Energy recovery system of underground mining battery carry-scraper

Abstract

The invention relates to the technical field of mining machinery, and discloses an underground mining battery carry-scraper energy recovery system which comprises an energy recovery module, an energy storage module, a sensor module, an energy management module and a communication module. The energy management module judges whether a vehicle enters a working condition where energy can be recycled or not according to operation state parameters, collected by the sensor module, of the carry-scraper, controls a motor and generator integrated unit in the energy recycling module to work in a generator mode, converts mechanical energy in the braking or downhill process into electric energy and controls the electric energy to be recycled. And meanwhile, the charging process of the energy storage module is precisely managed. According to the invention, the energy efficiency is obviously improved through internal cyclic utilization of energy; abrasion of mechanical parts is greatly reduced through the regenerative braking function; and through firm system design and intelligent real-time monitoring, the long-term operation reliability of the system under severe working conditions is ensured.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of mining machinery, in particular to an energy recovery system of a battery LHD for underground mine. BACKGROUND

[0002] When the LHD for underground mine is performing the transportation task, its working mode involves frequent reciprocating operation under heavy load and empty load. In this process, especially when downhill or braking deceleration, the vehicle will generate a large amount of inertial energy and gravity potential energy. In the existing technical solution, this part of energy is mainly converted into heat energy by mechanical friction braking system and dissipated, which cannot be effectively utilized, resulting in direct loss of energy and affecting the comprehensive energy use efficiency of the equipment.

[0003] At the same time, the high dependence on mechanical transmission system causes the related components to bear continuous physical wear and tear. The working environment of underground mine usually requires the LHD to perform frequent and high-intensity braking operation to ensure safety, which will accelerate the wear and tear of friction components such as brake disc and brake pad. As a result, the maintenance requirements and downtime of the equipment are increased, which has a negative impact on continuous production operation.

[0004] Although energy recovery technology, especially regenerative braking, has been applied in other technical fields such as highway electric vehicles, its direct application in LHD for underground mine faces specific environmental challenges. High concentration of dust, moisture and mechanical vibration generated by equipment operation exist in the mine, which puts higher requirements on the long-term working reliability and environmental tolerance of electronic controllers, sensors and electrical connectors. Therefore, the energy recovery system designed for conventional working conditions is usually difficult to meet the operation requirements of mine heavy equipment in terms of protection performance and vibration resistance, which also limits the application and development of this technology in this field. SUMMARY

[0005] In view of the shortcomings of the prior art, the present application provides an energy recovery system of a battery LHD for underground mine, which solves the problem of how to efficiently recover the braking and downhill energy of the battery LHD for underground mine under harsh underground mine working conditions, while reducing the wear and tear of the mechanical transmission system and ensuring the long-term stable operation of the energy recovery system itself.

[0006] To achieve the above purpose, the present application realizes the following technical scheme: an energy recovery system of a battery LHD for underground mine, comprising:

[0007] An energy recovery module for converting mechanical energy into electrical energy when the LHD brakes or goes downhill;

[0008] An energy storage module electrically connected to the energy recovery module for storing the electrical energy;

[0009] a sensor module for monitoring real-time operating state parameters of the shovel;

[0010] an energy management module connected to the energy recovery module, the energy storage module and the sensor module, for controlling energy flow from the energy recovery module to the energy storage module according to the operating state parameters;

[0011] a communication module connected to the energy management module, for data transmission.

[0012] Preferably, the energy recovery module comprises a motor-generator integrated unit, which functions as:

[0013] when working as a motor, for converting electrical energy from the energy storage module into mechanical energy to drive the shovel;

[0014] when working as a generator, for converting mechanical energy from the wheels during braking or downhill into electrical energy for energy recovery.

[0015] Preferably, the energy storage module comprises an energy storage device, for receiving and storing electrical energy converted by the energy recovery module, and releasing electrical energy when the shovel needs power.

[0016] Preferably, the energy storage device is a lithium-ion battery pack or a supercapacitor.

[0017] Preferably, the sensor module comprises:

[0018] a speed sensor for obtaining real-time driving speed of the shovel;

[0019] an acceleration sensor for obtaining real-time acceleration of the shovel to assist in determining braking conditions;

[0020] a current sensor for monitoring current size and direction of energy flow between the energy recovery module and the energy storage module.

