Mine robot hybrid power supply system

Abstract

The application discloses a kind of mine robot hybrid power supply systems, it is characterized in that, including: hybrid energy storage module: as energy source, for storing and preliminary regulating energy, support continuous low-power output and high-power peak discharge;The application is directly realized the complementary effect of energy density and power density by the parallel configuration of hybrid energy storage module, power battery pack provides high-capacity continuous output, super capacitor group supplements instantaneous high power, so as to ensure long endurance in conventional driving, and provide ≥120A peak current in high-power working conditions such as climbing or obstacle crossing.This direct effect is further amplified as the threshold switching of intelligent energy management unit, avoids the output limitation and capacity sacrifice problem caused by the increase of existing single storage battery internal resistance, finally forms the advantage that 35 ° climbing pass rate is improved to 100%, completely solves the contradiction of existing endurance short and power shortage, improves rescue mobility and range.

Description

Technical Field

[0001] This invention relates to the field of mining robot technology, specifically a hybrid power supply system for mining robots. Background Technology

[0002] As a key piece of equipment in mine disaster rescue, the power system and body structure of mining robots directly affect rescue efficiency and safety. The limitations of existing technology reveal contradictions and challenges that urgently need to be addressed. These problems mainly stem from the complexity of the mine environment (such as high gas concentration, severe vibration, and fluctuating low temperatures) and the dual requirements of the robot's mission (high mobility and high reliability).

[0003] The power system of mining robots must simultaneously meet the dual requirements of "long endurance" and "high instantaneous power," enabling long-distance inspections during normal travel (endurance ≥ 6km), while providing instantaneous high current output (≥ 100A) in complex terrains such as climbing slopes and overcoming obstacles. However, existing power supply systems mainly rely on a single battery, which presents the following core contradictions and problems:

[0004] The trade-off between range and power output: Traditional batteries (such as lead-acid or lithium-ion batteries) are inherently difficult to design to balance capacity and power. To achieve long range, high-capacity batteries (such as 200Ah) are typically chosen, but their high internal resistance (≥50mΩ) limits the maximum output current (≤50A). When climbing a 35° slope or overcoming obstacles, insufficient power results in a pass rate of only ≤30%, making it unsuitable for the steep terrain and obstacles in mines. Switching to high-rate batteries (supporting high-current discharge) significantly reduces capacity (≤100Ah), shortening the range to below 3km, making it difficult to complete large-scale disaster detection tasks. This limits the robot's rescue range and reduces efficiency.

[0005] High charging and discharging safety risks: The violent vibrations in mine environments (acceleration ≥10g) make batteries susceptible to electrode detachment and electrolyte decomposition under prolonged high-current discharge (≥80A), leading to a rapid temperature increase (≥70℃) and potential explosion hazards. Furthermore, traditional battery management systems (BMS) have long protection response times (≥100ms), failing to respond promptly to overcharging or over-discharging, resulting in a battery cycle life of only ≤500 cycles (far below 50% of the designed lifespan). In mines with high gas explosiveness, this safety risk directly threatens rescue personnel and equipment.

[0006] Low energy efficiency: When the robot travels on complex terrain, the load fluctuates drastically (current suddenly increases from 30A to 100A), and the battery output voltage fluctuates easily (≥5V), causing the motor efficiency to decrease by more than 20%. In addition, the regenerative energy during braking or downhill (accounting for about 15% of the total energy consumption) cannot be effectively recovered and is directly converted into heat energy and wasted. This not only reduces the overall energy efficiency, but also indirectly shortens the endurance and affects the execution of long-term tasks.

[0007] Poor adaptability to low temperatures: Mining disasters are often accompanied by low-temperature environments (≤5℃), which severely degrades battery capacity (high-capacity batteries decrease by 30%, such as 200Ah to 140Ah) and reduces charging acceptance (charging time is extended by 50%). This problem is particularly prominent in northern mines during winter, resulting in slow robot start-up, unstable power output, and prolonged rescue response time.

[0008] To address this, a hybrid power supply system for mining robots is proposed. Summary of the Invention

[0009] The purpose of this invention is to provide a hybrid power supply system for mining robots to solve the problems mentioned in the background art.

[0010] To achieve the above objectives, the present invention provides the following technical solution: a hybrid power supply system for a mining robot, characterized in that it comprises:

[0011] Hybrid energy storage module: As an energy source, it is used to store and initially regulate energy, supporting continuous low-power output and high-power peak discharge;

[0012] Bidirectional DC / DC converter: used to achieve bidirectional energy conversion, adjusting voltage matching according to duty cycle;

[0013] Intelligent energy management unit: used for operating condition identification and energy allocation decision-making, real-time monitoring of load current and control of bidirectional DC / DC converter to adjust energy flow direction;

[0014] Safety protection module: used for real-time monitoring of multiple parameters, quickly disconnecting the circuit and issuing a notification when the system malfunctions;

[0015] The hybrid energy storage module, bidirectional DC / DC converter, intelligent energy management unit, and safety protection module are mechanically connected through standardized interfaces and achieve electrical and signal interaction through a 72V DC bus and a CAN bus with a transmission rate of 1Mbps.

[0016] Preferably, the hybrid energy storage module includes a power battery pack, a supercapacitor pack, and a thermal management system, all of which are integrated into an aluminum alloy shell and fixed to the robot chassis with bolts.

[0017] The power battery pack is located at the bottom of the aluminum alloy casing and is stacked with the supercapacitor pack. The thermal management system is arranged around the power battery pack and the supercapacitor pack. The positive terminal of the power battery pack is connected to the main bus through a Schottky diode, and the supercapacitor pack is connected in parallel to the same main bus.

