Unleashing connected intelligence in off-highway vehicles 

Connected intelligence in off-highway vehicles 

While passenger and on-highway vehicles have established mature connected ecosystems delivering safety, convenience, and new revenue streams for OEMs, off-highway vehicles in mining, construction, and agriculture are experiencing their own transformation.  

While consumer IoT dominates global connectivity with over 18 billion devices worldwide¹, the off-highway sector is experiencing a new phase of growth. The installed base of connected construction equipment reached 2.1 million units in 2024, with mining and agriculture adding millions more connected assets, all growing at double-digit rates annually². The convergence of edge computing, ubiquitous 5G connectivity, cloud, and classical AI has enabled opportunities beyond traditional fleet management. The generative AI ecosystem and recent advancements in the wider availability of satellite connectivity promise to push the bar even further. 

For OEMs, connectivity unlocks product differentiation, newer revenue models (including subscription-based), and invaluable field data for R&D innovation and optimization. For operators, the benefits span fleet management efficiency, remote operations capability, and predictive maintenance that prevents costly downtime. The increasing adoption of connectivity in this sector provides the foundation for electric and autonomous vehicle deployment. 

From equipment sales to service ecosystems 

• Operational excellence through connected intelligence through IoT 

Fleet optimization in off-highway operations now encompasses sophisticated scheduling for equipment refueling and battery charging management. Electric construction equipment particularly benefits from connectivity that optimizes charging schedules across limited charging infrastructure at job sites. Enhancements in connected ecosystems help fleet managers optimize energy costs by scheduling to charge equipment during off-peak hours and/or when energy on the grid is clean. 

Predictive maintenance algorithms analyze vibration patterns, component temperature fluctuations, hydraulic pressure, and operational stress indicators. Equipment usage tracking captures operator behavior patterns, including harsh acceleration, excessive idling, and collision events that impact equipment longevity. Quest Global’s implementation for UNDP demonstrated some of these capabilities through fleet monitoring, achieving measurable reductions in fuel theft and unauthorized vehicle use while improving asset utilization rates. 

• New revenue models for OEMs 

Equipment-as-a-Service models reshape OEM business strategies, shifting from one-time sales to recurring revenue streams based on usage hours, performance metrics, and guaranteed uptime contracts. Connected equipment generates continuous data streams that enable OEMs to create tiered service packages, develop performance optimization algorithms sold as premium features, and identify component improvements that reduce warranty claims, all contributing to recurring revenue beyond initial equipment sales. 

McKinsey research indicates that AI-driven predictive maintenance can reduce equipment downtime by up to 50%³, creating significant value that OEMs can monetize through premium service contracts. The data itself becomes a revenue generator through benchmarking services, operational optimization consulting, and industry analytics offerings that help customers improve their competitive position. Data monetization is already a reality in off-highway markets. Caterpillar’s Cat Connect services generate substantial recurring revenue through productivity benchmarking and optimization recommendations. John Deere monetizes agronomic data through its Operations Center, offering yield mapping and prescription services that farmers purchase annually to improve profitability. 

• Convenience features enhance brand value 

Agricultural OEMs differentiate their brands through capabilities that allow farmers to remotely update equipment prescriptions from their offices, eliminating manual field programming. Mining operators can adjust drilling parameters, update blast patterns, and modify hauling routes without entering hazardous areas. Construction managers receive automated compliance reports for environmental and safety standards, streamlining regulatory requirements while maintaining operational focus. Remote diagnostics detect developing issues before catastrophic failures occur. Underground mining demands robust and reliable connectivity solutions, making connectivity fundamental for both remote-controlled and autonomous operations in hazardous environments where human presence carries significant risk. 

