Modularly configured drive system for pure electric mine AC dump truck

Abstract

The application discloses a drive system of a pure electric mine AC self-unloading vehicle with modularized power batteries, which comprises a vehicle controller, an external power source access system, a frequency conversion drive system, a vehicle auxiliary operation system and a power system which are electrically connected in sequence, and the vehicle controller is used for monitoring the running states of the power system, the frequency conversion drive system, the external power source access system and the vehicle auxiliary operation system in real time through a CAN communication bus, and sending control instructions to the systems according to the operation instructions of a driver and the states of the systems, so that the systems work cooperatively. According to the application, the power batteries of a mine electric transmission self-unloading vehicle with a load of 110t to 300t or more can be modularized, the power batteries can be configured according to the power demand of the vehicle, the vehicle can be operated in a pure electric mode, the fuel consumption of a mine can be reduced, the production cost of the mine can be lowered, and the green development of the mine can be realized.

Description

Technical Field

[0001] This invention relates to a pure electric AC dump truck drive system for mining, specifically a pure electric AC dump truck drive system with modularly configurable power batteries. Background Technology

[0002] Currently, large mining dump trucks with a load capacity of 110t to 300t and above are widely used in large open-pit mining and the construction of water conservancy and hydropower facilities, undertaking the task of transporting minerals and earthwork. Early large mining dump trucks were primarily powered by diesel engines. The transmission methods were mainly either mechanical transmission, where the diesel engine drives the rear wheels through a gearbox, or electric transmission, where the diesel engine drives a generator to produce electricity, which then drives the rear wheels. Regardless of the drive method, the diesel engine remained the primary power source.

[0003] In recent years, with the development of the new energy industry, the power systems of mining dump trucks with a load capacity of 110t and below have been replaced by pure electric power. However, for large mining dump trucks with a load capacity of more than 110t to 300t and above, it is difficult to achieve pure electric power system replacement. The reasons are: (1) The bus voltage of large mining dump trucks is above 1000V, which would be very costly to achieve with the current lithium battery technology; (2) The problem of battery pack voltage equalization caused by direct parallel connection of multiple branches of batteries is difficult to solve, and cannot meet the driving power requirements of the vehicle. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a pure electric AC dump truck drive system with modularly configurable power batteries.

[0005] The technical solution adopted by the present invention to solve its technical problem is a pure electric mining AC dump truck drive system with modularly configurable power batteries. The system includes a vehicle controller and an external power supply system, a variable frequency drive system, a vehicle auxiliary operation system, and a power system that are connected in sequence. The vehicle controller monitors the operating status of the power system, the variable frequency drive system, the external power supply system, and the vehicle auxiliary operation system in real time through a CAN communication bus, and issues control commands to each system according to the driver's operation instructions and the status of each system, so that the systems work together.

[0006] The power system consists of multiple power sub-modules, each comprising a power battery pack, a battery thermal management system, a battery high-voltage distribution cabinet, and a bidirectional DC-DC converter. The power system can be configured with multiple power sub-modules to meet the varying power and charge requirements of pure electric mining dump trucks with different load capacities. Each power sub-module can have different battery types and rated voltage levels than the other power battery sub-modules. The vehicle controller also has energy management functions. By collecting the SOC of each battery pack, the vehicle controller controls the discharge power of the bidirectional DC-DC converter during vehicle operation, ultimately ensuring that all battery packs have equal remaining charge during discharge. The output of the power system is the vehicle's high-voltage bus, which provides power to the frequency converter drive system and vehicle auxiliary operation system.

[0007] The variable frequency drive system consists of a braking resistor box, a left wheel traction inverter, a right wheel traction inverter, a left wheel traction motor, and a right wheel traction motor;

[0008] The vehicle auxiliary operation system consists of an auxiliary power supply, a hydraulic oil pump motor and oil pump motor driver, a vehicle thermal management system, a 24V low-voltage power supply system, and a cabin air conditioning system. The auxiliary power supply steps down the high-voltage power to a low-voltage power supply and releases it on the low-voltage bus. The oil pump motor driver, the vehicle thermal management system, the 24V low-voltage power supply system, the cabin air conditioning system, and the battery thermal management system are all powered by the low-voltage bus.

[0009] The output terminal of the external power supply system is also a high-voltage bus, connecting the external power supply to the high-voltage bus.

