Dumper electric driving system and method and hinged dumper

Abstract

The invention discloses a dumper electric driving system and method and a hinged dumper, and the dumper electric driving system comprises a power battery system which is arranged behind a cab and comprises a heat management unit, a BDU assembly and a power battery which are integrated in the same box body; the power transmission device comprises a driving assembly, a transmission shaft and a transfer case, the driving assembly is integrated with a speed reducer in a mode that four motors are connected in parallel, and the driving assembly is connected with the transfer case through the transmission shaft; the electric control heat dissipation device is arranged on the front rack and comprises a heat dissipation device, an all-in-one controller and a motor controller, and the electric control heat dissipation device is used for controlling the driving assembly and the heat dissipation device and conducting heat dissipation on the all-in-one controller, the motor controller and the driving assembly. The electric driving efficiency is high, and daily maintenance is relatively simple. And meanwhile, the electric driving system has the advantages of no tail gas emission, low noise and environmental protection during operation, so that the electric driving system is more suitable for countries and regions with higher environmental requirements.

Description

Technical Field

[0001] The present invention relates to an electric drive system and method for a dump truck and an articulated dump truck, belonging to the field of electric drive dump trucks. Background Art

[0002] Articulated dump trucks, with their unique articulated steering structure and all-terrain adaptability, have become critical equipment in complex operating environments such as mining, tunnel construction, and mountain engineering. The power transmission system of existing articulated dump trucks is centered around a diesel engine, typically a turbocharged diesel engine with a rated power output. After coupling through a torque converter, power enters an automatic transmission for speed and torque conversion, and is then transmitted to the transfer case via a universal joint. The transfer case drives the front and rear axles according to the operating conditions, and cooperates with wheel-mounted reduction mechanisms to achieve power output.

[0003] Existing articulated dump trucks are fuel-driven, with low energy conversion efficiency, high maintenance and labor costs, and therefore poor economic efficiency. Fuel consumption emits harmful gases into the environment, and oil leakage from components during maintenance can pollute the soil. Therefore, diesel engine drive systems can have an adverse impact on the environment.

[0004] When articulated dump trucks transition to electrification, they face a series of severe technical challenges. In terms of spatial layout, articulated dump trucks are inherently compact. Using only the space occupied by the engine and gearbox in fuel-powered vehicles would make it difficult to simultaneously accommodate both a high-power motor and a large-capacity battery. If a small-capacity battery were used, the vehicle would require frequent charging during operation, seriously impacting efficiency. Regarding heat dissipation, when the drive motor, battery, and cooling system are all located within the cabin, the problem of space congestion becomes prominent, resulting in poor heat dissipation. Furthermore, mutual interference exists between the motor cooling system, the electronic control cooling system, and the battery cooling system, exacerbating the heat dissipation problem and posing a threat to the vehicle's stable operation. Summary of the Invention

[0005] In view of the problems existing in the above-mentioned prior art, the present invention provides an electric drive system and method for a dump truck and an articulated dump truck which are energy-saving, environmentally friendly, have good heat dissipation effects and are easy to maintain.

[0006] In order to achieve the above-mentioned object, the present invention adopts an electric drive system for a dump truck, comprising:

[0007] The power battery system is located behind the cab and above the front frame. It includes a thermal management unit, a BDU assembly, and a power battery integrated into the same box. The BDU assembly is connected to the power battery and thermal management unit, respectively, and is connected to the electronically controlled heat dissipation device via pipelines. The BDU assembly is used to protect the electric drive system, and the power battery system is used to provide power for the entire vehicle.

[0008] The power transmission device is arranged in the middle of the front frame and includes a drive assembly, a transmission shaft, and a transfer case. The drive assembly uses four motors in parallel and integrates a reducer. The drive assembly is connected to the transfer case via a transmission shaft. The power transmission device is used to distribute the power source through the transmission shaft and from the transfer case to the corresponding transmission components for operation;

[0009] An electrically controlled heat dissipation device is arranged in the middle position of the front rack and includes a radiator, an all-in-one controller and a motor controller. The radiator is arranged at the front of the front rack and forms a heat dissipation circuit with the all-in-one controller and the motor controller through a heat dissipation pipe. The all-in-one controller and the motor controller are arranged between the radiator and the drive assembly. The electrically controlled heat dissipation device is used to control the drive assembly and the radiator, and to dissipate heat for the all-in-one controller, the motor controller and the drive assembly.