The technology stack enabling transformation 

• Beyond 5G to next-generation networks 

The transition from 4G to 5G was more than an incremental improvement. 5G’s ultra-low latency delivers sub-10ms response times, enabling real-time equipment control critical for autonomous operations where even 50ms delays could compromise safety. Massive IoT support allows thousands of sensors per square kilometer, monitoring everything from component wear to environmental conditions. While off-highway sites have lower vehicle density than urban environments, modern operations deploy extensive sensor networks. A single autonomous haul truck carries 200+ sensors, while mine sites monitor thousands of environmental and equipment health sensors, making massive IoT support increasingly relevant for comprehensive site digitalization. Enhanced mobile broadband delivers bandwidth for multiple high-definition video streams from equipment cameras, supporting remote operation centers. 

Network slicing creates dedicated virtual networks for critical applications, ensuring safety systems and autonomous vehicle control maintain guaranteed performance even during network congestion.  

According to the ITU and 3GPP roadmaps, 6G specifications should be ready by the end of 2028, with commercial systems expected by 2030⁴, promising terabit speeds and microsecond latency that will enable currently impossible applications. 

• Private 5G networks transform remote sites 

After the initial hype, the private 5G ecosystem has finally stabilized, with the ecosystem maturing over the last few years as industrial-grade 5G devices, industrial gateways, and chipsets became available, and more vendors launched commercial products. Mining operations increasingly deploy private 5G networks for underground and surface operations. Newmont Corporation’s deployment of private wireless networks in partnership with technology providers has delivered enhanced connectivity for autonomous equipment and smart applications while improving safety and productivity⁵. These networks provide complete control over security, bandwidth allocation, and coverage optimization. 

The emergence of 5G-in-a-box solutions simplifies private network deployment, making the technology accessible to smaller operations. Agricultural operations exploring private networks focus on precision farming applications, though adoption remains limited compared to mining. Construction sites benefit from temporary private networks that move with project progression, maintaining consistent connectivity across changing work areas. 

• Satellite connectivity eliminates coverage gaps 

Low Earth Orbit satellite constellations from providers like Starlink and OneWeb reshape connectivity economics for remote operations, while traditional GEO providers like Intelsat continue serving specific use cases. These LEO services deliver broadband speeds with latencies under 50ms to locations previously limited to expensive, high-latency satellite connections. 

Hybrid connectivity architectures combine terrestrial 5G with satellite backup, ensuring continuous operations regardless of location. While satellite bandwidth costs exceed terrestrial options, the elimination of connectivity dead zones and guaranteed availability justify investments for critical operations. Future 6G standards are expected to integrate satellite and terrestrial networks seamlessly, creating truly ubiquitous global coverage. 

• Edge computing and MEC architecture 

Edge computing brings processing power directly to equipment, enabling real-time decision-making without cloud dependency. Edge computing is becoming ubiquitous in the off-highway industrial segment because of technical (connectivity constraints in operating environments), economic (huge sensor data volumes and resulting backhaul costs), and operational needs (real-time decision making). The Edge computing ecosystem has also significantly matured with ARM-based rugged gateways, industrial PCs, and compute driven by NVIDIA Jetson, Intel Movidius, etc., being widely available. OEMs today embed edge compute in their connected machines as a default capability.  

Mobile Edge Compute infrastructure deployed at cell towers or on-site provides computing power closer to equipment, reducing latency for time-sensitive applications. This architecture supports applications requiring immediate response, such as collision avoidance systems and autonomous navigation, while reducing data transmission costs. 

Real-world applications delivering value today 

• Mining autonomy at scale 

The deployment of 100 autonomous electric mining trucks at the Yimin open-pit mine in Inner Mongolia, China, showcases how connected intelligence and 5G-Advanced networks enable large-scale autonomous operations. These trucks leverage IoT and edge computing to operate efficiently in extreme conditions⁷.These trucks operate continuously in -40°C conditions while delivering significantly improved efficiency compared to manually driven equivalents. Underground mining presents unique connectivity challenges that private 5G networks address effectively. Specialized solution providers have deployed extensive 4G/5G coverage in underground tunnels globally, enabling remote-controlled equipment operation from surface control rooms⁸. Sensors monitor air quality, ground stability, and equipment health continuously, preventing accidents while maintaining productivity. 