[0010] Furthermore, the external power access system includes a main positive contactor, a main negative contactor, a pre-charging circuit, an external voltage sensor, an on-board power receiving interface current sensor, an on-board power receiving interface temperature sensor, an on-board power receiving interface force sensor, and an external power supply system communication module. The external power access system interfaces with the external power supply system through the on-board power receiving interface. The vehicle controller obtains the connection status information between the on-board power receiving interface and the external power supply system through the external voltage sensor, the on-board power receiving interface temperature sensor, and the on-board power receiving interface force sensor. It also reads the external power supply system parameters through the external power supply system communication module to determine whether the external power supply can be enabled. If the external power supply can be enabled, the main negative contactor is closed first, and then the pre-charging circuit is connected. When the high-voltage bus voltage is slightly lower than the external power supply system voltage, the main positive contactor of the external power access system is connected, completing the electrical connection between the high-voltage bus and the external power supply system.

[0011] Furthermore, the high-voltage busbar serves as the physical connection entity for each system. The power system releases energy onto the high-voltage busbar to provide power to the frequency conversion drive system and the vehicle auxiliary operation system.

[0012] Furthermore, the braking resistor box, the left wheel traction inverter, and the right wheel traction inverter are mounted on the high-voltage bus: when the vehicle is traction-driven, the left wheel traction inverter and the right wheel traction inverter drive the left wheel traction motor and the right wheel traction motor to rotate, driving the vehicle forward; when the vehicle is under electric braking, the left wheel traction motor and the right wheel traction motor are converted into generators, converting the vehicle's kinetic energy into electrical energy, which is then rectified by the left wheel traction inverter and the right wheel traction inverter and released to the high-voltage bus.

[0013] Furthermore, the output terminals of the bidirectional DC-DC converter of each power battery submodule are connected in parallel to the high-voltage bus of the vehicle. The rated voltage of the high-voltage bus may not be equal to the rated voltage of each power battery submodule.

[0014] Furthermore, the power system can be configured with various power sub-modules according to the different power and energy requirements of the pure electric mining AC dump truck, so as to meet different power and energy requirements.

[0015] Furthermore, the external power supply system can introduce a qualified external power source into the vehicle's high-voltage bus, through which the power battery can be charged via a bidirectional DC-DC converter. The vehicle can also be driven forward via the left-wheel traction inverter and the right-wheel traction inverter, and the auxiliary systems can be powered via the auxiliary power supply, enabling the vehicle to operate with external power.

[0016] Furthermore, the vehicle controller also has an energy management function. By collecting the SOC of each battery pack and calculating the charge of each battery pack, the vehicle controller controls the discharge power of the bidirectional DC-DC converter during vehicle traction, ultimately achieving the goal of equal SOC of each battery pack during discharge.

[0017] This invention enables modular configuration of power batteries for mining electric drive dump trucks with load capacities ranging from 110t to 300t and above. The configuration is tailored to the vehicle's specific power requirements, allowing for pure electric operation. An external power supply system can be implemented by constructing overhead power lines along the road to provide power to the vehicles, enabling external power supply for pure electric vehicles. The widespread application of this invention helps reduce fuel consumption in mines, lowers production costs, and promotes green development in mining. Attached Figure Description

[0018] Figure 1 This is a structural block diagram of an embodiment of the present invention.

[0019] In the diagram: 01-Vehicle controller, 02-External power supply system, 03-Variable frequency drive system, 04-Power system, 05-Vehicle auxiliary operation system, 06-High voltage bus, 07-Low voltage bus, 08-Left wheel inverter, 09-Left wheel motor, 10-Right wheel inverter, 11-Right wheel motor, 12-Brake resistor box, 13-Auxiliary power supply. 14-Oil pump motor driver, 15-Oil pump motor, 16-24V low voltage power supply system, 17-Cabin air conditioning system, 18-Vehicle thermal management system, 19-On-board power receiving interface, 20-Charging control cabinet, 21-Battery pack, 22-Power distribution cabinet, 23-Bidirectional DC-DC converter, 24-Battery thermal management system, 25-Power battery sub-module. 26-On-board power receiving interface force sensor, 27-On-board power receiving interface temperature sensor, 28-External voltage sensor, 29-On-board power receiving interface current sensor, 30-External power supply access system main positive contactor, 31-External power supply access system main negative contactor, 33-External power supply system communication module. Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0021] See attached document Figure 1 This embodiment includes an external power supply system 02, a variable frequency drive system 03, a vehicle auxiliary operation system 05, and a power system 04, which are connected in sequence by electricity. This embodiment also includes a vehicle controller 01, which monitors the operating status of the power system 04, the variable frequency drive system 03, the external power supply system 02, and the vehicle auxiliary operation system 05 in real time via a CAN communication bus, and issues control commands to each system based on the driver's operating instructions and the status of each system, enabling the systems to work collaboratively.