[0021] Preferably, the energy management module comprises:

[0022] a controller as a physical hardware unit for performing calculations and issuing control instructions;

[0023] an energy management algorithm configured in the controller for making decisions according to the received operating state parameters to generate control instructions.

[0024] Preferably, the energy management algorithm is a fuzzy control-based algorithm or a neural network-based algorithm.

[0025] Preferably, the communication module uses CAN bus technology to connect with the central control system of the loader to achieve integrated vehicle control, or uses wireless communication technology to connect with a remote monitoring platform to achieve remote data monitoring and fault diagnosis.

[0026] Preferably, the energy management module controls the magnitude of the regenerative braking force applied to the wheels via the transmission system by adjusting the electromagnetic torque generated by the integrated motor and generator unit.

[0027] This invention provides an energy recovery system for underground mining battery-powered loader. It has the following beneficial effects:

[0028] 1. This invention incorporates an energy recovery module, enabling the integrated motor and generator unit to operate in generator mode during shovel loader braking or downhill, converting the mechanical energy generated during the process into electrical energy. This recovered electrical energy is stored in an energy storage module for subsequent driving, establishing an internal energy circulation path, reducing heat dissipation caused by braking, and thus improving the overall energy efficiency of the vehicle.

[0029] 2. This invention achieves regenerative braking by controlling electromagnetic torque through an energy management module. This function offloads most of the braking task, directly reducing the frequency of use and wear of traditional mechanical braking systems. At the same time, the recovered electrical energy replenishes the energy storage module, which can slow down the depth of discharge of the energy storage unit. This operating mode helps maintain the health of the energy storage unit and may extend its service life.

[0030] 3. The system architecture of this invention allows the use of a robust and durable integrated motor and generator unit to cope with vibration and dust conditions in underground mines. At the same time, the sensor module continuously monitors the system's operating parameters, enabling the energy management module to grasp the system status in real time. This data-based monitoring mechanism helps to identify potential anomalies in advance, thereby improving the overall system's operational stability in complex environments.

[0031] 4. The energy management module in the system of this invention is based on a preset control algorithm and can process real-time data such as speed and acceleration obtained from the sensor module. Based on this data, the energy management module dynamically adjusts the intensity and process of energy recovery to optimize the efficiency of energy recovery while meeting braking requirements and ensuring smooth operation. Through the communication module, relevant operating data can also be transmitted to provide data reference for the energy distribution and operation planning of the whole vehicle. Attached Figure Description

[0032] Figure 1 This is a flowchart of the system of the present invention;

[0033] Figure 2 This is a flowchart of the energy recovery module of the present invention;

[0034] Figure 3 This is a flowchart of the energy management module and energy storage module of the present invention;

[0035] Figure 4 This is a flowchart of the sensor module of the present invention. Detailed Implementation

[0036] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] Please refer to the appendix. Figure 1 An energy recovery system for an underground mining battery-powered loader includes the following modules:

[0038] The energy recovery module is responsible for converting part of the vehicle's kinetic or potential energy into electrical energy when the loader is braking or going downhill.

[0039] An energy storage module, which is connected to the energy recovery module in a circuit, is used to receive and store electrical energy converted by the energy recovery module;

[0040] The sensor module is placed in an appropriate position on the loader to continuously monitor and acquire key status parameters during the operation of the loader;

[0041] The energy management module, as the control center of the system, establishes signal connections with the energy recovery module, energy storage module and sensor module respectively, and makes decisions and controls the energy recovery process based on the received operating status parameters.

[0042] The communication module, which connects to the energy management module, provides an interface for the system to exchange data with external devices.

[0043] During system operation, these modules work together to form a closed-loop energy and information flow path. The energy management module is the core of the entire system, continuously receiving and processing real-time data streams from the sensor modules. When it is determined that the loader has entered a condition where energy recovery is possible, the energy management module issues a command to the energy recovery module, switching it from drive mode to power generation mode.

[0044] In this power generation mode, the electrical energy generated by the energy recovery module flows to the energy storage module for storage under the control of the energy management module. The energy management module also monitors the status of the energy storage module to ensure a safe and efficient charging process. The communication module is responsible for sending the system status, fault information, or energy recovery data processed by the energy management module to the loader's central control system or a remote monitoring platform.