• Precision agriculture and connected equipment  

Connected agricultural equipment enables dynamic prescription updates based on real-time field conditions. Variable rate application systems adjust inputs based on soil moisture sensors, weather forecasts, and satellite imagery analysis. During harvest, multiple machines coordinate through connectivity to optimize grain cart positioning, minimize compaction, and maximize throughput. Equipment manufacturers use connectivity to differentiate their offerings. Advanced operations centers from leading manufacturers enable farmers to monitor multiple machines simultaneously, share data with advisors, and optimize field operations from any location⁹. The convenience of remote equipment management becomes a key purchase factor as operations scale across larger geographic areas. 

• Construction site orchestration 

Industry data shows that construction equipment typically operates at 30-40% capacity due to poor coordination¹⁰. Connected systems optimize equipment deployment across multiple sites, reducing idle time while maximizing productivity. The need to control maintenance costs and reduce fleet downtime highlights the appeal of connected solutions centered on asset tracking, equipment diagnostics, prognostics, maintenance, and real-time monitoring. 

Connected construction sites leverage real-time data to prevent delays and improve safety. Predictive maintenance algorithms analyze equipment health to schedule service during planned downtime, avoiding unexpected breakdowns. Digital credential systems verify operator certifications before allowing equipment access, while geofencing ensures machines operate only within designated zones. These systems integrate directly with project management platforms like Trimble Works Manager and Komatsu Smart Construction, providing real-time updates on equipment hours, material volumes moved, and completion percentages against project plans. This visibility enables project managers to identify potential delays early and adjust resources accordingly. 

• Quest Global’s UNDP success story 

The UNDP fleet management implementation for legacy food and aid delivery trucks showcased connectivity’s practical benefits beyond basic tracking. Monitoring reduced fuel theft through real-time consumption analysis, improved safety through driver behavior monitoring, and enhanced utilization through optimized deployment strategies. These outcomes provide a proven template for commercial deployments across mining, construction, and agricultural sectors. 

Emerging technologies reshape the landscape 

• Satellite technology’s mainstream adoption 

The rapid proliferation of LEO satellite constellations marks a watershed moment for off-highway connectivity. Starlink’s 5,000+ satellite network now delivers 100+ Mbps speeds with sub-50ms latency to the most remote mining and agricultural sites. This wasn’t possible even two years ago. OneWeb’s polar orbit focus specifically targets high-latitude mining operations, while Amazon’s Project Kuiper promises to further drive down costs through competition. For off-highway operations, this means high-bandwidth applications like real-time video streaming for remote operation and cloud-based AI processing are finally viable anywhere on Earth. 

• AI evolution transforms maintenance operations 

Classical machine learning drives core predictive maintenance, analyzing sensor patterns to identify failures before they occur. These proven systems detect anomalies in vibration, temperature, and pressure data with increasing accuracy.  

Generative AI enhances these capabilities through natural language interfaces. Technicians can query conversationally: ‘Show me all hydraulic failures on excavators above 40°C.’ The system synthesizes maintenance histories, explains failure modes in plain language, and generates illustrated repair procedures. GE Digital and PTC are already integrating GPT-4 class models into their platforms.  

The next frontier is agentic AI; autonomous systems that manage maintenance without human intervention. These agents will detect impending failures, check parts inventory, schedule repairs during planned downtime, and assign certified technicians automatically. McKinsey research indicates that these AI-driven approaches can reduce equipment downtime by up to 50%, ³ with early agentic implementations showing even greater efficiency gains in maintenance planning. For operations managing hundreds of remote assets, agentic AI transforms maintenance from a reactive cost center to a proactive value driver. 

• Service aggregator platforms challenge traditional models 

Global equipment manufacturers increasingly partner with service aggregator platforms rather than individual telecom operators. Major telecommunications providers promote IoT architectures that simplify deployment post-manufacturing across 50+ countries without managing multiple carrier relationships. 

