Innovations in Autonomous EV Mining Operations Help Solve Complexities of Worker Safety

In China, a fleet of 100 electric, 5G-Advanced, Artificial Intelligence (AI)-driven autonomous vehicles now operates at the Yimin coal mine, maintaining temperatures in environments that regularly reach -55 degrees Fahrenheit (-48.5 Celsius). In Brazil, heavy industrial provider Caterpillar signed an agreement with multinational corporation Vale to expand its autonomous fleet from 14 to 90 by 2028. At Mesabi Metallics in Minnesota, a fleet of two-story autonomous vehicles is expected to exit the rollout phase this year. Across the world, the use of autonomous vehicles in mining is expanding, changing the reality of what and where is mineable.

Regardless of location, the rise of autonomous vehicles targets a common problem: safety. A recent ABI Research presentation, Digital Transformation Update: Process and Extractive Industries (PT-3937), showed the need to improve worker safety as a continued constant investment motivator, and worldwide Environment, Health, and Safety (EHS) software spending in the industry is expected to increase from US$217 million in 2026 to US$301 million by 2030 (see ABI Research’s Environmental Health and Safety (EHS) Software market data (MD-SWEE-23)). The move to Electric Vehicles (EVs), however, may address other impactful challenges, notably regarding compliance with mining laws and regulations—provided that mining-specific software platforms from companies such as Ideagen EHS and ABB are utilized.

Before the fleet of EVs took over the bulk of mining duties at the Yimin coal mine, estimates placed the annual mortality rate of the coal industry in the region of roughly 3,000 deaths per year. Nearly all (80%) stemmed from equipment failure—caused more frequently in areas impacted by extreme weather patterns. For underground locations, however, the challenge relates to visibility and detection.

Sensor and edge compute integration are key drivers for mining investment in 2026, in part to support efforts to improve process automation and operational safety. While line-of-sight detection (accomplished through cameras, radar, and Light Detection and Ranging (LiDAR)) reduce collisions above ground, detection ranges are greatly reduced below. As a result, many of these facilities are adopting Vehicle-to-Everything (V2X) communications, which functions by allowing vehicles, employees, and even key locations to exchange signals directly through cellular networks (or Wireless Local Area Networks (WLANs) in certain cases) in real time.

Autonomous EVs are often tailored in their design. Mining operations that leverage these vehicles can optimize which needs get priority. It will be vehicles that can withstand incredibly low temperatures for certain companies. For others, it will be products outfitted with V2X communications. Both cases reduce the accident rate.

Optimizing autonomous EV usage in mining requires holistic thinking. Given the varied complexity of needs, most software offerings do not attempt a complete solution, but rather focus on achieving a specific goal. For instance, vendors such as Ideagen EHS and EHS Insight both offer EHS solutions tailored for mine safety and compliance, with Ideagen EHS highlighting robust offline tools for remote operations, and EHS Insight focusing on rapid incident reporting and analytics capabilities.

Yet it is also essential to incorporate software designed for EV integration. Hexagon’s solution suite for the mining ecosystem is anchored on a single shared data infrastructure, vital for reducing reaction time and improving transparency across the organization. Importantly, its solution also offers a planned scaled approach to mining operations looking to integrate autonomous EV usage, starting at the pilot phase and then expanding to a fully automated operation. ABB in Mining echoes Hexagon’s approach with its ABB Ability eMine, understanding that many industry leaders still believe an instant overhaul is needed to see results—when the reality is far more measured. Even the act of simply replacing diesel engines with (even non-autonomous) EVs reduces not just overall air pollution but, more importantly, air quality in underground mines, thus improving working conditions. Vendors in this space know it does not have to be drastic to have an impact.

Autonomous EVs are an increasing presence in the mining industry going forward, with China currently serving as world leader in adoption. Yet it is more important to remember the goal: improving worker safety. Properly pairing autonomous EV technology with EHS software and integrated data ecosystem solutions will help mining companies take their safety ratings to the next level, and software vendors in this space should continue to lead with measured but progressive steps toward that future.