Intelligent drive series motor

Abstract

The present application relates to a kind of wisdom drive series motor, wisdom drive series motor is arranged on mine truck, comprising: double series motor, drive unit, intelligent control unit and sensor unit;Sensor unit is used to monitor the motor parameter of double series motor, and the travel parameter of mine truck, and motor parameter and travel parameter are sent to intelligent control unit;Intelligent control unit judges whether double series motor appears fault according to the value of motor parameter;In the case where double series motor appears fault, travel state judging result is generated based on travel parameter and motor parameter, and then industrial control instruction is generated, wherein, travel state judging result includes: climbing state and downhill state;And, in the case where double series motor is in fault, generate fault protection control instruction;Drive unit responds to industrial control instruction or fault protection control instruction, and drives double series motor to work.The device can provide intelligent, high adaptive power solution for mine heavy load transport equipment.

Description

Technical Field

[0001] This invention belongs to the field of dual-motor hybrid vehicle control technology, specifically relating to an intelligent drive series motor. Background Technology

[0002] In mining transportation scenarios, mining trucks frequently undertake overloaded transport tasks, especially on long distances and steep slopes, where the conflict between vehicle power performance and energy consumption management becomes particularly prominent. Traditional single-motor drive systems, limited by the maximum torque output of a single power source, struggle to continuously meet the high power demands of heavy-load uphill climbing, easily leading to insufficient power and reduced efficiency. This not only affects transportation efficiency but also poses a risk of equipment damage due to motor overload. Furthermore, the complex mining environment with frequent changes in slope makes it difficult for a single motor to flexibly adjust power output according to real-time operating conditions, often resulting in constant high power consumption and significant energy waste, exacerbating the problem of insufficient range in mining trucks. Therefore, how to optimize energy consumption and improve range while ensuring power performance for heavy-load uphill climbing has become a pressing technical challenge in the mining equipment field. Summary of the Invention

[0003] To address the aforementioned problems in the existing technology, this invention provides an intelligent drive series motor. The technical problem to be solved by this invention is achieved through the following technical solution:

[0004] The present invention provides an intelligent drive series motor, which is installed on a mining truck, and the intelligent drive series motor includes: a dual series motor, a drive unit, an intelligent control unit and a sensor unit;

[0005] The intelligent control unit is electrically connected to the sensor unit and the drive unit respectively. The sensor unit is used to monitor the motor parameters of the dual-series motor and the driving parameters of the mining truck, and sends the motor parameters and the driving parameters to the intelligent control unit. The intelligent control unit is used to determine whether the dual-series motor has malfunctioned based on the value of the motor parameters. If the dual-series motor malfunctions, it generates a driving status judgment result based on the driving parameters and the motor parameters, and generates an industrial control command for controlling the working state of the dual-series motor based on the driving status judgment result, wherein the driving status judgment result includes: climbing state and downhill state; and generates a fault protection control command if the dual-series motor is malfunctioning. The drive unit is used to drive the dual-series motor to work in response to the industrial control command or the fault protection control command.

[0006] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0007] To address the problem of insufficient range in mining trucks due to the inability of existing electrodes to flexibly adjust power output according to real-time operating conditions, resulting in significant energy waste, this invention provides an intelligent series motor for mining trucks. This motor uses a dual-motor series architecture to superimpose torque, multiplying the driving force and effectively solving the power shortage problem of heavy-duty mining trucks in long, steep slope scenarios. Secondly, based on real-time sensor-collected motor parameters (such as temperature and speed) and vehicle driving parameters (slope and load), the intelligent control unit can dynamically identify the climbing / descending status and intelligently switch between single / dual motor modes based on the remaining battery power. This ensures full power output on steep slopes while optimizing energy consumption on gentler sections, achieving a highly efficient balance between power and range. Finally, the system incorporates a fault diagnosis and protection mechanism. By monitoring abnormal parameters, it promptly triggers protection strategies such as load reduction and switching to a backup motor, significantly reducing the risk of downtime caused by motor overheating or overload and enhancing system robustness. This design breaks through the technical bottleneck of traditional drive systems that struggle to balance energy efficiency and reliability, providing an intelligent and highly adaptable power solution for heavy-duty mining transportation equipment. Attached Figure Description

