A mine dump truck fuel consumption monitoring method based on electric power analysis

Abstract

The application discloses a kind of based on electric power analysis's mining self-unloading truck oil consumption monitoring method, comprising: collecting the instantaneous electric power of truck engine, and the cumulative power consumption in fixed time period is calculated using instantaneous electric power;Statistical vehicle corresponding running time's refueling amount, calculate the coefficient model between power consumption and oil consumption in fixed time period;Through coefficient model, the fuel consumption of specified time period is converted by electric power collected by vehicle system;According to the division of working nature, the oil consumption in any working time period is obtained.The present application can accurately calculate the oil consumption in specified time period according to the instantaneous electric power of self-unloading truck, greatly improve the accuracy of oil consumption.And through the oil consumption of specified time period, the instantaneous fuel consumption and operating performance of target vehicle can be obtained according to the application time, and the driving oil consumption of operation driver can also be compared through cumulative oil consumption.

Description

Technical Field

[0001] This invention relates to the field of truck fuel consumption technology, and in particular to a method for monitoring the fuel consumption of mining dump trucks based on electrical power analysis. Background Technology

[0002] Large dump trucks consume a huge amount of fuel, using approximately 1.8 tons of diesel fuel per 24 hours. However, existing fuel consumption measurement methods, such as float-type fuel sensors, fuel rod sensors, and instantaneous engine fuel consumption, all have various problems, resulting in inaccurate fuel consumption statistics and failing to support the needs of refined management.

[0003] The existing fuel level detection devices have the following problems: The original float-type fuel level sensor is highly unreliable and will fail after prolonged use. Furthermore, in a giant fuel tank exceeding 2 tons, the fuel level fluctuates significantly due to inertia and road incline, causing substantial movement of the float and resulting in inaccurate readings. We later installed a fuel level sensor with a pressure gauge, which is more reliable, but this still does not solve the problem of inaccurate readings caused by fuel level fluctuations. Summary of the Invention

[0004] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the invention.

[0005] In view of the aforementioned existing problems, the present invention is proposed.

[0006] Therefore, the present invention provides a solution to the problem that the real-time fuel consumption monitoring of large dump trucks is inaccurate and cannot support refined management.

[0007] To solve the above-mentioned technical problems, the present invention provides the following technical solution, including: collecting the instantaneous electrical power of the truck engine and calculating the cumulative power consumption within a fixed time period using the instantaneous electrical power; statistically analyzing the amount of fuel refueling during the corresponding operating time of the vehicle and calculating a coefficient model between power consumption and fuel consumption within a fixed time period; converting the fuel consumption within a specified time period into the electrical power collected by the vehicle system using the coefficient model; and dividing the time period according to the nature of the work to obtain the fuel consumption within any working time period.

[0008] As a preferred embodiment of the fuel consumption monitoring method for mining dump trucks based on power analysis described in this invention, the cumulative power consumption over a fixed time period is:

[0009]

[0010] Where x: instantaneous power, in HP; S: sampling rate; H: cumulative power consumption (kWh) within a specified time period; hp / kw represents the coefficient for converting horsepower to kilowatts.

[0011] As a preferred embodiment of the method for monitoring fuel consumption of mining dump trucks based on electric power analysis described in this invention, the method includes: converting the sampling rate of x into a proportion after hours; if the sampling rate of x is 1 second, then S = 60 seconds × 60 minutes = 3600.

[0012] As a preferred embodiment of the fuel consumption monitoring method for mining dump trucks based on power analysis described in this invention, the coefficient between power consumption and fuel consumption over a fixed time period is:

[0013] C = H / L

[0014] Where L: refueling amount within a fixed time period; H: electricity consumption (kWh) within a fixed time period; C: coefficient between electrical power consumption and fuel consumption.

[0015] As a preferred embodiment of the fuel consumption monitoring method for mining dump trucks based on electrical power analysis described in this invention, wherein: the fuel consumption over a specified time period is...