[0010] As an improvement, there are three thermal management units, all arranged at the top, left or right side of the box.

[0011] As an improvement, multiple groups of power batteries are arranged at the lower part of the box, the BDU assembly is arranged directly above the power batteries in the box, and the thermal management unit is arranged near the power batteries.

[0012] As an improvement, the drive assembly is arranged in the middle position of the front frame in a manner of being supported on both left and right sides.

[0013] As an improvement, the rear power take-off port of the drive assembly is connected to one end of the transmission shaft by bolts, and the other end of the transmission shaft is connected to the upper port of the transfer case by bolts.

[0014] As an improvement, the all-in-one controller and the motor controller are arranged up and down, and are both located inside the front frame, below the cab, and between the drive assembly and the radiator.

[0015] A second aspect of the present invention further provides a method for controlling an electric drive system for a dump truck, using the electric drive system for a dump truck, comprising the following steps:

[0016] When the vehicle starts, the power battery begins supplying power, outputting DC power through the BDU assembly. The all-in-one controller converts the DC power into AC power with adjustable frequency and voltage, starting the drive assembly and cooling system. Once the drive assembly is powered, power is transmitted to the drive wheels via the drive shaft and transfer case, starting the vehicle. Simultaneously, the electronically controlled cooling device begins operating, monitoring the temperature and dissipating or cooling the heat accordingly.

[0017] During the operation of the vehicle, the battery management system adjusts the electrical energy output of the power battery according to demand. At the same time, the drive assembly and transfer case in the power transmission device automatically adjust the transmission ratio according to vehicle speed and road conditions to achieve power distribution and utilization; the electronically controlled cooling device continuously monitors temperature changes and adjusts the fan speed or coolant flow to maintain the optimal operating temperature.

[0018] According to a third aspect of the present invention, an articulated dump truck is provided, on which the electric drive system for the dump truck is installed.

[0019] As improvements, it also includes the front frame, articulated body, rear frame, transmission system, cargo box, hydraulic system, electrical system, cab and hood;

[0020] The front frame is connected to the rear frame through an articulated body to form a steerable double-frame structure. The front end of the front frame is integrated with a cab and a hood. The interior of the front frame is arranged with an electronically controlled heat dissipation device and a power transmission device of the electric drive system, and some actuators of the hydraulic system. The rear end of the rear frame is installed with a cargo box, and the middle part of the rear frame is integrated with a transmission system.

[0021] As an improvement, the cab has a side flipping function, the hood has an upward flipping function, and the bottom of the front frame is provided with a downward flipping bottom inspection door.

[0022] Compared to existing technologies, this invention applies the concept of replacing diesel engine drive with electric drive to the field of articulated dump trucks. Because the electric drive system's energy can be directly transferred to the actuator, it is more efficient than fuel systems, which suffer from heat loss during energy transfer. At the same time, daily maintenance of the electric drive system is relatively simple, eliminating the need for regular maintenance tasks such as blowing out the air filter, changing the engine oil and the "three filters," and repairing the clutch system. Furthermore, the electric drive system has the advantages of zero exhaust emissions, low noise, and environmental friendliness during operation, making it more suitable for countries and regions with high environmental requirements.

[0023] The power battery, thermal management unit and BDU assembly in the electric drive system of the present invention are integrated directly behind the cab, and the drive assembly and controller are integrated on the inside of the frame and located below the cab. The system has a high degree of integration and is conveniently located for repair and maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For those skilled in the art, other drawings can be obtained based on these drawings without paying any creative work.