[0045] Please refer to the appendix. Figure 2 and attached Figure 3 Specifically, the energy management module precisely regulates the energy recovery process by controlling the regenerative braking force applied to the wheels. The magnitude of this regenerative braking force depends on the electromagnetic torque generated by the energy recovery module. This control process can be described by the following relationship:

[0046]

[0047] In the formula, F regen Represents the regenerative braking force applied to the wheels; T em This represents the electromagnetic torque generated by the integrated motor and generator unit, a variable directly controlled by the energy management module; gg is the overall reduction ratio of the transmission system from the motor to the wheels; η t The value represents the mechanical efficiency of the transmission system; r is the rolling radius of the wheel.

[0048] Simultaneously, the energy management module also manages the charging power input to the energy storage module to ensure the stability of energy recovery and the safety of the energy storage device. The charging power and the regenerative braking power generated by the energy recovery module are related as follows:

[0049] P charge =P regen ·η charge ;

[0050] In the formula, P charge P represents the actual charging power input to the energy storage module. regen η is the total power generated by the energy recovery module during regenerative braking; charge The overall system charging efficiency, from the energy recovery module to the energy storage module, includes energy conversion losses in the inverter, lines, and energy storage devices themselves. The energy management module optimizes energy recovery efficiency by controlling this process.

[0051] Please refer to the appendix. Figure 2In one embodiment of the present invention, the energy recovery module includes an integrated unit of an electric motor and a generator. This unit is the physical carrier that realizes both driving and energy recovery functions. When the loader needs power output, it operates as an electric motor, consuming electrical energy from the energy storage module; when the loader brakes or goes downhill, it is driven in the opposite direction by the wheels, operating as a generator to produce electrical energy. This integrated unit can be a permanent magnet synchronous motor, which has the advantages of high efficiency, high power density, and stable torque; or a switched reluctance motor, which has a robust structure, no permanent magnets, and high reliability, and is especially suitable for long-term operation in harsh underground mine environments.

[0052] The core of the energy storage module is an energy storage device whose function is to receive and store recovered electrical energy and supply power to the motor when needed. In this invention, the energy storage device can be a lithium-ion battery pack, which has high energy density and can store a large amount of electrical energy, making it suitable for long-term energy dispatch. Alternatively, the energy storage device can be a supercapacitor, which has extremely high power density and rapid charging and discharging capabilities, making it particularly suitable for the rapid recovery and release of high-power energy under frequent, short-duration braking conditions.

[0053] In a preferred embodiment, lithium-ion battery packs can also be combined with supercapacitors to form a hybrid energy storage system.

[0054] Please refer to the appendix. Figure 4 In order to achieve precise control of the energy recovery process, the sensor module is used to acquire key state parameters of the system operation.

[0055] This module specifically includes:

[0056] Speed ​​sensors are typically installed at the wheel or transmission system output to provide real-time vehicle speed information, which is a fundamental parameter for determining the vehicle's operating status and calculating kinetic energy.

[0057] An acceleration sensor is used to measure the longitudinal acceleration of a vehicle, and its data can accurately reflect braking intention and braking intensity.

[0058] A current sensor is installed in the circuit between the energy recovery module and the energy storage module to monitor the magnitude and direction of the charging and discharging current, thereby achieving closed-loop control of the energy flow.

[0059] Furthermore, to further enhance the system's reliability under harsh operating conditions, the sensor module may also include temperature and vibration sensors. Temperature sensors monitor the temperature of the integrated motor and generator unit and the energy storage module, preventing damage or performance degradation of critical components due to overheating. Vibration sensors monitor the system's mechanical vibration status, providing a basis for early fault diagnosis.

[0060] The energy management module is the control core of the system, physically consisting of a controller, such as a microcontroller (MCU) or a digital signal processor (DSP). This controller internally runs an energy management algorithm. The algorithm's function is to receive and analyze all data from the sensor modules, determine the current operating condition based on a preset control strategy, and generate control commands. These commands, such as pulse width modulation (PWM) signals, are sent to the power electronic converter of the energy recovery module, thereby precisely controlling the magnitude of the electromagnetic torque and the direction of energy flow.