[0016]

[0017] Where O: fuel consumption within a specified time period; H i : Electricity consumption (kWh) within a specified time period; C: Coefficient between electrical power consumption and fuel consumption.

[0018] As a preferred embodiment of the fuel consumption monitoring method for mining dump trucks based on electric power analysis described in this invention, the instantaneous electric power acquisition system built into the truck engine performs preliminary processing on the data according to requirements to form calculated cumulative power consumption data; the data is reset to zero at a fixed time every day according to different work requirements, and is spliced ​​before use.

[0019] As a preferred embodiment of the fuel consumption monitoring method for mining dump trucks based on electrical power analysis described in this invention, wherein: when H i When the time interval becomes extremely short, such as 1 second, the corresponding O value is equivalent to the instantaneous fuel consumption. In vehicles without a fuel flow meter or where the instantaneous fuel consumption is inaccurate, this value is used to replace the display of instantaneous fuel consumption.

[0020] As a preferred embodiment of the fuel consumption monitoring method for mining dump trucks based on electric power analysis described in this invention, the fuel consumption O for a specified time period can be arbitrarily divided according to the nature of the work to obtain the cumulative fuel consumption within any time period; combined with the statistics of refueling volume, the fuel consumption O for each driver in a specified time period can be calculated; by calculating the accurate cumulative fuel consumption within each driver's driving time period, a precise comparison of the fuel consumption of driver operations can be achieved.

[0021] As a preferred embodiment of the method for monitoring fuel consumption of mining dump trucks based on power analysis described in this invention, the following steps are taken: by comparing the actual fuel consumption with the refueling amount L and the power consumption H within a fixed time period, the coefficient C of power consumption and fuel consumption for different vehicles is calculated; using the coefficient C of power consumption and fuel consumption for the same vehicle, the influence of the target vehicle's operating conditions and its own characteristics on fuel consumption is determined, and the smaller C is, the optimal target vehicle is selected.

[0022] The beneficial effects of this invention are as follows: This invention derives power consumption and fuel consumption coefficients based on the instantaneous electrical power of the dump truck, enabling accurate calculation of fuel consumption over a specified period, thus greatly improving the accuracy of fuel consumption data. Furthermore, the fuel consumption data obtained using this method can be applied according to usage time to determine the instantaneous fuel consumption and operating performance of the target vehicle. Simultaneously, it allows for comparison of the driver's fuel consumption through cumulative fuel consumption. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein:

[0024] Figure 1 This is a flowchart illustrating the method for monitoring fuel consumption of mining dump trucks based on electrical power analysis, as described in an embodiment of the present invention.

[0025] Figure 2 This is a graph showing the truck's electric power data for the fuel consumption monitoring method for mining dump trucks based on electric power analysis, as described in an embodiment of the present invention.

[0026] Figure 3 This is a comparison chart of power consumption and fuel consumption for the mining dump truck fuel consumption monitoring method based on power analysis, as described in this embodiment of the invention.

[0027] Figure 4 This is a data graph showing the statistics of the refueling metering system for the fuel consumption monitoring method for mining dump trucks based on electric power analysis, as described in an embodiment of the present invention. Detailed Implementation

[0028] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0029] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0030] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0031] This invention is described in detail with reference to the schematic diagrams. When detailing the embodiments of this invention, for ease of explanation, the cross-sectional views illustrating the device structure may be partially enlarged, not adhering to the usual scale. Furthermore, the schematic diagrams are merely examples and should not be construed as limiting the scope of protection of this invention. In actual fabrication, the three-dimensional spatial dimensions of length, width, and depth should be included.