[0008] Figure 1 This is a structural block diagram of an intelligent drive series motor provided by the present invention;

[0009] Figure 2 This is a structural block diagram of the intelligent control unit provided by the present invention;

[0010] Figure 3 This is an overall structural diagram of the first motor provided by the present invention;

[0011] Figure 4 This is an overall structural diagram of the first motor provided by the present invention from another perspective;

[0012] Figure 5 This is a half-sectional view of the first motor provided by the present invention;

[0013] Figure 6 This is a half-sectional view of the first motor provided by the present invention from another perspective. Detailed Implementation

[0014] The present invention will be further described in detail below with reference to specific embodiments, but the implementation of the present invention is not limited thereto.

[0015] In the description of this invention, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0016] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0017] The present invention will now be described in detail with reference to the accompanying drawings.

[0018] Figure 1 This is a structural block diagram of an intelligent drive series motor provided by the present invention. Figure 1 As shown, an intelligent drive series motor is installed on the mining truck, and the intelligent drive series motor includes: a dual series motor, a drive unit, an intelligent control unit, and a sensor unit; the intelligent control unit is electrically connected to the sensor unit and the drive unit respectively; the sensor unit is used to monitor the motor parameters of the dual series motor and the driving parameters of the mining truck, and send the motor parameters and driving parameters to the intelligent control unit; the intelligent control unit is used to determine whether the dual series motor has malfunctioned based on the value of the motor parameters; in the case of a dual series motor malfunction, it generates a driving status judgment result based on the driving parameters and motor parameters, and generates an industrial control command for controlling the working state of the dual series motor based on the driving status judgment result, wherein the driving status judgment result includes: climbing state and downhill state; and, in the case of a dual series motor malfunction, it generates a fault protection control command; the drive unit is used to drive the dual series motor to work in response to the industrial control command or the fault protection control command.

[0019] After describing the structure of the dual-series motor, the sensor unit will now be described in detail. The sensor unit includes various types of sensors with different functions, which can closely monitor the motor's operating status and the vehicle's driving status. For example, a temperature sensor is used to monitor the motor temperature, a gradient sensor to monitor the driving gradient, and a current sensor to monitor the motor current, etc. Here, the motor parameters collected by the sensor unit include: motor speed, motor current, motor temperature, and motor output power, as well as driving parameters including: vehicle weight, cargo weight, driving speed, and driving gradient.

[0020] The specific composition of the intelligent control unit will now be described in detail.

[0021] Figure 2 This is a structural block diagram of the intelligent control unit provided by the present invention. Figure 2As shown, the intelligent control unit includes: an industrial control instruction generation subunit, a fault handling subunit, and a cooling subunit.

[0022] Specifically, the dual-series motor includes a first motor and a second motor connected in series. Both have identical structures and models. The industrial control instruction generation subunit generates a first industrial control instruction when the driving state is determined to be in an uphill state, to control the first and second motors to work synchronously; and generates a second industrial control instruction when the driving state is determined to be in a downhill state, to control the first motor and / or the second motor to work. When both the first and second motors are working, their corresponding output power is less than their maximum output power.

[0023] Here, the intelligent control unit acquires motor and driving parameters returned by the sensor unit in real time. First, it determines if a motor malfunction exists. If the motor is confirmed to be working normally, it determines the vehicle's current driving status by comparing the two parameters. For example, when the vehicle is traveling at a constant speed, considering different vehicle loads, the motor's output power corresponds to a range of vehicle speeds. When climbing a hill, the vehicle speed will be less than this range, and when descending a hill (without deceleration or braking), the vehicle speed will exceed this range.

