel.
Where mining machines
are headed
The aim of the industry is to
construct new fleets of fully
electrified machines, regardless
of their size or job. The focus
will be to increase total machine
efficiency by reducing energy
losses in all hydraulic subsystems
including the drive line. Energy
recovery is harder to do based on
the fact actual duty cycle is mostly
resisting loads rather than driving
loads.
By doing this, it will allow the
machines to increase performance
with less power, extending their
duty cycles and the time they can
spend on the job between charges.
By moving in this direction,
companies can optimise four
specific areas of their mining
operation.
8
A fully electrified fleet
means:
• F ewer operators needed:
The fewer people working in
the mining environment, the
less money spent on ventilation
costs and the lower the risk to
human life.
• Lower operational costs:
Mining machines will not cost
as much to maintain and the
cost of fueling them would drop
dramatically. Consider:
• 1 gallon of US diesel oil
produces as much energy as
40.7KWh of electricity.
• In early 2018, a gallon of US
diesel oil cost around
US$3.06/gal (€2.46/gal).
• The cost of electricity for
mining companies drops
precipitously as the billing
demand rises. A company
seeking 50,000KWh would
pay just US$0.049/KWh
(€0.039/KWh).
•T
 hat would put the cost of
40.7KWh at US$1.99 (€1.60)
compared to US$3.06 (€2.46)
for a gallon of diesel, a drop
in expenditures of 35% for
powering vehicles.
•A
 safer work environment:
No more diesel fumes causing
sickness amongst workers,
resulting in less downtime and
fewer medical expenses.
•H
 igher equipment utilisation:
More hours are worked, and
more miles are travelled before
the machine needs to be
repaired or replaced by more
diagnostics and predictable
maintenance to minimise any
unplanned stops.
In order to pave the way for these
new fleets, energy losses from
diesel powered machines will
need to be reduced. To cut the
losses down, existing hydraulic
parts will need to be replaced by
more efficient ones. The result
will be a fully electrified fleet
providing greater efficiency levels
at a reduced cost.
With a fully electrified fleet,
expenses would be greater
for the machine’s original
cost, but far lower for all other
components, resulting in
significant overall savings:
•T
 he machine’s original cost
would be about 40% greater
than diesel-driven machines;
 ut savings would be made on:
•B
• Ventilation (about 50% less
than diesel-driven machines);
• Travel (about 50% less than
diesel-driven machines);
• Maintenance (about 75% less
than diesel-driven machines).
9
Mining automation: close up on
the tomorrow’s smart machines
Throughout the history of mining,
irrespective of how good the
equipment has been, the biggest
challenges have ultimately
needed human hands to guide
them from inside the worksite.
The need for human intervention
means higher costs, but to
make worksites safer and more
efficient, mobile construction
machine builders and mining
companies alike need to look for
solutions that work to decrease
human involvement. The good
news is that this has already
begun, and it is where the high
concept of mining technology
comes in. Offering a safe work
environment as well as higher
equipment utilisation and
lower operational costs, mining
technology and smart machines
represent the future of the
industry.
What is mining automation?
Mining automation is a process
that uses increased digitalisation
as well as software development
to reduce the need for human
interaction in the machine.
Designed with safety, increased
efficiency and cost reductions
in mind, the goal is to produce
a future in which an entire fleet
of mining machines could be
controlled by an office located on
the surface.
Ultimately it means fewer
operators and increased
productivity, which in turn leads
to more compact and efficient
designs because the space for
an operator to sit and control
the vehicle is no longer required.
Additionally, mining automation
helps to reduce downtime.
Machines currently only work
as long as operators, but with
automation, sites can become
much more efficient. Automation
allows for much longer shifts
without operators, so instead of
shutting down work at the end of
the day, machines can continue to
make progress unmanned.
How does it work?
As mining machines become fully
automated, they will also become
fully electrical. The ability to control
them from the surface will require
a combination of cameras and
sensors that will take the place
of the human operator. Until now,
human operators have used their
senses, knowledge and experience
of the type of work being done.
Sensors will make the process
much more efficient and will
include:
• Cameras
• Speed sensors
• Angle sensors
• Pressure sensors
• Position sensors
These machines will require fully
electrical steering and braking
solutions, allowing manufacturers
to make them lighter and more
compact by removing as many
mechanical components as
possible. There are several
industries already using this
approach. Within the forestry
industry for example, human
operators use the equivalent of a
joystick on the surface to control
the machine’s movements.
The drive towards a fully
autonomous worksite
The next step will be to sync
multiple machines together. This
can be achieved by allowing the
sensors to share data with the
other machines in your fleet. By
sharing information, actions can
be taken based on sensor data.
Meanwhile at the surface level,
human operators can access
all kinds of data on the fleet
operating below, from efficiency
and uptime, to maintenance
requirements. Users will not
only be able to take advantage
of having a bird’s eye view of the
entire worksite, but they can
harness the data collected and
analyse it with machine learning,
giving the companies a much
better chance of optimising future
operations.
10
Electrification and automation:
the most promising processes
Safety, efficiency and the
reduction of emissions are the
core principles that the heavy-
duty equipment industry must
inhabit as we move further
into the 21st century.
Rewriting the script
of how construction
equipment is
manufactured is
essential to replace older,
diesel-reliant vehicles that
struggle to uphold the new
initiatives in energy efficiency
and reduction of emissions.
Electrification and automation
are the most promising
processes towards achieving
these goals.
For the construction industry,
future successes will hinge on
whether or not manufacturers
are able to explore hybrid
solutions for city-based
projects. With more and
more smaller machines
moving away from fossil fuels surface. Utilising the growing
towards full electrification, technology means far less
manufacturers will have risks for workers, fewer
to overcome significant operators and much increased
obstacles if they want to levels of productivity.
make larger machinery
more energy efficient. With
heavy-duty machinery having
a demanding work cycle that
cannot be powered by
electricity alone, it is vital that
hybrid solutions such as a
combination of EHA and EHP
are explored.
Mining faces a similar
problem to construction in
terms of energy efficiency, but
there are added pressures
of worker safety and cost
control. Automation can
play a key role in helping to
increase safety whilst cutting
down costs and emissions.
Combined with greater
electrification, the future of
mining could see fleets of
mining machines controlled
from within an office on the
11
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