[0032] Furthermore, in the description of this invention, it should be noted that the terms "upper," "lower," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are used solely for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. In addition, the terms "first," "second," or "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] Unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" in this invention should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; similarly, they can refer to mechanical connections, electrical connections, or direct connections, or indirect connections through an intermediate medium, or internal connections between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0034] Example 1

[0035] Reference Figure 1This is the first embodiment of the present invention, which provides a method for monitoring fuel consumption of mining dump trucks based on electrical power analysis, including:

[0036] The power system of large dump trucks consists of a diesel engine driving a coaxial generator. The generator's output current, after being regulated by the control system, is then sent to two rear-wheel drive motors, enabling the vehicle to move. From the perspective of energy conservation, even considering various losses between the engine and generator, the engine's output power and the generator's output power should have a linear relationship. The engine we used has a maximum power rating of approximately 2570 HP according to official documentation, while our own data shows that the maximum output power of its electronic control system is around 2500 HP. This proves that the power output loss between the engine and generator is very small. To calculate the detailed changes in fuel consumption, the specific operating steps are as follows.

[0037] S1: Collect the instantaneous electrical power of the truck engine and use the instantaneous electrical power to calculate the cumulative power consumption within a fixed time period;

[0038] The instantaneous power acquisition system built into the truck engine performs preliminary processing on the data according to the requirements to form the calculated cumulative power consumption data. The data will be reset to zero at a fixed time every day according to different work requirements, and will be spliced ​​before use.

[0039] The cumulative power consumption within a fixed time period is

[0040]

[0041] Where x: instantaneous electrical power, in HP; S: sampling rate;

[0042] H: Cumulative power consumption (kWh) within the specified time period; hp / kw represents the power conversion factor from horsepower to kilowatts.

[0043] The sampling rate of x is converted to a proportion after hours. If the sampling rate of x is 1 second, then...

[0044] S = 60 seconds × 60 minutes = 3600.

[0045] S2: Statistically calculate the amount of fuel refueling for vehicles within a corresponding operating time, and calculate the coefficient model between power consumption and fuel consumption within a fixed time period.

[0046] The coefficient for electricity consumption and fuel consumption over a fixed period of time is:

[0047] C = H / L

[0048] Where L: refueling amount within a fixed time period; H: electricity consumption (kWh) within a fixed time period; C: coefficient between electrical power consumption and fuel consumption.

[0049] S3: Calculate the fuel consumption over a specified time period by combining the coefficient model with the electrical power collected by the vehicle system.

[0050] Fuel consumption over a specified time period

[0051]

[0052] Where O: fuel consumption within a specified time period; H i : Electricity consumption (kWh) within a specified time period; C: Coefficient between electrical power consumption and fuel consumption.

[0053] S4: Divide according to the nature of the work to obtain the fuel consumption in any working time period.

[0054] When H i When the time interval becomes extremely short, such as 1 second, the corresponding O value is equivalent to the instantaneous fuel consumption. In vehicles without a fuel flow meter or where the instantaneous fuel consumption is inaccurate, this value is used to replace the display of instantaneous fuel consumption.

[0055] Furthermore, the fuel consumption O for a specified time period can be arbitrarily divided according to the nature of the work to obtain the cumulative fuel consumption for any time period.

[0056] Traditional fuel metering systems can only calculate the cumulative fuel consumption between two refueling stops, without further breakdown of fuel consumption within that interval. This makes it impossible to calculate the fuel consumption of each driver if multiple drivers were involved in the same refueling session. However, by combining refueling data with the calculated fuel consumption, we can determine each driver's fuel consumption over a specific time period. Furthermore, by accurately calculating the cumulative fuel consumption over each driver's driving time, we can achieve a precise comparison of fuel consumption based on driver activity.

[0057] Furthermore, by analyzing the difference between the amount of fuel refueling (L) and the amount of electricity consumed (H) within a fixed time period and the actual fuel consumption, the coefficient C between electricity consumption and fuel consumption for different vehicles is calculated. Using the coefficient C between electricity consumption and fuel consumption for the same vehicle, the impact of the target vehicle's operating conditions and its own characteristics on fuel consumption is determined. The smaller C is, the optimal target vehicle is selected.