[0022] The vehicle controller 01 has multiple I / O interfaces and a CAN communication interface. It is the central hub of the vehicle control system and the core component that coordinates the operation of the power system 04, the variable frequency drive system 03, the external power supply system 02, and the vehicle auxiliary operation system 05. It is the main control component that realizes functions such as vehicle driving, regenerative braking and battery charging, fault diagnosis and handling, and vehicle status monitoring.

[0023] The vehicle controller 01 primarily collects information from the accelerator pedal, electric brake pedal, and various control switch signals on the instrument panel via I / O interfaces. It then interprets the driver's operational intentions and ultimately translates them into control requirements for various vehicle systems. Simultaneously, the vehicle controller monitors the real-time operating status of the powertrain, variable frequency drive system, external power supply system, and vehicle auxiliary operating systems via the CAN communication bus, and performs intelligent regulation to ensure their coordinated operation. The specific structure of the vehicle controller 01 is existing technology and will not be described in detail here.

[0024] The power system 04 consists of multiple power sub-modules 25, each of which comprises a power battery pack 21, a battery thermal management system 24, a battery high-voltage distribution cabinet 22, and a bidirectional DC-DC converter 23. The power system 02 can be configured with various power sub-modules according to the different power and energy requirements of the pure electric mining AC dump truck, in order to meet different power and energy requirements.

[0025] The output of the power system 04 is the high-voltage bus 06 of the vehicle, which provides power to the variable frequency drive system 03 and the vehicle auxiliary operation system 05.

[0026] The variable frequency drive system 03 consists of a braking resistor box 12, a left wheel traction inverter 08, a right wheel traction inverter 10, a left wheel traction motor 09, and a right wheel traction motor 11.

[0027] The vehicle auxiliary operation system 05 consists of an auxiliary power supply 13, a hydraulic oil pump motor 15 and an oil pump motor driver 14, a vehicle thermal management system 18, a 24V low-voltage power supply system 16, and a cabin air conditioning system 17.

[0028] The external power supply access system 02 consists of a high-voltage control cabinet 19 and a vehicle-mounted power receiving interface 20. The output end of the external power supply access system 02 is also the high-voltage bus 06, which connects the external power supply to the high-voltage bus 06.

[0029] The vehicle controller 01 is the core component of the entire system. The vehicle controller 01 monitors the operating status of the power system 04, the variable frequency drive system 03, the external power supply system 02, and the vehicle auxiliary operation system 05, and issues control commands to each system according to the driver's operation instructions and the status of each system, so that the systems work together.

[0030] Each power battery submodule 25's power battery pack 21, battery thermal management system 24, and battery high-voltage distribution cabinet 23 are isolated 23 from the power battery pack 21, battery thermal management system 24, and battery high-voltage distribution cabinet of other power battery submodules. The battery type and rated voltage level of each power battery submodule 25 may be different. The output terminal of the bidirectional DC-DC converter 23 of each power battery submodule 25 is connected in parallel to the high-voltage bus 06 of the vehicle. The rated voltage of the high-voltage bus 06 may not be equal to the rated voltage of each power battery submodule 25.

[0031] The power system 04 can be configured with various power sub-modules 25 according to the different power and energy requirements of the pure electric mining AC dump truck, so as to meet the different power and energy requirements.

[0032] The vehicle controller 01 also has energy management functions. By collecting the SOC of each battery pack 21, the vehicle controller 01 calculates the charge of each battery pack 21. During vehicle traction, the controller 01 controls the discharge power of the bidirectional DC-DC converter 23 accordingly, so as to achieve the goal of equal SOC of each battery pack 21 during the discharge process.

[0033] High-voltage bus 06 is the physical connection entity for each system. Power system 04 releases energy to high-voltage bus 06 to provide power to variable frequency drive system 03 and vehicle auxiliary operation system 05.

[0034] The braking resistor box 12, left wheel traction inverter 08, and right wheel traction inverter 10 in the variable frequency drive system 03 are mounted on the high-voltage bus. When the vehicle is traction, the left wheel traction inverter 08 and the right wheel traction inverter 10 drive the left wheel traction motor 09 and the right wheel traction motor 11 to rotate, respectively, driving the vehicle forward. When the vehicle is braking, the left wheel traction motor 09 and the right wheel traction motor 11 become generators, converting the vehicle's kinetic energy into electrical energy, which is then rectified by the left wheel traction inverter 08 and the right wheel traction inverter 10 and released onto the high-voltage bus 06.

