When upgrading makes more sense than buying a new machine

AE60 type locomotives are among the long proven solutions in mining traction. Mechanically robust, structurally stable and adapted to the demanding conditions of underground operation. Their limitation, however, tends to be the original lead battery technology.

As part of the modernization project , we carried out the overhaul of the AE60Pb locomotive, during which the original 332V / 340Ah battery was replaced by VONSCH LV01 147Ah Li-ion modules. The aim was not only to increase the capacity. The aim was to stabilise performance, reduce operational constraints and bring the power architecture of the machine up to current standards.

Limits of the original lead technology

The original lead-acid battery provided a real usable energy of approximately 68 kWh while respecting a safe depth of discharge. In practice, however, typical phenomena characteristic of lead-based systems occurred. Namely, voltage drop at higher loads, higher system weight and the need for regular maintenance.

For longer duty cycles, this meant fluctuations in the performance of the traction converters and a gradual degradation of the parameters. From the operator’s point of view, these are factors that affect both machine availability and the scheduling of service intervals.

New configuration: li-ion system VONSCH LV01 147Ah

The upgrade consisted in the implementation of 15 VONSCH 1P12S147Ah LV01 modules connected in series. With a capacity of 147 Ah and an energy of 6.544 kWh, each module is designed for traction and industrial applications in harsh environments.

Li-ion technology delivers a more stable voltage characteristic throughout the entire working cycle. The traction converters thus operate in the optimum range without significant voltage drops, which is directly reflected in the performance of the locomotive.

The system is integrated with the VONSCH LOKO BMS, which provides charge management, cell monitoring, over-current and short circuit protection and enables remote monitoring of the battery status. Energy management thus moves from a passive mode to a controlled and predictive model.

Energy and operational benefits of modernisation

Switching from lead to Li-ion means approximately 40-45% more usable energy for the same space availability. At the same time, there is a significant reduction in the weight of the battery system and an extended lifetime of over 2,000 charge cycles.

For the operator, this means more stable performance throughout the work shift, lower service interventions and more predictable system behaviour. The modernisation is thus not only technically, but also economically, especially in the long term TCO.

Repas as a comprehensive intervention in energy architecture

The AE60Pb refurbishment project was not limited to the replacement of the battery system. It included modifying the battery tray, implementing a new 24V power supply with UPS to power the BMS, upgrading the instrumentation ranges and updating the locomotive control software.

New DC safety relays and disconnectable connectors for service and charging were fitted. The entire intervention was carried out vertically from the power electronics to the machine control logic.

This approach allows the mechanical robustness of the original locomotive to be preserved, while at the same time significantly upgrading its power core.

Li-ion upgrading in mining traction as a milestone of the decade

Repase AE60Pb with Liion modules VONSCH 147Ah LV01 represents the biggest technological leap in the last decades in the field of mining battery locomotives. It makes the vintage locomotive a modern, powerful and safe machine ready for many more years in demanding service.

Summary of modernisation

• Original battery: 332 V / 340 Ah
• New system: 15× VONSCH LV01 147Ah
• +40-45 % usable energy
• Stable performance throughout the shift
• Lifetime over 2000 cycles

VONSCH – the energy conversion expert

We have been in the power electronics business for more than 30 years. We design solutions for mining traction, Small Hydropower Plants, Battery Storage and specific industrial applications.

The Repas AE60Pb is an example of a complex solution where technical expertise, detailed knowledge of energy processes and the ability to implement a functional unit come together.

We are searching for a technical truth. With enthusiasm. So that the result is not a compromise but a stable solution.

Are you considering upgrading your traction locomotive?

If you operate a locomotive with lead-acid battery technology and are considering switching to a Li-ion system, we will be happy to assess the technical and economic options for upgrading.

Write to us.

When you move testing from the mine to a controlled environment.

When upgrading 6 mining locomotives in Australia, it was not just a question of implementing the LMC control system.

A fundamental operational issue arose:

How to reduce the technological risk before the system enters real operation and at the same time prepare operators to use it safely and efficiently?

In a mining environment, any unplanned downtime is costly.Every operational intervention means logistics, safety measures and time.

The aim was to gain control of the testing before deployment to the mine and to create conditions for systematic training of operators outside the real operation.

• Train operators as a project priority without depending on locomotive availability
• Verify LMC functionality before installation
• Reduce commissioning time
• Minimise risk during SAT/FAT
• Enable secure software development in parallel with operation

Classical laboratory testing did not provide realistic feedback of the traction system or full conditions for operator training.

Testing directly in the field was a risk.

Solution:
VONSCH Testing Room

We designed and delivered a hardware-in-the-loop testing ecosystem that moves testing and operator training out of the mine and into a controlled environment.

The system consists of two interconnected parts.

DASH BOX – identical operator interface

• driving joystick
• pair of HMI panels
• LMC control unit
• full physical signalling

The operator works in the same environment as in a real TL30, allowing realistic training and verification of reactions without risk to operations.

TEST BOX – traction system emulation

• power converters
• control cards
• relay logic
• two 0,37 kW induction motors with encoder

The system reproduces the real dynamics of traction drives including acceleration, braking and fault conditions without working with 600 V traction voltages.

Technological approach

The Testing Room was not a simulator. It was a physical validated testing tool designed for both technical validation and systematic operator training.

The developed variant of the LMC software allows:

• simulation of safety and hydraulic inputs
• testing of failure scenarios
• advanced diagnostics
• maintaining realistic communication flows

The architecture is modular and ready for next generation systems and future training scenarios.

Business Impact

Testing Room brought:

✔ Reduction of technological risk before commissioning

✔ More predictable commissioning process

✔ Possibility of safe software development outside the mine

✔ High level of operator readiness before entering into real operation

✔ Greater control over the quality of implementation

The project has not only moved forward technologically. It has moved process-wise, including a systematic approach to training operators as part of implementation.

Why this project is a reference

In the mining segment it is standard to supply a control system.

Less standard is to create an entire testing and training environment that allows:

• realistic traction emulation
• safe development
• risk reduction before deployment
• systematic training of operators
• long-term technological control

The Testing Room moved VONSCH from the position of an electronics supplier to that of a technology partner.

ABOUT VONSCH

We are a second-generation, family-owned company with over 30 years of experience in power electronics.

We specialize in:

• control of AC motors
• Traction Drives
• energy systems
• custom solutions in challenging environments

We are searching for a technical truth. With enthusiasm.

Powered by expertise. Powered by VONSCH.

Modernization of the lift in Polomka

VONSCH products don’t just move material underground. In some projects, they help people get closer to heaven. For example, in the modernisation of the ski lift in Polomka.

As part of the reconstruction we implemented:

• complete renewal of the switchgear and lift control,

• new control with graphic display ( visual will be added on 18.12.2025),

• modernisation of the main drive of the lift.

From now on, the VONSCH® UNIFREM 400 132 frequency converter, developed and manufactured in-house, takes care of the smooth and comfortable start-up of the skiers.

Such projects are typical custom solutions for us, where safety, reliability and technical precision are combined with real operation in demanding conditions.