These platforms simplify global deployments through unified billing, consistent service levels, and single-point management across diverse geographic regions. Modern connectivity providers offer eSIM technology that automatically switches between networks based on coverage and cost optimization algorithms. For OEMs selling equipment globally, these platforms eliminate the complexity of negotiating with dozens of national carriers. 

• Sustainability through connected efficiency 

Electric off-highway equipment adoption accelerates as battery technology improves and emissions regulations tighten. Connected systems enable smart charging that monitors grid conditions, automatically scheduling charging during off-peak hours to reduce costs and grid load. Advanced implementations integrate with utility APIs to prioritize renewable energy sources, charging equipment when solar or wind power is available. Mining operations in Chile already demonstrate this capability¹⁴, timing electric haul truck charging with peak solar generation to minimize carbon footprint beyond tailpipe emissions. Combined with route optimization, battery health monitoring, and automated carbon tracking, these connected capabilities address both operational efficiency and sustainability reporting requirements. 

• 6G preparation begins now 

While 6G networks are expected to be available for public use by 2030, preparation starts today. The technology promises terabit speeds, microsecond latency, and integrated terrestrial-satellite networks. Unlike previous wireless technologies, 6G will seamlessly integrate satellite and terrestrial networks, ensuring continuous connectivity regardless of location. 

Environmental sensing capabilities using terahertz waves will detect chemical compositions, enabling new safety applications in mining and agriculture. Digital twin synchronization will occur in real-time, supporting advanced simulation and optimization. Organizations investing in 5G infrastructure today should ensure upgrade paths to 6G, avoiding stranded investments. 

Quest Global’s engineering excellence in connected off-highway systems 

Quest Global brings unique capabilities to the connected off-highway transformation. With our engineers supporting 70% of top automotive manufacturers, we have demonstrated deep expertise in the core technologies enabling this evolution. The automotive team’s experience in software-defined vehicles (SDVs), ADAS, and electric powertrains directly translates to off-highway equipment challenges. 

Beyond automotive, Quest Global’s 21,000+ engineers and consultants across embedded systems, digital engineering, and IoT create solutions spanning silicon to systems to cloud. The company’s proven track record includes developing robust operator interface systems and ruggedized control units for harsh environment applications, demonstrating the reliability and durability required for mission-critical off-highway deployments. 

The company’s experience with hardware, embedded, and digital technologies (edge compute, cloud compute, data analytics, and AI) positions it as an ideal partner for OEMs navigating the convergence of autonomy, electrification, and connectivity in off-highway equipment. 

Quest Global brings 28+ years of pure-play engineering expertise spanning the complete technology stack from chip design to cloud applications and AI implementation. The company’s experience across automotive, aerospace, energy, semiconductor, and hi-tech verticals provides unique cross-industry insights that accelerate innovation in off-highway applications. Chip-to-cloud capabilities enable solutions that span embedded systems design, connectivity implementation, platform development, and application creation. Hardware expertise includes sensor integration, edge computing platforms, and power management for harsh environments. Software capabilities encompass real-time operating systems, communication protocols, cloud architectures, and AI/ML algorithm development. Platform development expertise ensures scalable, secure solutions that grow with operational needs. Integration capabilities connect disparate systems, including ERP, maintenance management, and operational databases. Partnerships with technology providers, including semiconductor manufacturers, connectivity providers, and cloud platforms, ensure access to the latest innovations. Application development and AI capabilities transform raw data into actionable insights. Machine learning models trained on diverse datasets identify patterns invisible to traditional analysis. Natural language processing enables conversational interfaces that simplify complex system interactions. Computer vision algorithms support autonomous operations and quality inspection applications. 

The next evolution awaits 

The off-highway industry stands at an inflection point where connectivity transitions from differentiator to foundation. Organizations that mastered basic telematics over the past decade must now embrace the next evolution. Generative AI will transform how equipment communicates problems and solutions. Agentic AI systems will autonomously manage fleet optimization without human intervention. 6G networks will enable applications we cannot yet imagine, while satellite constellations ensure no location remains disconnected. 