[0035] When the vehicle brakes, the vehicle controller 01 collects the SOC of each battery pack 21 and calculates the charge of each battery pack 21. Based on this, it controls the charging power of the bidirectional DC-DC converter 23 of each group to recover the energy released by the left wheel traction inverter 08 and the right wheel traction inverter 10 on the high-voltage bus 06, thereby achieving the purpose of vehicle braking energy recovery. During the recharging process, it ensures that the SOC of each power battery pack 21 is equal.

[0036] If the power system 04 cannot recover all the braking energy, the vehicle controller 01 controls the high-voltage bus 06 to connect the braking resistor box 12, releasing the unrecoverable energy as heat, thereby ensuring that the vehicle has sufficient electric braking force.

[0037] The vehicle auxiliary operation system 05 uses the auxiliary power supply 13 to step down the high voltage power to low voltage power and release it on the low voltage bus 07. The oil pump motor driver 14, the vehicle thermal management system 18, the 24V low voltage power supply system 16, the cabin air conditioning system 17, and the battery thermal management system 24 are all powered by the low voltage bus.

[0038] The vehicle controller 01 monitors the vehicle status in real time and, in conjunction with the driver's operating instructions, controls the hydraulic oil pump motor 15 through the oil pump motor driver 14 to provide power to the vehicle's hydraulic system, controls the operation of the vehicle's thermal management system 18, and controls the cabin air conditioning system 17 to regulate the cab temperature.

[0039] The external power supply system 02 can introduce a qualified external power source into the vehicle's high-voltage bus 06. The bidirectional DC-DC converter 23 uses the energy from the high-voltage bus 06 to charge the battery pack 21. The left-wheel traction inverter 08 and the right-wheel traction inverter 09 can also use the energy from the high-voltage bus 06 to drive the vehicle forward. The auxiliary power supply 13 can also use the energy from the high-voltage bus 06 to power the vehicle's auxiliary operation system 05.

[0040] The external power supply access system 02 includes a main positive contactor 30, a main negative contactor 31, a pre-charging circuit 32, an external voltage sensor 28, an on-board power receiving interface current sensor 29, an on-board power receiving interface temperature sensor 27, an on-board power receiving interface force sensor 26, and an external power supply system communication module 33.

[0041] The external power access system 02 connects to the external power supply system through the vehicle power receiving interface 19. The vehicle controller 01 obtains the connection status information between the vehicle power receiving interface 19 and the external power supply system through the external voltage sensor 28, the vehicle power receiving interface temperature sensor 27, and the vehicle power receiving interface force sensor 26. It also reads the external power supply system parameters through the external power supply system communication module 33 to determine whether the external power supply can be enabled. If the external power supply can be enabled, the main negative contactor 31 is closed first.

[0042] After the vehicle-mounted power receiving interface 19 is connected to the external power supply system, if the bidirectional DC-DC 23 is in a discharging state, first close the external power supply connection system main negative contactor 31, adjust the discharge voltage of the bidirectional DC-DC 23 so that the voltage of the high-voltage bus 06 is slightly lower than the voltage of the external power supply system, then connect the external power supply connection system main positive contactor 30 so that the high-voltage bus 06 is electrically connected to the external power supply system.

[0043] After the vehicle-mounted power receiving interface 19 is connected to the external power supply system, when the bidirectional DC-DC converter 23 is in the off state, first close the main negative contactor 31 of the external power supply connection system, and then start the pre-charging circuit 32. When the voltage of the high-voltage bus 06 is slightly lower than the voltage of the external power supply system, connect the main positive contactor 30 of the external power supply connection system to complete the electrical connection between the high-voltage bus 06 and the external power supply system.

[0044] This embodiment enables the pure electric operation of large dump trucks with a load capacity of 110t to 300t and above used in open-pit mines or water conservancy and hydropower construction, which helps to reduce fuel consumption in mines, lower production costs in the mining and water conservancy and hydropower construction process, and achieve green development of mines.

[0045] Those skilled in the art can make various modifications and variations to this invention. If such modifications and variations are within the scope of the claims of this invention and their equivalents, then such modifications and variations are still within the protection scope of this patent.

[0046] The contents not described in detail in the specification are prior art known to those skilled in the art.

