Brake-by-wire system and brake method for pure electric mining dump truck
By designing a pure electric mines including sensor modules, control modules, and braking modules, the control system of dumping lines for the vehicle is solved. The problem of insufficient electrical braking realizes more flexible and reliable braking performance.
Patent Information
- Application Number
- CN202411695998.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-25
- Publication Date
- 2025-01-24
AI Technical Summary
Pure electric mining dump trucks slip and collide when turning in a narrow underground space, and lack of electric braking when passing through a large ramp when heavy loads pass through a large ramp and emergency braking of one-way vehicles.
A pure electric mining dump truck brake-by-wire system is designed, including a sensor module, a control module and a braking module. The sensor module monitors the vehicle status through a variety of sensors. The control module coordinates the braking method through the electronic control unit and the vehicle controller. The braking module includes electric braking, eddy current braking and hydraulic braking, and intelligently distributes braking torque to Cope with different working conditions.
Effectively solve the slide and load of vehicles in the underground narrow space during the underground stenosis space. Through the problem of insufficient electrical production when growing up the ramp, the vehicle's braking flexibility and reliability of the vehicle under the underground conditions.
Smart Images
Figure CN119348590A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of dump trucks, and in particular to a brake-by-wire system and method for a pure electric mining dump truck. Background Art
[0002] Pure electric mining dump trucks are increasingly being used. Currently, pure electric mining dump trucks are mainly used in open-pit mining operations. In underground mining, the ground is wet and the friction coefficient is low, especially when emergency braking and turning, the dump truck is prone to slipping and sliding sideways; the underground space is narrow, and pure electric mining dump trucks will have insufficient electric braking and emergency braking problems when passing a one-way long ramp with heavy load. Summary of the invention
[0003] The technical problem to be solved by the present invention is to provide a wire-controlled braking system and method for a pure electric mining dump truck, which solves the problems of slipping and collision when the pure electric mining dump truck is emergency braked and turned in a narrow underground space, insufficient electric braking when heavily loaded through a long slope, and emergency braking when meeting a one-way vehicle.
[0004] In order to solve the above technical problems, the technical solution of the present invention is: a wire-controlled brake system for a pure electric mining dump truck, comprising a sensor module, a control module and a brake module; The sensor module includes a brake pedal travel sensor, a wheel speed sensor, an acceleration sensor, a cargo box load sensor, a battery status sensor and a detection radar; the brake pedal travel sensor is used to accurately monitor the driver's braking intention; the wheel speed sensor monitors the wheel speed in real time; the acceleration sensor is used to sense the acceleration change of the vehicle; the cargo box load sensor accurately measures the vehicle load; the battery status sensor monitors information such as battery power and temperature; and the radar is used to detect obstacles within a certain range around the vehicle; The control module includes an electronic control unit ECU and a vehicle control unit VCU; the electronic control unit ECU receives the signal from the sensor module, analyzes and processes the sensor signal, and transmits the sensor module information and the processed information to the vehicle control unit VCU through the CAN bus. The vehicle control unit VCU can coordinate various systems according to the overall status information of the vehicle and allocate the braking mode more accurately; The braking module includes electric braking, eddy current braking and hydraulic braking; the electric braking includes a traction motor and an all-in-one controller. During the braking process, according to the instructions of the vehicle controller VCU, the traction motor is used as a generator to convert the vehicle's kinetic energy into electrical energy and store it in the battery; during eddy current braking, the stator winding in the eddy current retarder generates a magnetic field after direct current is passed through it. When the rotor rotates in the magnetic field, eddy currents are generated from the inside. The eddy currents interact with the magnetic field to generate a braking torque in the opposite direction of rotation, helping the vehicle to slow down; the addition of eddy current braking enables the dump truck to work in conjunction with the electric brake in non-emergency braking on a long downhill slope, and cooperate with the electric brake to recover energy; when the battery is fully charged, the braking force is shared in time, the working intensity of the hydraulic brake is reduced, and the maintenance of the braking system is extended cycle; hydraulic braking includes a hydraulic pump, a hydraulic oil tank, an accumulator, a brake line, a pressure relief valve, a proportional valve and a brake valve group. When the vehicle starts, the electronic control unit ECU controls the hydraulic motor to work. The hydraulic pump absorbs the hydraulic oil in the hydraulic oil tank under the action of the hydraulic motor. The pressurized oil is transported to the spring brake through the brake line. The brake is released and the vehicle can drive normally. When braking, the vehicle controller VCU determines that hydraulic braking is needed through vehicle status information and braking information. The electronic control unit ECU controls the pressure relief valve to open, and the hydraulic oil in the spring brake is depressurized to achieve timeliness and effectiveness of vehicle braking. At the same time, the electronic control unit ECU further adjusts the pressure in the braking system through the proportional valve. In the braking system, the accumulator plays a role in maintaining pressure stability.