The convergence of autonomy, electrification, and intelligence demands engineering expertise that spans disciplines. Organizations that today make proactive investments in their product roadmap will shape industry standards rather than scrambling to meet them. 

References 

1. IoT Analytics. “State of IoT 2024: Number of connected devices growing 13% to 18.8 billion globally.” IoT Analytics Research, 2024.  https://iot-analytics.com/number-connected-iot-devices/ 

2. Berg Insight. “The installed base of construction equipment OEM telematics systems will reach 12 million units worldwide by 2028.” Berg Insight, 2024. https://iotbusinessnews.com/2024/12/11/30100-the-installed-base-of-construction-equipment-oem-telematics-systems-will-reach-12-million-units-worldwide-by-2028/ 

3. McKinsey & Company. “Digitally enabled reliability: Beyond predictive maintenance.” McKinsey Global Institute, 2018. https://www.mckinsey.com/capabilities/operations/our-insights/digitally-enabled-reliability-beyond-predictive-maintenance 

4. International Telecommunication Union. “IMT-2030 (6G) Vision and Requirements.” ITU-R Working Party 5D, 2024. https://www.itu.int/en/ITU-R/study-groups/rsg5/rwp5d/imt-2030/Pages/default.aspx 

5. Newmont Corporation & Ericsson. “Newmont Trial of Underground 5G at Cadia Mine Delivers Strong Results.” Business Wire, 2024. https://finance.yahoo.com/news/newmont-trial-underground-5g-cadia-210000991.html 

6. Mining Connectivity via Satellite Market Research Report 2033. “Fixed Satellite Services dominate with 62% market share.” Market Intelo, 2024. https://marketintelo.com/report/mining-connectivity-via-satellite-market 

7. Huawei. “World’s First Fleet of 100 5G-A Autonomous Electric Mining Trucks Launched at Yimin Mine.” Huawei News, 2025. https://www.huawei.com/en/news/2025/5/yimin-Huaneng-Intelligent-Mining 

8. International Mining. “5G underground networks receive Newmont’s seal of approval following Cadia trial.” IM Mining, 2024. https://im-mining.com/2024/08/09/5g-underground-networks-receive-newmonts-seal-of-approval-following-cadia-trial/ 

9. John Deere. “Operations Center – Data Management for Precision Agriculture.” Deere & Company, 2024. https://www.deere.com/en/technology-products/precision-ag-technology/data-management/operations-center/ 

10. Construction Equipment. “How to Manage Engine Idling for Efficiency – 30-40% idle time industry average.” Construction Equipment Magazine, 2024. https://www.constructionequipment.com/sustainability/article/10757122/how-to-manage-engine-idling-for-efficiency 

11. Siemens. “Siemens introduces AI agents for industrial automation with generative AI-based assistants.” Siemens Press, 2024. https://press.siemens.com/global/en/pressrelease/siemens-introduces-ai-agents-industrial-automation 

12. Aeris. “IoT Accelerator Platform Provides Global Enterprises with eSIM Orchestration – Managing 34 million eSIMs.” Aeris Communications, 2025. https://www.aeris.com/resources/aeris-expands-its-iot-accelerator-platform-to-provide-global-enterprises-with-esim-orchestration-and-platform-visibility-and-control-across-operators/ 

13. MarketsandMarkets. “Electric Construction Equipment Market to reach $44.8 billion by 2030.” Markets and Markets Research, 2024. https://www.marketsandmarkets.com/Market-Reports/off-highway-electric-vehicle-market-129288251.html 

14. BHP. “BHP targets 100 per cent renewable energy at Escondida and Spence operations.” BHP Media Centre, 2019. https://www.bhp.com/news/media-centre/releases/2019/10/bhp-targets-100-per-cent-renewable-energy-at-escondida-and-spence-operations-and-elimination-of-water-usage-from-aquifers-in-chile