[0025] Figure 1 It is a structural schematic diagram of the electric articulated dump truck of the present invention;

[0026] Figure 2 Schematic diagram of the internal structure of the power battery system of the present invention;

[0027] Figure 3 is an exploded view of the power transmission device of the present invention;

[0028] Figure 4 An exploded view of the power transmission device of an existing engine system;

[0029] Figure 5 It is a structural cross-sectional view of the electrically controlled heat dissipation device of the present invention;

[0030] Figure 6 This is a schematic diagram of the vehicle maintenance status of the present invention;

[0031] In the figure: 1. Cab, 2. Electrical system, 3. Electric drive system, 4. Hydraulic system, 5. Cargo box, 6. Transmission system, 7. Rear frame, 8. Articulated body, 9. Front frame, 10. Hood, 11. Thermal management unit, 12. BDU assembly, 13. Power battery, 14. Transfer case connecting bolts, 15. Drive connecting bolts, 16. Drive assembly, 17. Drive shaft, 18. Transfer case, 19. Gearbox connecting bolts, 20. Gearbox, 21. Diesel engine, 22. Radiator, 23. All-in-one controller, 24. Motor controller, 25. Bottom access door. DETAILED DESCRIPTION

[0032] In order to make the objectives, technical solutions and advantages of the present invention clearer, the technical solutions of the present application are described in detail below through specific embodiments. It should be understood that the embodiments of the present application and the specific features in the embodiments are detailed descriptions of the technical solutions of the present application, rather than limitations on the technical solutions of the present application. Unless there is a conflict, the embodiments of the present application and the technical features in the embodiments can be combined with each other.

[0033] Example 1

[0034] like Figures 1-6 As shown, a dump truck electric drive system includes a power battery system, a power transmission device and an electronically controlled heat dissipation device;

[0035] The power battery system is arranged behind the cab 1 and above the front frame 9. It is not affected by the loading and unloading of the cargo box 5 and is close to the electronically controlled heat dissipation device, which can shorten the layout distance of the line. The power battery system includes a thermal management unit 11, a BDU assembly 12 and a power battery 13 integrated in the same box. The BDU assembly 12 is connected to the power battery 13 and the thermal management unit 11 respectively, with a high degree of integration, which is convenient for wiring and maintenance management. In addition, the BDU assembly 12 is connected to the electronically controlled heat dissipation device through a pipeline, which can protect the entire electric drive system. The power battery system is used to provide a power source for the entire vehicle.

[0036] The power transmission device is arranged in the middle of the front frame 9 and includes a drive assembly 16, a transmission shaft 17, and a transfer case 18. The drive assembly 16 adopts a four-motor parallel connection method and integrates a reducer. The four-motor parallel connection method can effectively reduce the layout length of the transmission components inside the vehicle, saving layout space in the power transmission direction, thereby reducing the design length of the vehicle, which is beneficial for turning and transportation of the vehicle. The drive assembly 16 is connected to the transfer case 18 via the transmission shaft 17. The main function of the power transmission device is to distribute the power source from the transfer case 18 to the corresponding transmission components through the transmission shaft 17 to operate.

[0037] The electronically controlled heat dissipation device is arranged in the middle of the front frame 9, and includes a radiator 22, an all-in-one controller 23 and a motor controller 24. Usually, there is a signal line connecting the all-in-one controller 23 and the motor controller 24 with the vehicle's vehicle controller (VCU). The vehicle controller (VCU) sends control instructions to the all-in-one controller 23 and the motor controller 24 through the signal line according to the vehicle's operating status and feedback signals from various sensors, so as to realize the control of the vehicle's steering, braking, air-conditioning compressor and driving motor travel functions. At the same time, the all-in-one controller 23 and the motor controller 24 may also feedback their own working status information to the vehicle controller (VCU) through the signal line. The radiator 22 is arranged at the front end of the vehicle, and forms a heat dissipation circuit with the all-in-one controller 23 and the motor controller 24 through a heat dissipation pipeline. For example, a cooling water pipeline can be used to connect the radiator 22 with the heat dissipation channels of the all-in-one controller 23 and the motor controller 24. The cooling medium circulates in the pipeline, taking away the heat generated during operation, thereby ensuring operation within an appropriate temperature range; the all-in-one controller 23 and the motor controller 24 are arranged between the radiator 22 and the drive assembly 16, which is convenient for the connection of heat dissipation pipelines and cables; the electronically controlled heat dissipation device is used to control the drive assembly 16 and the radiator 22, and to dissipate heat from the all-in-one controller 23, the motor controller 24 and the drive assembly 16.