[0005] Braking method of the present invention: (1) Service brake mode: When the driver steps on the brake pedal during normal vehicle driving, the brake pedal travel sensor and other sensors transmit signals to the electronic control unit ECU. The electronic control unit ECU determines the braking demand based on the signals from each sensor and transmits the signal to the vehicle controller VCU. The vehicle controller VCU determines the degree of participation of electric braking based on the braking demand, the real-time status of the vehicle and the battery power. Electric brake priority: At this time, the electric brake system takes priority, and the drive motor is used as a generator to convert the vehicle's kinetic energy into electrical energy and store it in the battery to achieve energy recovery. At the same time, it generates braking torque to slow down the vehicle. The electronic control unit ECU is responsible for controlling the energy recovery of the motor in the electric brake system. Eddy current brake assist: When the vehicle controller VCU determines that the braking torque generated by the electric brake is insufficient through the sensors and vehicle information status information transmitted by the electronic control unit ECU, the eddy current brake is controlled to intervene. After receiving the instruction from the vehicle controller VCU, the electronic control unit ECU controls the excitation current of the eddy current retarder, thereby adjusting the braking torque of the eddy current brake to provide additional braking force for the vehicle; Hydraulic brake supplement: When the braking torque generated by the combined action of electric brake and eddy current still cannot meet the braking needs of the vehicle, the vehicle controller VCU triggers the hydraulic brake system to start working, and the electronic control unit ECU adjusts the oil pressure entering the spring brake through the pressure relief valve and proportional valve to ensure the accurate execution of hydraulic braking and provide sufficient braking force to ensure safe braking of the vehicle; (2) Emergency braking mode: In emergency braking, the driver presses the brake pedal hard, and the electronic control unit ECU determines the degree of braking urgency through the brake pedal travel sensor and activates the hydraulic brake first; Hydraulic brake priority: At this time, the electronic control unit ECU controls the pressure relief valve to release the hydraulic oil in the spring brake to generate braking force, thereby slowing down the vehicle in the shortest time and ensuring driving safety; If during this process, the acceleration sensor detects that the vehicle is accelerating while the wheels are locked, that is, the vehicle is slipping or sliding, and the body radar detects obstacles around the vehicle, the electronic control unit ECU will transmit the signals detected by the sensor and radar to the vehicle controller VCU in a timely manner. The vehicle controller VCU will reallocate the braking method based on the vehicle status information, the degree of vehicle sliding, the size of the obstacle, and the distance between the dump truck and the obstacle; The vehicle controller VCU controls the electronic control unit ECU to adjust the excitation current of the proportional valve and eddy current retarder in the hydraulic brake system at the same time, appropriately reduce the hydraulic brake, and add eddy current brake to ensure that the dump truck has sufficient braking force and the wheels can rotate to adjust the vehicle to avoid collision with the lane and obstacles. During braking, the electronic control unit ECU monitors the vehicle status in real time through the sensor module, and the vehicle controller VCU analyzes and calculates based on the received information, and timely allocates the input ratio of hydraulic braking, eddy current braking and electric braking; (3) Electric brake failure mode: When the electric brake system fails, the vehicle's monitoring system immediately detects it and issues an alarm through the fault indicator light on the instrument panel, while the fault code is stored in the vehicle's diagnostic system; Braking system adjustment: At this time, the vehicle controller VCU recalculates the braking distribution plan and controls the electronic control unit ECU to intervene in the hydraulic braking system in advance to enhance the braking force. At the same time, it redistributes the power distribution plan and increases the eddy current braking torque. If the electric brake fails during normal driving, the braking force originally borne mainly by the electric brake is quickly transferred to the eddy current brake and hydraulic brake; if the electric brake fails during emergency braking, the hydraulic brake works at maximum capacity, and the eddy current brake also assists within its capacity to provide additional braking force.
[0006] Compared with the prior art, the present invention has the following beneficial effects: 1. Compared with the fuel dump trucks currently used in underground mines, pure electric mining dump trucks can effectively reduce pollutant emissions and noise pollution, and improve the underground working environment; 2. The electronic control method of the wire control brake system greatly improves the braking response speed. Whether it is normal braking or emergency braking, it can respond quickly to ensure vehicle safety; 3. Compared with the pure electric mining dump trucks used in open-pit mines, the redistribution of braking force when the vehicle slips or slides in the emergency braking mode of this design improves the flexibility of the vehicle's braking under complex underground working conditions and effectively ensures the braking performance and reliability of the vehicle in underground humid environments. BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Figure 1 This is the brake system block diagram.
