Suncor has reached one other essential milestone in its autonomous haulage journey with the launch of its first Autonomous Working Zone at Syncrude’s Mildred Lake – with the Syncrude operations being managed by Suncor since late 2021 . It says this achievement builds on the profitable implementation of AHS with a fleet of about 140 autonomous vehicles at Base Plant in 2024 and exhibits what might be completed when expertise, experience and collaboration come collectively throughout its operations.
At present, 19 363 t class mechanical drive Caterpillar 797F vehicles have been retrofitted for autonomous operation with Caterpillar’s Command for hauling at Mildred Lake, with plans to transform an extra 21 by the tip of 2026. Suncor works with Caterpillar and its vendor Finning Canada on the set up of the system.
Suncor said: “As we proceed to give attention to optimising mining efficiency, improvements like AHS are serving to drive productiveness, reliability and value competitiveness throughout the enterprise…this summer season, the autonomous gas module will probably be introduced on-line and groups will proceed increasing coaching and making use of classes realized to help the deliberate development of the AHS fleet to 70 vehicles. The Base Plant deployment confirmed what was potential. Syncrude proves it wasn’t a one-time success. That’s what going back-to-back appears to be like like.”
Speaking of Base Plant, which has a 363 t class diesel electrical drive Komatsu 980E fleet and operates utilizing Komatsu’s FrontRunner AHS, the time period ‘Mud Mode’ not too long ago got here up on oil sands mining main Suncor’s Q2 2026 earnings name. So what’s it? Suncor says Mud Mode began in an surprising place: an remark by somebody decided to resolve a sensible drawback. For Michael Gartenburg, Director Operations – AHS Deployment, Base Plant, the spark got here from a well-recognized supply: the drive mode in his personal car.
He states: “Identical to my car has totally different settings to assist it deal with snow, mud or tough terrain, I knew there needed to be a method to make use of the information in our AHS system to do one thing comparable at a bigger scale on our haul vehicles.” At Base Plant, house to what Suncor says is the world’s largest ultra-class autonomous haul truck fleet at a single mining website, the idea had the potential to resolve an actual problem. Delicate floor and moist climate can have an effect on traction, resulting in truck stoppages and discipline interventions.
Mud Mode 2.0 has been rolled out on 90% of the Komatsu AHS fleet at Base Plant
Mud Mode helps AHS vehicles higher reply to these circumstances. Suncor says utilizing knowledge already generated by AHS and truck drive methods, the expertise permits haul vehicles to take care of higher traction and keep away from pointless stops. The answer concerned work from Suncor, Komatsu and Komatsu vendor SMS Gear, and combines knowledge, testing and real-world expertise to maintain vehicles transferring safely and effectively. Applied in spring 2025, Mud Mode 1.0 targeted on slippage throughout ahead journey. Suncor says the outcomes have been spectacular. Slippage-related stoppages improved considerably and enabled the motion of roughly six million extra tonnes, producing an estimated C$25 million in worth.
The group constructed on that early success by way of continued testing, studying and refinement, resulting in the launch of Mud Mode 2.0 in Spring 2026. The improved model operates at larger speeds and in reverse, together with when vehicles are backing as much as a shovel or dump, and offers vehicles extra time to regain traction earlier than stopping in slippery circumstances.
Suncor: “The timing couldn’t have been higher. With snow and rainfall this spring reaching ranges not seen in many years, Mud Mode 2.0 was put to the check – and delivered. Since testing started in early Might, efficiency has improved by 40% over Mud Mode 1.0 throughout a spread of climate circumstances, demonstrating the good thing about steady enchancment. Mud Mode 2.0 has been rolled out in 90% of the fleet, with completion on monitor within the third quarter.”