[0038] In some embodiments, as Figure 2As shown, multiple groups of power batteries 13 are arranged at the bottom of the box to ensure sufficient power for the entire vehicle. The BDU assembly 12 is arranged directly above the power batteries 13 in the box. As a disconnect unit for the power batteries 13, it can quickly disconnect the battery power supply when the power batteries 13 fail, ensuring the safety of the power batteries 13 and preventing casualties. The power batteries 13 generate heat during operation. At the same time, when the power batteries 13 are too cold in high-altitude areas, they need to be heated. The thermal management unit 11 is a device for managing the heat of the power batteries. It is easy to arrange it near the power batteries 13 to ensure that the power batteries 13 are always at a suitable temperature for operation. In the present invention, three thermal management units 11 (but not limited to three) can be used. They are all arranged at the top of the battery box, close to the power batteries 13, facilitating the layout of wiring and heat detection and management, while also reducing the lateral width of the box. The three thermal management units 11 can also be arranged on the left or right side of the box, without affecting wiring and heat dissipation, while reducing the height of the box. The thermal management unit 11 can be reasonably adjusted according to the layout requirements of the entire vehicle.

[0039] In some embodiments, as Figure 3 As shown, the drive assembly 16 (four motors in parallel + reducer) is connected to one end of the transmission shaft 17 via the drive connecting bolt 15, and the other end of the transmission shaft 17 is connected to the transfer case 18 via the transfer case connecting bolt 14. Figure 4 As shown, in the power transmission device of a conventional diesel engine drive system, the diesel engine 21 and the drive shaft 17 need to be converted through a separate gearbox 20, and the gearbox 20 is connected to the drive shaft 17 through a gearbox connecting bolt 19. In comparison, the electric drive solution of the present invention can achieve direct drive, reduce potential failure points, and improve the reliability of the entire machine.

[0040] In some embodiments, as Figure 5 As shown, the radiator 22 is located at the front end of the vehicle to dissipate heat for the entire control system (all-in-one controller 23, motor controller 24) and drive assembly. The all-in-one controller 23 and motor controller 24 are arranged vertically and are both located inside the front frame 9, below the cab 1, and between the drive assembly 16 and the radiator 22. The all-in-one controller 23 primarily controls the vehicle's steering, braking, and air conditioning compressor, while the motor controller 24 primarily controls the drive motor to achieve driving functions. Therefore, the components of the electronically controlled heat dissipation device are arranged close to the drive assembly 16, facilitating wiring and maintenance.

[0041] This invention separates the drive motor and power battery system. On the one hand, the drive motor and its cooling system are placed inside the cabin, providing ample space and sufficient heat dissipation distance. On the other hand, the power battery and its cooling system are independently located behind the cab and above the vehicle frame, which is more friendly to the cooling system. This also allows for the use of larger-capacity batteries, providing a longer driving range for the entire vehicle and significantly improving its overall efficiency.

[0042] The arrangement of the present invention facilitates the overall battery replacement solution for the power battery system and enables continuous operation of the vehicle.

[0043] Example 2

[0044] like Figures 1 to 6 As shown, an articulated dump truck is equipped with the above-mentioned electric drive system 3, and also includes a front frame 9, an articulated body 8, a rear frame 7, a transmission system 6, a cargo box 5, a hydraulic system 4, an electrical system 2, a cab 1 and a hood 10;

[0045] The front frame 9 has the cab 1 and hood 10 integrated at the front end. The front frame 9 is fixed to the front end of the hinged body 8 by bolts. The front frame 9 is internally arranged with the electronically controlled heat dissipation device (such as the radiator 22, the all-in-one controller 23, and the motor controller 24) and the power transmission device (the drive assembly 16 and the transmission shaft 17) of the electric drive system 3, as well as some actuators of the hydraulic system 4 (such as the steering cylinder);

[0046] The rear frame 7 has a cargo box 5 installed at the rear end, the rear frame 7 is connected to the rear end of the hinged body 8, and the middle part of the rear frame 7 is integrated with the transmission system 6;

[0047] The articulated body 8 may adopt a central pivot and a hydraulic steering cylinder structure to connect the front and rear frames and achieve ±45° steering. A steering hydraulic pipeline is arranged inside the articulated body 8 and communicated with the steering pump of the hydraulic system 4.

