Fortescue Uses KUKA Robots for 6 MW Truck Charging
The modified welding robots manage heavy liquid-cooled cables to charge 240-tonne Liebherr trucks in 30 minutes.
Fortescue has deployed modified KUKA welding robots to handle the massive charging cables required for its 6 MW charging system, designed to power ultra heavy-duty electric mining trucks in Australia.
What Happened
The mining company released a video detailing how it uses industrial robots, typically found in automotive assembly lines, to connect liquid-cooled copper cables to its Liebherr T264E electric haul trucks. These cables deliver 6 MW of power, a rate necessary to charge the truck’s 3.2 MWh battery pack in approximately 30 minutes. Fortescue stated that the cables are too heavy and dangerous for human operators to handle manually. The development was supported by a $10 million AUD grant from the Australian Renewable Energy Agency (ARENA), aimed at creating a test unit for this high-power charging infrastructure.
Why It Matters
While consumer electric vehicles are trending toward 2 MW flash charging capabilities, Fortescue’s initiative highlights the extreme infrastructure challenges in heavy-duty industrial electrification. By repurposing existing robotic technology for energy transfer, the company addresses the logistical hurdles of scaling charging power beyond what is currently standard in the automotive industry. This approach supports Fortescue’s stated goal of achieving net zero operations by 2030 and demonstrates a viable pathway for charging vehicles with battery capacities equivalent to roughly 40 Tesla Model Ys.
The Bottom Line
Fortescue is using KUKA welding robots to automate the connection of 6 MW charging cables for its 240-tonne electric mining trucks, enabling 30-minute charging times for 3.2 MWh battery packs.