[0058] Theoretically, two identical vehicles, operating under the same conditions, will consume the same amount of energy. However, because actual operating conditions vary from car to car, even two identical models have subtle differences in their inherent characteristics, resulting in different actual fuel consumption for each vehicle. This is reflected in the formula, where the value of C differs for each car. Conversely, this characteristic can be used to determine the impact of a car's operating conditions and inherent characteristics on fuel consumption using each car's C value; the smaller the C value, the higher the car's fuel consumption.

[0059] Example 2

[0060] To verify the effectiveness of the technology used in this method, this embodiment selects existing vehicle data to be used in the test, and uses scientific demonstration methods to verify the test results, thereby verifying the real effect of this method.

[0061] The power system of large dump trucks consists of a diesel engine driving a coaxial generator. The generator's output current, after being regulated by the control system, is then sent to two rear-wheel drive motors, enabling the vehicle to move. Therefore, from the perspective of energy conservation, even considering various losses between the engine and generator, the engine's output power and the generator's output power should have a linear relationship. The maximum power of the currently used engine, as found in official materials, is approximately 2570 HP, while the maximum output power of its electronic control system is also around 2500 HP. This proves that the power output loss between the engine and generator is very small. Its electrical power data curve... Figure 2 As shown.

[0062] Figure 3 The white line with large fluctuations represents the cumulative power consumption H calculated using the engine's instantaneous electrical power. For ease of use, we designed this cumulative value to be reset to 0 at each driver shift change. Our shift change times are 1:00, 8:00, and 17:00 daily. The two points marked with gray boxes in the graph represent shift change times, so the cumulative power consumption data is reset to 0. The black curve with smaller fluctuations represents engine speed. Comparing the two curves, we can see that the cumulative power consumption curve continuously increases during the engine's continuous operation.

[0063] Within box 1, the engine remains at idle, resulting in a slow increase in cumulative energy consumption. In box 2, the engine speed is 0, indicating the engine is off, and cumulative energy consumption does not increase during this period. Overall, the cumulative energy consumption calculated from instantaneous energy consumption follows a trend consistent with fuel consumption patterns.

[0064] Engine output power is proportional to fuel consumption. Therefore, by collecting the output power of the vehicle's electronic control system in real time (with a sampling rate no greater than 1 second), the cumulative electrical power consumed over a certain period can be integrated. Then, by calculating the amount of fuel refueled during the corresponding operating time, the coefficient between the vehicle's generator power and fuel consumption can be calculated. Using this coefficient, the real-time fuel consumption can be calculated from the electrical power collected by the vehicle system. The fuel consumption calculated using this coefficient and the vehicle's real-time electrical power feedback is compared with the refueling amount recorded by the refueling system, and the error is within 5%. Considering that the full tank level cannot be precisely controlled during each refueling, this error is within an acceptable range.

[0065] Actual data analysis revealed that even for the same model with identical configurations, there are slight differences in this coefficient between different individuals, but it is generally around 3.0. Therefore, this coefficient needs to be calibrated individually for each car to obtain more accurate results.

[0066] Table 1: Data sheet for truck No. 3.

[0067]

[0068]

[0069] Furthermore, regarding data collection, since we have performed preliminary data processing on the vehicle power consumption collection system according to our needs, the data recorded in the table is already the calculated cumulative power consumption data, in kWh. For ease of statistics, this data is reset to zero at 1:00 AM, 8:00 AM, and 5:00 PM daily, so manual data splicing is required when using it. These 1:00 AM, 8:00 AM, and 5:00 PM times are based on the current work schedule, where drivers change shifts and hand over duties at these times.

[0070] Due to the influence of external environmental parameters such as temperature, the "mass" data in the "actual density refueling information" should be used when using this product. Other data such as volume may be inaccurate.

[0071] First, we take a refueling record to calculate the coefficient C. The logic is as follows: find two consecutive refueling records. The time between the end of the first refueling and the start of the second refueling is the fuel consumption time corresponding to the amount of fuel refueled in the second refueling.

[0072] For example, Figure 4 As shown, the fuel consumption recorded by the refueling system between 12:11:29 on 2021-12-28 and 10:44:28 on 2021-12-29 is 1328.51 kg.