[0008] Figure 2 The figure is a flow chart of the braking method. DETAILED DESCRIPTION
[0009] The present invention will be further described below in conjunction with the accompanying drawings.
[0010] like Figure 1 As shown, a wire-controlled braking system for a pure electric mining dump truck includes a sensor module, a control module and a braking module.
[0011] The sensor module includes a brake pedal travel sensor, a wheel speed sensor, an acceleration sensor, a cargo box load sensor, a battery status sensor and a detection radar; the brake pedal travel sensor is used to accurately monitor the driver's braking intention; the wheel speed sensor monitors the wheel speed in real time; the acceleration sensor is used to sense the acceleration changes of the vehicle; the cargo box load sensor accurately measures the vehicle load condition; the battery status sensor monitors information such as battery charge and temperature; and the radar is used to detect obstacles within a certain range around the vehicle.
[0012] The control module includes an electronic control unit ECU and a vehicle controller VCU; the electronic control unit ECU receives signals from the sensor module, analyzes and processes the sensor signals, and at the same time transmits the sensor module information and processed information to the vehicle controller VCU through the CAN bus. The vehicle controller VCU can coordinate various systems according to the overall status information of the vehicle and allocate braking methods more accurately.
[0013] The braking module includes electric braking, eddy current braking and hydraulic braking. The electric brake includes a traction motor and an all-in-one controller. During the braking process, according to the instructions of the vehicle controller VCU, the traction motor is used as a generator to convert the vehicle's kinetic energy into electrical energy and store it in the battery. During eddy current braking, the stator winding in the eddy current retarder generates a magnetic field after direct current is passed through it. When the rotor rotates in the magnetic field, eddy currents are generated from the inside. The interaction between the eddy current and the magnetic field generates a braking torque opposite to the direction of rotation, helping the vehicle to slow down; the addition of eddy current braking enables the dump truck to work in conjunction with the electric brake in non-emergency braking on a long downhill slope, and cooperate with the electric brake for energy recovery; when the battery is fully charged, the braking force is shared in time, the workload of the hydraulic brake is reduced, and the maintenance cycle of the braking system is extended. Hydraulic brakes include a hydraulic pump, a hydraulic oil tank, an accumulator, a brake line, a pressure relief valve, a proportional valve and a brake valve group. When the vehicle starts, the electronic control unit ECU controls the hydraulic motor to work. The hydraulic pump absorbs the hydraulic oil in the hydraulic oil tank under the action of the hydraulic motor. The pressurized oil is transported to the spring brake through the brake line. The brake is released and the vehicle can drive normally. When braking, the vehicle controller VCU determines that hydraulic braking is needed based on the vehicle status information and braking information. The electronic control unit ECU controls the pressure relief valve to open, and the hydraulic oil in the spring brake is depressurized to achieve timeliness and effectiveness of vehicle braking. At the same time, the electronic control unit ECU further adjusts the pressure in the braking system through the proportional valve. In the braking system, the accumulator plays a role in maintaining pressure stability.
[0014] like Figure 2 As shown, the braking method of the present invention: (1) Service brake mode: When the driver steps on the brake pedal during normal vehicle driving, the brake pedal travel sensor and other sensors transmit signals to the electronic control unit ECU. The electronic control unit ECU determines the braking demand based on the signals from each sensor and transmits the signal to the vehicle controller VCU. The vehicle controller VCU determines the degree of participation of electric braking based on the braking demand, the real-time status of the vehicle and the battery power. Electric brake priority: At this time, the electric brake system takes priority, and the drive motor is used as a generator to convert the vehicle's kinetic energy into electrical energy and store it in the battery to achieve energy recovery. At the same time, it generates braking torque to slow down the vehicle. The electronic control unit ECU is responsible for controlling the energy recovery of the motor in the electric brake system. Eddy current brake assist: When the vehicle controller VCU determines that the braking torque generated by the electric brake is insufficient through the sensors and vehicle information status information transmitted by the electronic control unit ECU, the eddy current brake is controlled to intervene. After receiving the instruction from the vehicle controller VCU, the electronic control unit ECU controls the excitation current of the eddy current retarder, thereby adjusting the braking torque of the eddy current brake to provide additional braking force for the vehicle; Hydraulic brake supplement: When the braking torque generated by the combined action of electric braking and eddy current still cannot meet the braking needs of the vehicle, the vehicle controller VCU triggers the hydraulic braking system to start working, and the electronic control unit ECU adjusts the oil pressure entering the spring brake through the pressure relief valve and proportional valve to ensure the accurate execution of hydraulic braking and provide sufficient braking force to ensure safe braking of the vehicle.