[0061] In a specific implementation of this invention, the energy management algorithm can be based on fuzzy control, which can effectively handle nonlinear systems and fuzzy inputs, simulating empirical decision-making processes. Alternatively, the algorithm can be based on neural networks, which, through learning and training, achieves adaptive optimization of energy recovery strategies under complex operating conditions to achieve higher overall efficiency.

[0062] The energy recovery process of this invention is a dynamic closed-loop control process. The process begins with the energy management module accurately identifying the current operating condition of the loader. During system operation, the energy management module continuously receives and processes data streams from sensor modules, including but not limited to real-time vehicle speed, longitudinal acceleration, and current direction.

[0063] When the driver applies the brakes or the vehicle enters a downhill section under heavy load, the sensor module will capture the corresponding changes in physical quantities. For example, the acceleration sensor will detect that the vehicle's longitudinal acceleration is negative and its absolute value exceeds a preset braking recognition threshold; or, when the vehicle is maintaining a certain speed downhill, the energy management module combines speed and gradient information (gradient information can be provided by GPS, inertial navigation unit or preset mining area map) to determine that the vehicle's potential energy is being converted into kinetic energy.

[0064] Once the energy management module determines, based on its algorithm, that the vehicle has entered a condition suitable for energy recovery, its internal energy management algorithm immediately begins calculations. The algorithm calculates a target electromagnetic torque value based on the current vehicle speed, acceleration (reflecting braking intensity), and the receiving capacity of the energy storage module. Subsequently, the energy management module sends precise control commands, such as pulse width modulation (PWM) signals with a specific duty cycle, to the power electronic converter (e.g., the inverter) within the energy recovery module.

[0065] Upon receiving the command, the integrated motor and generator unit immediately switches its operating mode from electric motor mode (consuming electrical energy) to generator mode (generating electrical energy). At this time, the vehicle's inertial kinetic energy or gravitational potential energy drives the unit's rotor to rotate in the reverse direction through the wheels and transmission system. Based on the principle of electromagnetic induction, the rotor's rotation cuts through the magnetic field, thereby inducing alternating current in the unit's stator windings.

[0066] The generated AC power is then rectified by a power electronic converter and converted into DC power. During this process, the energy management module does not cease its control function but enters a phase of refined management of the charging process. It continuously communicates with the energy storage module (e.g., reading data from the battery management system, BMS) to obtain key state parameters of the energy storage device in real time, particularly the state of charge (SOC), terminal voltage, and internal temperature.

[0067] The energy management module uses these state parameters as feedback signals to perform closed-loop control of the charging process. If the state of charge (SOC) of the energy storage module approaches its safe upper limit, the energy management module will actively reduce the target electromagnetic torque, thereby reducing the regenerative braking force and charging power to prevent damage to the energy storage device due to overcharging. Similarly, if the temperature sensor detects that the temperature of the energy storage device or motor exceeds the preset safe operating range, the energy management module will also limit the charging current accordingly to ensure the thermal management safety of the entire system. This series of actions ensures that energy recovery is not only efficient but also always occurs within the safe operating range of each component.

[0068] The communication module provides the system with the ability to exchange data with external devices.

[0069] In one implementation, the communication module uses CAN bus technology to connect with the loader's own vehicle controller via the CAN bus. This approach enables a high degree of integration and coordinated control between the energy recovery system and other vehicle systems (such as the braking system and display system).

[0070] In another implementation, the communication module uses wireless communication technology, such as Wi-Fi or cellular networks, to transmit the system's operating data, status information, and fault diagnosis results to a remote monitoring platform in real time, thereby enabling remote management and preventive maintenance of the loader.

[0071] Working principle: During the normal operation of the loader, the system's sensor module continuously monitors and acquires key operating parameters in real time, including vehicle speed, acceleration, and current direction, and continuously sends these data streams to the energy management module.

[0072] When the loader begins to brake or enters a downhill section under gravity, its operating state changes significantly. Accumulated inertial energy or gravitational potential energy is transferred through the transmission system to the integrated motor and generator unit in the energy recovery module, applying a reverse driving force. Simultaneously, the sensor module accurately detects this change, for example, detecting negative longitudinal acceleration. After receiving and analyzing this data, the control algorithm within the energy management module immediately responds once it determines that the current operating condition meets the preset energy recovery trigger conditions.