[0073] The data processing and calculation process was quite complicated. Using Python code, the power consumption was determined to be 3670.3 kWh.

[0074] Using this power consumption H, the coefficient C = 3670.03 / 1328.51 ≈ 2.76 can be calculated using C = H / L.

[0075] Then use this coefficient to verify another refueling record. For example, between 10:44:28 on 2021-12-29 and 10:58:30 on 2021-12-30, the fuel consumption recorded by the refueling system is 1391.51Kg.

[0076] Based on the formula O = H / C, the calculated fuel consumption is O = 3917.17 / 2.76 ≈ 1491.26 kg. Comparing this to the 1391.51 kg recorded by the refueling system, the error is approximately 0.077%.

[0077] After multiple tests, the error was mostly within 5%. When calculating the coefficient C, it is recommended to perform multiple calculations and then take the average value after removing outliers; this will yield a more accurate result.

[0078] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for monitoring fuel consumption of mining dump trucks based on electrical power analysis, characterized in that, include: The instantaneous electrical power of the truck engine is collected, and the cumulative power consumption over a fixed time period is calculated using the instantaneous electrical power. The amount of fuel added to a vehicle during its corresponding operating time is statistically analyzed, and a coefficient model is calculated between the power consumption and fuel consumption within a fixed time period. By combining the coefficient model with the electrical power collected by the vehicle system, the fuel consumption over a specified time period can be calculated. Based on the nature of the work, the fuel consumption within any working time period can be calculated; The cumulative power consumption over a fixed period of time is, Where x: instantaneous electrical power, in HP; S: sampling rate; H: Cumulative power consumption (kWh) within the specified time period; hp / kw represents the factor for converting horsepower to kilowatts; The coefficient for electricity consumption and fuel consumption over a fixed period of time is: C = H / L Where L: refueling amount within a fixed time period; H: electricity consumption (kWh) within a fixed time period; C: coefficient between electrical power consumption and fuel consumption; Fuel consumption over a specified time period is: Where O: fuel consumption within a specified time period; H i Electricity consumption (kWh) within a specified time period; The instantaneous power acquisition system built into the truck engine performs preliminary data processing according to requirements to generate calculated cumulative power consumption data. The data is reset to zero at fixed times every day according to different work requirements and is spliced ​​before use. The fuel consumption O for a specified time period can be arbitrarily divided according to the nature of the work to obtain the cumulative fuel consumption within any time period. By combining the data of fuel consumption L, the fuel consumption O of each driver in a specified time period can be calculated. By statistically analyzing the accurate cumulative fuel consumption of each driver during their driving time, a precise comparison of fuel consumption during driver operations can be achieved.

2. The method for monitoring fuel consumption of mining dump trucks based on electrical power analysis as described in claim 1, characterized in that, include: The sampling rate S is the proportion of the sampling rate of x converted to hours. If the sampling rate of x is 1 second, then S = 60 seconds × 60 minutes = 3600.

3. The method for monitoring fuel consumption of mining dump trucks based on electrical power analysis as described in claim 2, characterized in that, include: When H i When the time period is less than or equal to 1 second, the fuel consumption O within the specified time period is equivalent to the instantaneous fuel consumption. In vehicles without a fuel flow meter or where the instantaneous fuel consumption is inaccurate, this value is used to replace the display of instantaneous fuel consumption.

4. The method for monitoring fuel consumption of mining dump trucks based on electrical power analysis as described in claim 3, characterized in that, include: By analyzing the difference between the amount of fuel refueling (L) and the amount of electricity consumed (H) within a fixed time period and the actual fuel consumption, the coefficient C between the electricity consumption and fuel consumption of different vehicles is calculated. By using the coefficient C of different vehicles' power consumption and fuel consumption, the impact of the target vehicle's operating conditions and its own characteristics on fuel consumption can be determined. The smaller C is, the more optimal the target vehicle is.

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