[0015] (2) Emergency braking mode: In emergency braking, the driver presses the brake pedal hard, and the electronic control unit ECU determines the degree of braking urgency through the brake pedal travel sensor and activates the hydraulic brake first; Hydraulic brake priority: At this time, the electronic control unit ECU controls the pressure relief valve to release the hydraulic oil in the spring brake to generate braking force, thereby slowing down the vehicle in the shortest time and ensuring driving safety; If during this process, the acceleration sensor detects that the vehicle is accelerating while the wheels are locked, that is, the vehicle is slipping or sliding, and the body radar detects obstacles around the vehicle, the electronic control unit ECU will transmit the signals detected by the sensor and radar to the vehicle controller VCU in a timely manner. The vehicle controller VCU will reallocate the braking method based on the vehicle status information, the degree of vehicle sliding, the size of the obstacle, and the distance between the dump truck and the obstacle; The vehicle controller VCU controls the electronic control unit ECU to adjust the excitation current of the proportional valve and eddy current retarder in the hydraulic brake system at the same time, appropriately reduce the hydraulic brake, and add eddy current brake to ensure that the dump truck has sufficient braking force and the wheels can rotate to adjust the vehicle to avoid collision with the lane and obstacles. During braking, the electronic control unit ECU monitors the vehicle status in real time through the sensor module. The vehicle controller VCU analyzes and calculates based on the received information and promptly allocates the input ratio of hydraulic braking, eddy current braking and electric braking.
[0016] (3) Electric brake failure mode: When the electric brake system fails, the vehicle's monitoring system immediately detects it and issues an alarm through the fault indicator light on the instrument panel, while the fault code is stored in the vehicle's diagnostic system; Braking system adjustment: At this time, the vehicle controller VCU recalculates the braking distribution plan and controls the electronic control unit ECU to intervene in the hydraulic braking system in advance to enhance the braking force. At the same time, it redistributes the power distribution plan and increases the eddy current braking torque. If the electric brake fails during normal driving, the braking force originally borne mainly by the electric brake is quickly transferred to the eddy current brake and hydraulic brake; if the electric brake fails during emergency braking, the hydraulic brake works at maximum capacity, and the eddy current brake also assists within its capacity to provide additional braking force.
Claims
1. A pure electric mining dump truck brake-by-wire system, characterized in that: Including sensor module, control module and brake module; The sensor module includes a brake pedal travel sensor, a wheel speed sensor, an acceleration sensor, a cargo box load sensor, a battery status sensor and a detection radar; the brake pedal travel sensor is used to accurately monitor the driver's braking intention; the wheel speed sensor monitors the wheel speed in real time; the acceleration sensor is used to sense the acceleration change of the vehicle; the cargo box load sensor accurately measures the vehicle load; the battery status sensor monitors information such as battery power and temperature; and the radar is used to detect obstacles within a certain range around the vehicle; The control module includes an electronic control unit ECU and a vehicle control unit VCU; the electronic control unit ECU receives the signal from the sensor module, analyzes and processes the sensor signal, and transmits the sensor module information and the processed information to the vehicle control unit VCU through the CAN bus. The vehicle control unit VCU can coordinate various systems according to the overall status information of the vehicle and allocate the braking mode more accurately; The braking module includes electric braking, eddy current braking and hydraulic braking; the electric braking includes a traction motor and an all-in-one controller. During the braking process, according to the instructions of the vehicle controller VCU, the traction motor is used as a generator to convert the vehicle's kinetic energy into electrical energy and store it in the battery; during eddy current braking, the stator winding in the eddy current retarder generates a magnetic field after direct current is passed through it. When the rotor rotates in the magnetic field, eddy currents are generated from the inside. The eddy currents interact with the magnetic field to generate a braking torque in the opposite direction of rotation, helping the vehicle to slow down; the addition of eddy current braking enables the dump truck to work in conjunction with the electric brake in non-emergency braking on a long downhill slope, and cooperate with the electric brake to recover energy; when the battery is fully charged, the braking force is shared in time, the working intensity of the hydraulic brake is reduced, and the maintenance of the braking system is extended cycle; hydraulic braking includes a hydraulic pump, a hydraulic oil tank, an accumulator, a brake line, a pressure relief valve, a proportional valve and a brake valve group. When the vehicle starts, the electronic control unit ECU controls the hydraulic motor to work. The hydraulic pump absorbs the hydraulic oil in the hydraulic oil tank under the action of the hydraulic motor. The pressurized oil is transported to the spring brake through the brake line. The brake is released and the vehicle can drive normally. When braking, the vehicle controller VCU determines that hydraulic braking is needed through vehicle status information and braking information. The electronic control unit ECU controls the pressure relief valve to open, and the hydraulic oil in the spring brake is depressurized to achieve timeliness and effectiveness of vehicle braking. At the same time, the electronic control unit ECU further adjusts the pressure in the braking system through the proportional valve. In the braking system, the accumulator plays a role in maintaining pressure stability.