[0048] The cargo box 5 is hinged to the rear frame 7 at the bottom through a lifting hydraulic cylinder (a component of the hydraulic system 4), and the other end of the hydraulic cylinder is fixed to the hydraulic support of the rear frame 7; the lifting action is driven by the single vane pump of the hydraulic system 4 and controlled by the lifting switch of the electrical system 2.

[0049] Since all components of the electronically controlled heat dissipation device are located inside the vehicle, they are effectively protected during normal operation. In response to the maintenance needs of the electronically controlled heat dissipation device, multiple movable components are designed in the front vehicle part. The cab 1 is designed to flip sideways, such as by using a hydraulic flipping mechanism, which can increase the space above the front frame 9, making it easier for maintenance personnel to perform maintenance operations from above, especially for maintenance above the all-in-one controller 23 and the motor controller 24. The hood 10 is designed to have an upward flipping function, such as by using an electric hydraulic lifting system, which can facilitate maintenance personnel to perform maintenance operations from the side, especially for maintenance of the radiator 22. The bottom of the front frame 9 is provided with a bottom maintenance door 25 that can be flipped downward, which is convenient for maintenance personnel to perform maintenance operations from below, especially for maintenance below the all-in-one controller 23 and the motor controller 24.

[0050] During the process from vehicle startup to operation, the power battery system, power transmission device and electronically controlled cooling device work together to ensure efficient and safe operation of the vehicle.

[0051] When the vehicle starts, the power battery 13 begins supplying power, outputting direct current (DC) through the BDU assembly 12. The all-in-one controller 23 converts the DC power into alternating current (AC) with adjustable frequency and voltage, activating the drive assembly 16 and cooling system to ensure a smooth vehicle start. After receiving the electrical energy, the drive assembly 16 transmits power to the drive wheels via transmission components such as the drive shaft 17 and transfer case 18, allowing the vehicle to begin running. Simultaneously, the electronically controlled cooling device begins operating, monitoring the temperature and dissipating heat or cooling when necessary. As the vehicle accelerates, the power transmission device may require more power, which increases the battery's discharge and heat generation. At this point, the cooling system needs to enhance heat dissipation to prevent overheating and affect the normal operation of related components.

[0052] During vehicle operation, the battery management system adjusts the power output of the power battery 13 based on demand, for example, providing higher current when climbing a slope and recovering energy back into the battery when descending. During this process, the drive assembly 16 and transfer case 18 in the power transmission automatically adjust the transmission ratio based on factors such as vehicle speed and road conditions to ensure optimal power distribution and utilization. Simultaneously, the electronically controlled cooling system continuously monitors temperature changes and adjusts fan speed or coolant flow to maintain optimal operating temperature.

[0053] This invention applies the concept of replacing diesel engine drive with electric drive to the field of articulated dump trucks. Because the electric drive system's energy can be directly transferred to the actuator, it has higher efficiency than fuel systems, which suffer from heat loss during energy transfer. At the same time, the electric drive system is relatively simple to maintain daily, eliminating the need for regular maintenance tasks such as blowing out the air filter, changing the engine oil and the "three filters," and repairing the clutch system. Furthermore, the electric drive system has the advantages of zero exhaust emissions, low noise, and environmental friendliness during operation, making it more suitable for countries and regions with high environmental requirements.

[0054] Furthermore, those skilled in the art will appreciate that, although some embodiments described herein include certain features included in other embodiments but not other features, combinations of features from different embodiments are also intended to fall within the scope of protection of the present invention and form different embodiments. For example, in the above embodiments, those skilled in the art will be able to use them in combination based on the known technical solutions and the technical problems to be solved by this application.