[0024] Here, in response to the first industrial control command controlling the first and second motors to work synchronously, if the slope is not steep (e.g., between 20° and 60°), the two motors are adjusted to output lower power, which can maintain the vehicle's stable climbing while minimizing energy consumption. If the slope is steep (e.g., between 60° and 90°), it means that the vehicle needs greater driving force to overcome resistance such as gravity. Therefore, the two motors need to be controlled to work at maximum power to generate sufficient torque to drive the vehicle to overcome the huge resistance brought by the steep slope, ensuring that the vehicle can steadily climb the slope and successfully pass through the critical stage where the load is heaviest and the climbing difficulty is greatest.

[0025] Here, during the downhill process, because the mining truck itself is relatively large in mass and inertia, it is not necessary to drive the motor, or it can rely solely on a single motor with higher efficiency and relatively lower energy consumption. It should be noted that although the two motors are of the same type and structure, they may not be used for the same amount of time, thus there are differences in efficiency and energy consumption.

[0026] The fault handling subunit, when determining that the dual-series motors are faulty, determines whether both the first and second motors are faulty based on the motor parameters of the first and second motors; when either the first or second motor is faulty, it generates a power adjustment command to adjust the output power of either motor to ensure that the output power of either motor is within a preset power protection range; when both the first and second motors are faulty, it generates a stop-work command. Furthermore, the fault handling subunit is also used to generate fault indication information when it is determined that the first and / or second motors are faulty.

[0027] Here, because the mining truck is equipped with dual series motors, even if one motor fails, the other motor can still maintain a certain power output, allowing the truck to continue climbing or move to a safe area to await repairs. This greatly improves the reliability and fault tolerance of the entire drive system under heavy-load climbing scenarios. Specifically, after the fault handling subunit determines that a motor has failed, it first checks the number and location of the faulty motors to assess the severity and type of the fault. If the fault is minor, the fault handling subunit will attempt to adjust the motor's operating parameters to restore normal operation. If the fault is more serious, the fault handling subunit will readjust the power distribution based on the vehicle's actual needs and the motor's performance parameters to ensure that the working motor can provide sufficient power output. Here, when one motor fails, the vehicle's driving stability may be affected to some extent. The intelligent control unit will also adjust the vehicle's braking system, steering system, etc., to maintain the vehicle's driving stability as much as possible. Furthermore, the corresponding fault warning information is displayed on the vehicle's instrument panel to remind the driver to park the vehicle in a safe place as soon as possible and contact professional maintenance personnel for inspection.

[0028] Here, to ensure the safe operation of the motors that are functioning normally, the intelligent control unit is also equipped with various protection mechanisms. For example, when one motor fails, the fault handling subunit will limit the output power of another motor that is functioning normally to prevent motor overload.

[0029] The cooling subunit is used to cool the first motor and / or the second motor when a fault is determined. Cooling the motors via the cooling subunit prevents overheating and damage.

[0030] Please refer to this section. Figure 1The intelligent drive series motor also includes a kinetic energy recovery unit. This unit, electrically connected to the intelligent control unit, is used to convert the mechanical kinetic energy of the mining truck into electrical energy in response to a kinetic energy recovery activation command sent by the intelligent control unit when the driving status is determined to be downhill. The electrical energy is then stored in the battery pack installed on the mining truck. Furthermore, the kinetic energy recovery unit is also used to acquire the remaining battery charge and battery temperature, determining whether the remaining charge has reached its maximum value and whether the battery temperature is within a preset temperature range. If the remaining charge reaches its maximum value or the battery temperature exceeds the preset temperature range, kinetic energy recovery is stopped.

[0031] Specifically, when the mining truck descends a slope, the kinetic energy recovery unit controls the motor to switch from drive mode to generator mode. This utilizes the principle of electromagnetic induction to convert the truck's mechanical function into electrical energy, which is then transmitted to the battery pack via circuitry. It's important to note that the kinetic energy recovery unit controls the charging current and voltage based on the battery pack's current status, such as charge level and temperature, to achieve optimal charging performance. Simultaneously, the kinetic energy recovery unit monitors the charging process to prevent overcharging, overheating, and other issues.

[0032] Here, by utilizing two motors simultaneously for kinetic energy recovery, the kinetic energy recovered during downhill braking can be more comprehensively recovered compared to using a single motor. The two motors can share the energy recovery task, thereby converting the vehicle's kinetic energy into electrical energy in a shorter time and effectively improving the efficiency of energy recovery.