2. A braking method for a brake-by-wire system of a pure electric mining dump truck as claimed in claim 1, characterized in that: include: (1) Service brake mode: When the driver steps on the brake pedal during normal vehicle driving, the brake pedal travel sensor and other sensors transmit signals to the electronic control unit ECU. The electronic control unit ECU determines the braking demand based on the signals from each sensor and transmits the signal to the vehicle controller VCU. The vehicle controller VCU determines the degree of participation of electric braking based on the braking demand, the real-time status of the vehicle and the battery power. Electric brake priority: At this time, the electric brake system takes priority, and the drive motor is used as a generator to convert the vehicle's kinetic energy into electrical energy and store it in the battery to achieve energy recovery. At the same time, it generates braking torque to slow down the vehicle. The electronic control unit ECU is responsible for controlling the energy recovery of the motor in the electric brake system. Eddy current brake assist: When the vehicle controller VCU determines that the braking torque generated by the electric brake is insufficient through the sensors and vehicle information status information transmitted by the electronic control unit ECU, the eddy current brake is controlled to intervene. After receiving the instruction from the vehicle controller VCU, the electronic control unit ECU controls the excitation current of the eddy current retarder, thereby adjusting the braking torque of the eddy current brake to provide additional braking force for the vehicle; Hydraulic brake supplement: When the braking torque generated by the combined action of electric brake and eddy current still cannot meet the braking needs of the vehicle, the vehicle controller VCU triggers the hydraulic brake system to start working, and the electronic control unit ECU adjusts the oil pressure entering the spring brake through the pressure relief valve and proportional valve to ensure the accurate execution of hydraulic braking and provide sufficient braking force to ensure safe braking of the vehicle; (2) Emergency braking mode: In emergency braking, the driver presses the brake pedal hard, and the electronic control unit ECU determines the degree of braking urgency through the brake pedal travel sensor and activates the hydraulic brake first; Hydraulic brake priority: At this time, the electronic control unit ECU controls the pressure relief valve to release the hydraulic oil in the spring brake to generate braking force, thereby slowing down the vehicle in the shortest time and ensuring driving safety; If during this process, the acceleration sensor detects that the vehicle is accelerating while the wheels are locked, that is, the vehicle is slipping or sliding, and the body radar detects obstacles around the vehicle, the electronic control unit ECU will transmit the signals detected by the sensor and radar to the vehicle controller VCU in a timely manner. The vehicle controller VCU will reallocate the braking method based on the vehicle status information, the degree of vehicle sliding, the size of the obstacle, and the distance between the dump truck and the obstacle; The vehicle controller VCU controls the electronic control unit ECU to adjust the excitation current of the proportional valve and eddy current retarder in the hydraulic brake system at the same time, appropriately reduce the hydraulic brake, and add eddy current brake to ensure that the dump truck has sufficient braking force and the wheels can rotate to adjust the vehicle to avoid collision with the lane and obstacles. During braking, the electronic control unit ECU monitors the vehicle status in real time through the sensor module, and the vehicle controller VCU analyzes and calculates based on the received information, and timely allocates the input ratio of hydraulic braking, eddy current braking and electric braking; (3) Electric brake failure mode: When the electric brake system fails, the vehicle's monitoring system immediately detects it and issues an alarm through the fault indicator light on the instrument panel, while the fault code is stored in the vehicle's diagnostic system; Braking system adjustment: At this time, the vehicle controller VCU recalculates the braking distribution plan and controls the electronic control unit ECU to intervene in the hydraulic braking system in advance to enhance the braking force. At the same time, it redistributes the power distribution plan and increases the eddy current braking torque. If the electric brake fails during normal driving, the braking force originally borne mainly by the electric brake is quickly transferred to the eddy current brake and hydraulic brake; if the electric brake fails during emergency braking, the hydraulic brake works at maximum capacity, and the eddy current brake also assists within its capacity to provide additional braking force.