Claims

1. A dump truck electric drive system, characterized in that: include: A power battery system is arranged behind the cab (1) and above the front frame (9), and includes a thermal management unit (11), a BDU assembly (12), and a power battery (13) integrated in the same box. The BDU assembly (12) is connected to the power battery (13) and the thermal management unit (11) respectively, and is connected to the electronically controlled heat dissipation device through a pipeline. The BDU assembly (12) is used to protect the electric drive system, and the power battery system is used to provide a power source for the operation of the entire vehicle. A power transmission device is arranged in the middle of the front frame (9), and includes a drive assembly (16), a transmission shaft (17), and a transfer case (18). The drive assembly (16) adopts a four-motor parallel connection mode and integrates a reducer. The drive assembly (16) is connected to the transfer case (18) through the transmission shaft (17). The power transmission device is used to distribute the power source through the transmission shaft (17) and the transfer case (18) to the corresponding transmission components for operation; An electrically controlled heat dissipation device is arranged in the middle of the front frame (9), and comprises a radiator (22), an all-in-one controller (23) and a motor controller (24). The radiator (22) is arranged at the front of the front frame (9). The radiator (22) forms a heat dissipation loop with the all-in-one controller (23) and the motor controller (24) through a heat dissipation pipeline. The all-in-one controller (23) and the motor controller (24) are arranged between the radiator (22) and the drive assembly (16). The electrically controlled heat dissipation device is used to control the drive assembly (16) and the radiator (22), and to dissipate heat for the all-in-one controller (23), the motor controller (24) and the drive assembly (16).

2. The electric drive system for a dump truck according to claim 1, characterized in that: The thermal management units (11) are provided with three, and are all arranged at the top, left or right side inside the box.

3. The electric drive system for a dump truck according to claim 1, characterized in that: Multiple groups of power batteries (13) are arranged at the bottom of the box body, the BDU assembly (12) is arranged directly above the power batteries (13) in the box body, and the thermal management unit (11) is arranged at a position close to the power batteries (13).

4. The electric drive system for a dump truck according to claim 1, characterized in that: The drive assembly (16) is arranged in the middle position of the front frame (9) in a manner of being supported on both left and right sides.

5. The electric drive system for a dump truck according to claim 1, characterized in that: The rear power take-off port of the drive assembly (16) is connected to one end of a transmission shaft (17) via a bolt, and the other end of the transmission shaft (17) is connected to an upper port of a transfer case (18) via a bolt.

6. The electric drive system for a dump truck according to claim 1, characterized in that: The all-in-one controller (23) and the motor controller (24) are arranged up and down, and are both located inside the front frame (9), below the cab (1), and between the drive assembly (16) and the radiator (22).

7. A method for controlling an electric drive system of a dump truck, characterized in that: The electric drive system for a dump truck according to any one of claims 1 to 6 comprises the following steps: When the vehicle is started, the power battery (13) starts to supply power and outputs direct current through the BDU assembly (12). The all-in-one controller (23) converts the direct current into alternating current with adjustable frequency and voltage, and starts the drive assembly (16) and the cooling system. After the drive assembly (16) is powered, the power is transmitted to the drive wheels through the transmission shaft (17) and the transfer case (18), so that the vehicle starts to run. At the same time, the electronically controlled cooling device starts to work, monitors the temperature and dissipates heat or cools the vehicle accordingly. During the operation of the vehicle, the battery management system adjusts the electric energy output by the power battery according to demand. At the same time, the drive assembly (16) and the transfer case (18) in the power transmission device automatically adjust the transmission ratio according to the vehicle speed and road condition information to achieve power distribution and utilization; the electronically controlled cooling device continuously monitors temperature changes and adjusts the fan speed or coolant flow to maintain the optimal operating temperature.

8. An articulated dump truck, characterized in that: The articulated dump truck is equipped with the dump truck electric drive system according to any one of claims 1 to 6.

9. The articulated dump truck according to claim 8, characterized in that: It also includes a front frame (9), an articulated body (8), a rear frame (7), a transmission system (6), a cargo box (5), a hydraulic system (4), an electrical system (2), a cab (1) and a hood (10); The front frame (9) is connected to the rear frame (7) through a hinged body (8) to form a steerable double-frame structure. The front end of the front frame (9) is integrated with a cab (1) and a hood (10). The interior of the front frame (9) is arranged with an electric control heat dissipation device and a power transmission device of an electric drive system (3), and some actuators of a hydraulic system (4). The rear end of the rear frame (7) is installed with a cargo box (5), and the middle part of the rear frame (7) is integrated with a transmission system (6).

10. An articulated dump truck according to claim 8 or 9, characterized in that: The cab (1) has a side-turning function, the hood (10) has an upward-turning function, and a bottom inspection door (25) that turns downward is provided at the bottom of the front frame (9).

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