[0033] Here, the kinetic energy recovery unit is also used to power the dual series-connected motors using the electrical energy stored in the battery pack when the driving status is determined to be climbing. Specifically, when the vehicle accelerates, the electrical energy stored in the battery pack is released instantaneously to drive the dual series-connected motors, effectively increasing the driving range of the mining truck.

[0034] Here, the specific structures of the first motor and the second motor are described. Figure 3 This is an overall structural diagram of the first motor provided by the present invention. Figure 4 This is an overall structural diagram of the first motor provided by the present invention from another perspective. Figure 5 This is a half-sectional view of the first motor provided by the present invention. Figure 6 This is a half-sectional view from another perspective of the first motor provided by the present invention. For ease of explanation, [the following is a simplified description]. Figures 3 to 6 Some important components are numbered.

[0035] like Figure 3 As shown, numbers 001 and 002 are the U, V, and W three-phase cable ports of the first motor. Their function is to input high voltage. By swapping the connection order of any two phases of the U, V, and W three-phase lines, the phase sequence of the current in the stator winding can be changed, thereby changing the rotation direction of the rotating magnetic field.

[0036] Number 003 is a lifting ring, used for lifting and moving.

[0037] Number 004 is the connecting flange, which is used to connect the coupling. The rigid coupling directly connects the motor shaft and the gearbox shaft together through bolts, keys and other connecting parts to achieve rigid power transmission. This type of coupling has a simple structure and high transmission efficiency.

[0038] Number 005 is the output inner spline sleeve of the second motor, which is used to connect the outer spline shaft of the coupler.

[0039] Number 006 represents two sets of motor mounting holes on each side, which serve to support and fix the motors. After the mounting is installed, it connects to the car's chassis.

[0040] Number 007 refers to the motor housing. Its function is to utilize the lightweight cast aluminum housing, which has a high thermal conductivity and heat dissipation properties, allowing it to more effectively transfer the heat generated inside the motor to the outside. This effectively achieves the IP68 protection rating.

[0041] Number 008 is a cable fixing bracket, its function is to precisely position the cable in the required location. This prevents cables from becoming tangled or misaligned, ensuring a clear and orderly cable layout. Under external forces, such as wind, vibration, or collisions with other equipment, the cable may shift. The structure is easy to install, maintain, and repair.

[0042] Number 009 is a cable gland, whose function is to provide a reliable seal, preventing rainwater, dust, moisture, corrosive liquids (such as acids and alkalis in chemical plants), and various gases (such as flammable and explosive gases) from entering the equipment. The rigid structure of the gland buffers and disperses external pressure, friction, and tension. Reducing electromagnetic interference (EMI) and radio frequency interference (RFI), glands with electromagnetic shielding effectively reduce the impact of external electromagnetic interference on the cable's signal transmission, while also preventing electromagnetic radiation generated internally by the cable from leaking into the external environment.

[0043] like Figure 4 As shown, number 10 is the liquid flow balance sensor. Its function, in conjunction with the pressure balance sensor, is to control the flow rate of coolant entering the motor by adjusting the flow regulating valve at the inlet nozzle. Appropriate flow rate is crucial for the motor's cooling effect. For example, in the cooling of high-precision motors, excessive flow may lead to excessive internal pressure, damaging the motor's seals and structure; insufficient flow will fail to effectively remove the heat generated by the motor. By controlling the flow rate through the inlet nozzle, the cooling effect can be optimized according to the actual operating conditions of the motor (such as load size, ambient temperature, etc.).

[0044] Number 011 is the motor water outlet. Its function is to allow hot water to flow out of the motor through the outlet and then enter an external heat exchanger (such as a radiator) for cooling.

[0045] Number 012 is a pressure balance sensor. Its function is to address the issue of coolant volume changing with temperature during circulation within the motor. As the coolant temperature rises, its volume expands. The outlet provides a drainage channel for the coolant, thus balancing the pressure inside the motor caused by the change in liquid volume. This pressure balance helps maintain the normal operation of the motor cooling system, preventing problems such as cooling pipe rupture or damage to other sealing components due to excessive internal pressure.