Claims

1. A pure electric AC dump truck drive system for mining applications with modularly configurable power batteries, the system including a vehicle controller, characterized in that: The system includes an external power supply system, a variable frequency drive system, a vehicle auxiliary operation system, and a power system, which are connected in sequence. The vehicle controller monitors the operating status of the power system, the variable frequency drive system, the external power supply system, and the vehicle auxiliary operation system in real time through the CAN communication bus, and issues control commands to each system according to the driver's operation instructions and the status of each system, so that the systems work together. The power system comprises multiple power sub-modules, each consisting of a power battery pack, a battery thermal management system, a battery high-voltage distribution cabinet, and a bidirectional DC-DC converter. The vehicle controller also has energy management functions. By collecting the SOC of each battery pack, the vehicle controller controls the discharge power of each bidirectional DC-DC converter during vehicle operation, ultimately achieving the goal of equal remaining charge in each battery pack during discharge. The output of the power system is the vehicle's high-voltage bus, which provides power to the frequency converter drive system and vehicle auxiliary operation system. The power system can be configured with various power sub-modules according to the different power and charge requirements of pure electric mining AC dump trucks, to meet the power and charge requirements of vehicles with different load capacities. The variable frequency drive system consists of a braking resistor box, a left wheel traction inverter, a right wheel traction inverter, a left wheel traction motor, and a right wheel traction motor; The vehicle auxiliary operation system consists of an auxiliary power supply, a hydraulic oil pump motor and oil pump motor driver, a vehicle thermal management system, a 24V low-voltage power supply system, and a cabin air conditioning system. The auxiliary power supply steps down the high-voltage power to a low-voltage power supply and releases it on the low-voltage bus. The oil pump motor driver, the vehicle thermal management system, the 24V low-voltage power supply system, the cabin air conditioning system, and the battery thermal management system are all powered by the low-voltage bus. The output terminal of the external power supply system is also a high-voltage bus, connecting the external power supply to the high-voltage bus; The system can be powered by an external power source by constructing overhead power lines along the road to supply power to the vehicles. The external power access system includes a main positive contactor, a main negative contactor, a pre-charging circuit, an external voltage sensor, an on-board power receiving interface current sensor, an on-board power receiving interface temperature sensor, an on-board power receiving interface force sensor, and an external power supply system communication module. The external power access system interfaces with the external power supply system through the on-board power receiving interface. The vehicle controller obtains the connection status information between the on-board power receiving interface and the external power supply system through the external voltage sensor, the on-board power receiving interface temperature sensor, and the on-board power receiving interface force sensor, and reads the external power supply system parameters through the external power supply system communication module to determine whether it can be enabled. If an external power supply is available, first close the main negative contactor, then connect the pre-charging circuit. When the high-voltage bus voltage is slightly lower than the external power supply system voltage, connect the external power supply to the system's main positive contactor to complete the electrical connection between the high-voltage bus and the external power supply system. The external power supply system can introduce a qualified external power source into the vehicle's high-voltage bus. Through the high-voltage bus, the power battery can be charged via a bidirectional DC-DC converter, the vehicle can be driven forward via the left-wheel traction inverter and the right-wheel traction inverter, and the vehicle's auxiliary systems can be powered via the auxiliary power supply, thus enabling the vehicle to operate under external power supply. The high-voltage busbar is the physical connection entity of each system. The power system releases energy to the high-voltage busbar to provide power to the frequency conversion drive system and the vehicle auxiliary operation system. The vehicle controller also has energy management functions. By collecting the SOC of each battery pack and calculating the charge of each battery pack, the vehicle controller controls the discharge power of the bidirectional DC-DC converter during vehicle traction, ultimately achieving the goal of equal SOC of each battery pack during discharge.

2. The pure electric mining AC dump truck drive system with modularly configurable power batteries according to claim 1, characterized in that: The braking resistor box, left wheel traction inverter, and right wheel traction inverter are mounted on the high-voltage bus. When the vehicle is traction, the left wheel traction inverter and the right wheel traction inverter drive the left wheel traction motor and the right wheel traction motor to rotate, driving the vehicle forward. When the vehicle is under electric braking, the left wheel traction motor and the right wheel traction motor are converted into generators, converting the vehicle's kinetic energy into electrical energy, which is then rectified by the left wheel traction inverter and the right wheel traction inverter and released to the high-voltage bus.

3. The pure electric mining AC dump truck drive system with modularly configurable power batteries according to claim 1, characterized in that: The output terminals of the bidirectional DC-DC converter of each power battery submodule are connected in parallel to the high-voltage bus of the vehicle. The rated voltage of the high-voltage bus may not be equal to the rated voltage of each power battery submodule.

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