Switch Technologies

Pioneering hybrid solutions for heavy vehicles. Switch Technologies has evolved from its origins developing an electric superbike in 2014 to become a specialist in heavy vehicle hybridisation.

An engineering team that spun out of a battery company, Switch Technologies made a strategic decision to focus on the development of hybrid solutions in 2022. Recently appointed CEO Jan Haak brings extensive experience in software engineering and scaling technology companies, having built Amazon Web Services’ Western Australian presence and developed clean tech consultancy First Mode.

Switch Technologies combines expertise in heavy equipment and battery technology to drive innovation in sustainable mining operations, leveraging a unique understanding of both the technical challenges and practical operational requirements of the mining sector.

The challenge

The mining industry faces a significant challenge in transitioning to cleaner energy solutions for heavy vehicle fleets. While there is growing interest in full battery-powered mining trucks, most mine sites lack sufficient energy infrastructure to support fully electric vehicles. The cost and complexity of implementing completely new systems can also be prohibitive, with many proposed solutions requiring extensive modifications to existing mine infrastructure and operations.

Switch Technologies identified an opportunity to develop hybrid solutions that could capture and utilise energy that is typically lost in traditional mining operations, particularly in deep pit mines where trucks descend long distances. This approach addresses both environmental concerns and operational efficiency, offering mining companies a practical pathway to reducing their carbon footprints without requiring complete fleet replacement or extensive infrastructure upgrades.

The challenge extends beyond technical considerations to include maintenance requirements, operator familiarity, and the need to maintain operational reliability while introducing new technology. Switch Technologies recognised that success would require a solution that could seamlessly integrate with existing operations while delivering meaningful improvements in efficiency and environmental performance.

Developing a solution

Switch Technologies is taking a pragmatic approach to vehicle hybridisation, starting with a Toyota Land Cruiser prototype as a proof of concept. The test vehicle incorporates a 300-kilowatt electric motor alongside custom battery technology featuring liquid cooling systems and a proprietary battery management system.

The innovative technology enables seamless integration between conventional and electric drive systems, allowing the vehicle to operate as either a pure electric vehicle or a traditional diesel-powered unit. The company chose to conduct its initial testing at the Australian Automation and Robotics Precinct in Neerabup, leveraging its controlled environment and specialised features.

Switch Technology’s comprehensive testing program will begin with initial trials on the AARP’s figure-eight track, performance testing of acceleration and braking systems, and validation of power generation and battery charging during descent using the facility’s ramp. This controlled environment will allow for thorough system reliability testing before deployment to actual mining operations.

The solution maintains the fundamental serviceability of the base vehicle, ensuring that if the electrical system is disabled, operators still have a familiar, functional machine. This approach minimises operational risk while maximising the potential benefits of hybridisation, setting the stage for broader application across larger mining vehicles and other heavy equipment.

Expected results

Switch Technologies anticipates the AARP testing program will validate multiple aspects of its hybrid technology. Initial testing will focus on basic vehicle operations and safety systems using the prototype Land Cruiser, ensuring all electrical and mechanical systems work together seamlessly. The program will then progress to validating the hybrid system’s energy capture capabilities during downhill operations, along with testing the vehicle’s performance characteristics, including acceleration, braking, and handling with the added hybrid components.

The testing will demonstrate successful integration between conventional diesel and electric drive systems while verifying safety systems and operational parameters. The comprehensive performance data collected will support future mine site deployments, providing valuable insights for scaling the technology to larger mining trucks. Initial projections suggest that the hybrid system could substantially reduce diesel consumption while maintaining or improving vehicle performance.

The controlled testing environment at AARP will allow for precise measurement of energy recovery rates during descent, validation of battery thermal management systems under load, and verification of all safety systems. This methodical approach is expected to significantly reduce implementation risks when deploying to active mine sites, while providing quantifiable data on fuel savings and carbon reduction benefits.

“The AARP provides us with a unique competitive advantage. While there are other testing options available, having access to these facilities close to home, with the right terrain and a controlled environment, is invaluable. It’s not just about the physical testing capabilities – it’s about being part of an ecosystem of innovation. The facility allows us to validate our technology thoroughly before deploying it to mine sites, saving considerable time and resources while ensuring maximum reliability. The ability to showcase our technology to potential clients in a professional setting adds significant value to our development process.” – Switch Technologies, CEO, Jan Haak.