[0046] Number 013 is the motor water inlet nozzle. Its function is to provide the starting point for a complex network of pipes, the "water supply system".

[0047] Number 014: Resolver communication port. Its function is to detect motor position and provide speed feedback, enabling vector control of the motor. The position information provided by the resolver allows the motor controller to accurately decompose the current, thereby achieving independent control of the motor's magnetic field and torque, optimizing motor operating performance, and precisely regulating the motor drive.

[0048] like Figure 5 As shown, number 015 is the coolant circulation channel. Its function is to address the issue that during motor operation, the current flowing through the windings generates Joule heat, and the motor core also generates iron loss heat due to changes in the magnetic field. This heat causes the motor temperature to rise. The coolant circulation channel delivers coolant to the heat-generating parts of the motor, such as the stator windings and around the core. After absorbing the heat, the coolant carries it away, effectively reducing the motor temperature. This extends the motor's lifespan and ensures safe and stable operation.

[0049] Numbers 016 and 017 are the stator windings of the motor. Their function is to generate a rotating magnetic field inside the motor when three-phase alternating current is applied to the stator windings. This rotating magnetic field cuts the rotor conductors, thereby inducing an electromotive force and an induced current in the rotor windings. According to the law of electromagnetic induction, the current-carrying conductors experience a force in the magnetic field, causing the rotor to rotate following the rotating magnetic field, thus realizing the electromechanical energy conversion of the motor.

[0050] like Figure 6 As shown, numbers 018 and 019 are motor shafts. Their function is to transmit the power generated by the motor rotor to external equipment, enabling the motor to operate normally. They also support the windings, ensuring their stable rotation within the motor. Because the rotor rotates at high speed during operation, without the stable support provided by the motor shafts, the rotor is prone to problems such as eccentricity and vibration, thus affecting the motor's performance and lifespan.

[0051] To address the problem that existing electrodes used in mining trucks cannot flexibly adjust power output according to real-time operating conditions, resulting in significant energy waste and exacerbating the insufficient range of mining trucks, this invention provides an intelligent drive series motor for mining trucks. This motor has the following technical advantages:

[0052] (1) Optimization of power performance and energy efficiency

[0053] The dual series motors, using the same model structure, provide multiplied driving force through torque superposition. Combined with the high-precision position detection and vector control of the resolver communication port, this ensures full-power output from both motors on steep slopes (60°–90°), effectively overcoming heavy load resistance. On gentle slopes (20°–60°) or flat roads, it intelligently switches between single / dual motor low-power modes to reduce energy consumption. The kinetic energy recovery unit converts mechanical energy into electrical energy for storage during downhill driving and dynamically adjusts the charging process based on battery status, improving range.

[0054] (2) Intelligent fault tolerance and system protection

[0055] The intelligent control unit diagnoses the status of the dual motors in real time based on data from multiple sensors such as temperature and current. When a single motor fails, the fault handling subunit automatically adjusts the power of the other motor to a safe range to maintain basic power output and links with the cooling subunit to start liquid cooling circulation (precisely controlling the flow and pressure of coolant through liquid flow balance sensors and pressure balance sensors) to prevent overheating damage. When both motors fail, the system is forced to stop and the braking system is triggered to stabilize the vehicle body, significantly improving the system's reliability and fault tolerance.

[0056] (3) Structural strengthening and thermal management optimization

[0057] The cast aluminum housing (IP68 protection) combined with the coolant circulation channel efficiently dissipates heat from the stator windings and core, extending motor life; the cable fixing bracket and shielded gland ensure interference resistance, dust and water resistance, adapting to harsh mining environments; the rigid coupling and suspension fixing hole design enhance power transmission stability.