[0073] The core action of the response is that the energy management module sends a control command to the power electronic converter within the energy recovery module, causing its internal integrated motor and generator unit to instantly switch to generator operating mode. In this mode, the rotor, driven in the opposite direction by the wheels, rotates and cuts the magnetic field, converting the input mechanical energy into alternating current based on the principle of electromagnetic induction.

[0074] This conversion process is accompanied by a crucial physical effect: the electromagnetic torque generated during power generation applies a braking torque to the wheels in the opposite direction of travel through the transmission system, namely regenerative braking force, thereby assisting the vehicle in slowing down smoothly.

[0075] The generated alternating current is then rectified by a power electronic converter into direct current suitable for charging the energy storage module. This is not a simple energy injection process, but a closely monitored and regulated one. The energy management module acquires real-time feedback data on the energy storage module's state of charge, voltage, and temperature, and dynamically adjusts its control commands based on this data.

[0076] By continuously adjusting commands, the energy management module can precisely control the magnitude of the electromagnetic torque, thereby regulating the amount of regenerative braking force to adapt to different braking demands and ensure smooth driving. Simultaneously, it also finely manages the charging current or power supplied to the energy storage module to prevent overcharging and overheating, ensuring the safety and efficiency of the charging process and maximizing the lifespan of the energy storage device.

[0077] Finally, through the communication module, the status data of the entire energy recovery process can also be exchanged with the central control system or remote monitoring platform of the loader.

[0078] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An energy recovery system for an underground mining battery-powered loader, characterized in that, include: The energy recovery module is used to convert mechanical energy into electrical energy when the loader is braking or going downhill; An energy storage module, electrically connected to the energy recovery module, is used to store the electrical energy; Sensor modules are used to monitor the operating status parameters of the loader in real time; An energy management module is connected to the energy recovery module, the energy storage module, and the sensor module, respectively, and is used to control the energy flow from the energy recovery module to the energy storage module according to the operating status parameters; A communication module, connected to the energy management module, is used for data transmission.

2. The energy recovery system for an underground mining battery-powered loader according to claim 1, characterized in that, The energy recovery module includes an integrated motor and generator unit, and the function of the integrated motor and generator unit in the system is as follows: When operating as an electric motor, it is used to convert electrical energy from the energy storage module into mechanical energy to drive the shovel loader; When operating as a generator, it converts the mechanical energy transmitted from the wheels during braking or downhill driving into electrical energy for energy recovery.

3. The energy recovery system for an underground mining battery-powered loader according to claim 1, characterized in that, The energy storage module includes an energy storage device for receiving and storing electrical energy converted from the energy recovery module, and releasing the electrical energy when the loader needs power.

4. The energy recovery system for an underground mining battery-powered loader according to claim 3, characterized in that, The energy storage device is a lithium-ion battery pack or a supercapacitor.

5. The energy recovery system for an underground mining battery-powered loader according to claim 1, characterized in that, The sensor module includes: Speed ​​sensor, used to obtain the real-time travel speed of the loader; An accelerometer is used to acquire the real-time acceleration of the loader to help determine the braking condition; A current sensor is used to monitor the magnitude and direction of the current flowing between the energy recovery module and the energy storage module.

6. The energy recovery system for an underground mining battery-powered loader according to claim 1, characterized in that, The energy management module includes: A controller is a physical hardware unit used to perform calculations and issue control commands. An energy management algorithm, configured within the controller, is used to make decisions based on the received operating status parameters in order to generate control commands.

7. The energy recovery system for an underground mining battery-powered loader according to claim 6, characterized in that, The energy management algorithm is either a fuzzy control-based algorithm or a neural network-based algorithm.

8. The energy recovery system for an underground mining battery-powered loader according to claim 1, characterized in that, The communication module uses CAN bus technology to connect with the central control system of the loader to achieve integrated vehicle control, or uses wireless communication technology to connect with a remote monitoring platform to achieve remote data monitoring and fault diagnosis.

9. The energy recovery system for an underground mining battery-powered loader according to claim 2, characterized in that, The energy management module controls the magnitude of the regenerative braking force applied to the wheels via the transmission system by adjusting the electromagnetic torque generated by the integrated motor and generator unit.

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