[0058] (4) Adaptive control and dynamic response

[0059] The industrial control instruction generation subunit determines the climbing / descending status in real time based on parameters such as vehicle weight, gradient, and speed, and dynamically adjusts the dual-motor coordination strategy to achieve optimal matching between power output and energy consumption. This system overcomes the problems of insufficient power, short range, and high failure risk of traditional mining trucks, providing an intelligent and robust power solution for heavy-duty transportation in mines.

[0060] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the scope of protection of the present invention.

Claims

1. A smart drive series motor, characterized in that, The intelligent drive series motor is installed on the mining truck, and the intelligent drive series motor includes: a dual series motor, a drive unit, an intelligent control unit, and a sensor unit; the intelligent control unit is electrically connected to the sensor unit and the drive unit respectively; wherein, the dual series motor includes: a first motor and a second motor with the same structure connected in series; The sensor unit is used to monitor the motor parameters of the dual-series motors and the driving parameters of the mining truck, and to send the motor parameters and the driving parameters to the intelligent control unit; the motor parameters include: motor speed, motor current, motor temperature and motor output power; the driving parameters include: vehicle weight, cargo weight, driving speed and driving gradient; The intelligent control unit is used to determine whether the dual-series motor has malfunctioned based on the values ​​of the motor parameters; if the dual-series motor has malfunctioned, it generates a driving state judgment result based on the driving parameters and the motor parameters, and generates an industrial control command for controlling the working state of the dual-series motor based on the driving state judgment result, wherein the driving state judgment result includes: climbing state and downhill state; and, if the dual-series motor is malfunctioning, it generates a fault protection control command. The drive unit is used to drive the dual series motors to work in response to the industrial control command or the fault protection control command.

2. The intelligent drive series motor according to claim 1, characterized in that, The dual-series motor includes: a first motor and a second motor connected in series; the intelligent control unit includes: an industrial control command generation subunit; The industrial control instruction generation subunit is used to generate a first industrial control instruction when the driving state judgment result is the climbing state, so as to control the first motor and the second motor to work synchronously; and to generate a second industrial control instruction when the driving state judgment result is the descending state, so as to control the first motor and / or the second motor to work, wherein when both the first motor and the second motor are working, the corresponding output power is less than the maximum output power.

3. The intelligent drive series motor according to claim 1, characterized in that, The dual-series motor includes: a first motor and a second motor; the intelligent control unit also includes: a fault handling subunit; The fault handling subunit is used to determine whether both the first motor and the second motor are faulty when it is determined that the dual-series motor is faulty, based on the motor parameters of the first motor and the motor parameters of the second motor; when the first motor or the second motor is faulty, generate a power adjustment command to adjust the output power of the second motor or the first motor so that the output power of the second motor or the output power of the first motor is within a preset power protection range; when both the first motor and the second motor are faulty, generate a stop operation command.

4. The intelligent drive series motor according to claim 3, characterized in that, The fault handling subunit is also used to generate fault prompt information when it is determined that the first motor and / or the second motor is in a fault.

5. The intelligent drive series motor according to claim 3, characterized in that, The intelligent control unit also includes: a cooling subunit; The cooling subunit is used to cool down the first motor and the second motor when it is determined that the first motor and / or the second motor is in a fault.

6. The intelligent drive series motor according to claim 1, characterized in that, The intelligent drive series motor further includes: a kinetic energy recovery unit; the kinetic energy recovery unit is electrically connected to the intelligent control unit and is used to convert the mechanical kinetic energy of the mining truck into electrical energy in response to the start kinetic energy recovery command sent by the intelligent control unit when the driving state judgment result is a downhill state, and store the electrical energy in the battery pack installed on the mining truck.

7. The intelligent drive series motor according to claim 6, characterized in that, The kinetic energy recovery unit is also used to acquire the remaining power and battery temperature of the battery pack, determine whether the remaining power has reached its maximum value, and whether the battery temperature is within a preset temperature range; and stop kinetic energy recovery when the remaining power reaches the maximum value or the battery temperature exceeds the preset temperature range.

8. The intelligent drive series motor according to claim 6, characterized in that, The kinetic energy recovery unit is also used to supply power to the dual series motors using the electrical energy stored in the battery pack when the driving state determination result is the climbing state.

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