[0018] Preferably, the power battery pack is formed by connecting 20 series-10 parallel lithium iron phosphate battery cells in series and parallel through laser welding copper busbars. The lithium iron phosphate battery cells are packaged in aluminum shells and have individual specifications of 3.2V and 20Ah. The total voltage of the power battery pack is 72V and the capacity is 200Ah.

[0019] The supercapacitor bank consists of 10 strings of activated carbon supercapacitor cells, which are connected in parallel to the copper busbar by screws. The activated carbon supercapacitor cells are cylindrical and have a cell specification of 7.2V and 50F.

[0020] The thermal management system includes a liquid cooling plate, a heating film, and thermally conductive adhesive. The liquid cooling plate is made of aluminum with a channel diameter of 4 mm and a flow rate of 1 L / min. The heating film is made of PTC material with a power of 100 W. The liquid cooling plate is attached to the surface of the power battery pack and the supercapacitor pack using thermally conductive adhesive. The thermal management system is equipped with an NTC-type temperature sensor and a PID controller. The temperature sensor is connected to the PID controller, and the PID controller outputs a PWM signal to control the liquid cooling pump and the heating film, maintaining the temperature of the power battery pack and the supercapacitor pack at 25–40 °C.

[0021] Preferably, the intelligent energy management unit is based on an STM32F4 series microcontroller, encapsulated in an aluminum housing, and fixed above the hybrid energy storage module;

[0022] The intelligent energy management unit includes a Hall-type current sensor, a microcontroller, and a CAN transceiver. The Hall-type current sensor has a sampling rate of 1kHz, is connected in series with a 72V DC bus, and outputs an analog signal to the ADC interface of the microcontroller. The CAN transceiver is connected to the CAN bus. The microcontroller controls the relay through GPIO pins, and the intelligent energy management unit draws 5V from the hybrid energy storage module as its power input.

[0023] Preferably, the intelligent energy management unit has a built-in operating condition identification and energy allocation algorithm, and the algorithm execution flow is as follows:

[0024] After the system starts up, the Hall-type current sensor collects the load current I in real time;

[0025] If 30A≤I≤50A, the system enters the normal power supply mode, where the power battery pack provides power independently and the bidirectional DC / DC converter is turned off.

[0026] If I≥80A, the system enters high-power supply mode, with the power battery pack and supercapacitor pack connected in parallel for power supply, and the duty cycle of the bidirectional DC / DC converter adjusted to 80%.

[0027] If I < 0A, the system enters regenerative energy recovery mode, transferring regenerative energy to the supercapacitor bank for storage, and the duty cycle of the bidirectional DC / DC converter is adjusted to 20%.

[0028] After completing the mode switch, the loop returns to the load current acquisition step.

[0029] Preferably, the bidirectional DC / DC converter adopts a phase-shifted full-bridge topology, is encapsulated in an aluminum profile heat sink housing, and is fixed to the robot chassis with thermal grease, with an energy conversion efficiency of ≥95%;

[0030] The bidirectional DC / DC converter includes four IRF series MOSFET switches, an EE type iron core phase-shifting transformer, a 100μH output filter inductor, and a 1000μF filter capacitor.

[0031] The bidirectional DC / DC converter is equipped with a PWM driver, which is connected to the microcontroller of the intelligent energy management unit. The PWM driver receives the control signal from the microcontroller and adjusts the duty cycle of the phase-shifted full-bridge topology. The duty cycle adjustment range is 0 to 100%.

[0032] Preferably, the safety protection module is integrated on the PCB board, and the abnormal response time is ≤20ms;

[0033] The safety protection module includes a voltage sensor, a current sensor, a temperature sensor, a comparator, a relay drive circuit, a CAN interface, and a battery equalization circuit.

[0034] The voltage sensor has an accuracy of 0.1V and is connected in parallel across the power battery pack and the supercapacitor pack. The current sensor is connected in series with the 72V DC bus. The temperature sensor is connected to the thermal management system of the hybrid energy storage module. The comparator is connected to the voltage, current, and temperature sensors respectively, and its output is connected to the relay drive circuit. The CAN interface is connected to the CAN bus and is used to send abnormal notifications to the outside.

[0035] Preferably, the system abnormality thresholds preset by the safety protection module are 78V voltage, 120A current, and 60℃ temperature. When any of the monitored parameters exceeds the threshold, the comparator triggers the relay drive circuit to control the relay to disconnect the 72V DC bus.

[0036] The battery balancing circuit includes a 1A balancing resistor connected to both ends of the individual cells in the power battery pack. When the voltage difference between the individual cells in the power battery pack is ≥50mV, the battery balancing circuit is automatically activated.

[0037] Compared with existing technologies, the beneficial effects of this invention are as follows: This invention, through the parallel configuration of hybrid energy storage modules (the power battery pack provides high-capacity continuous output, and the supercapacitor pack supplements instantaneous high power), directly achieves a complementary effect between energy density and power density, thereby ensuring long range during normal driving and providing a peak current of ≥120A under high-power conditions such as climbing hills or overcoming obstacles. This direct effect is further amplified by the threshold switching of the intelligent energy management unit, avoiding the output limitation and capacity sacrifice problems caused by the increased internal resistance of existing single batteries. Ultimately, this results in a 100% success rate for climbing 35° hills, completely resolving the contradiction between short range and insufficient power, and improving rescue mobility and range.

[0038] Similarly, the safety protection module of this invention introduces multi-parameter monitoring and a ≤20ms fast response mechanism, directly cutting off the risk chain of rapid temperature rise and slow BMS response under vibration environment. It also suppresses electrode detachment and electrolyte decomposition induced by overcharging / over-discharging through an active balancing circuit. This protective effect is further extended to the optimization of cycle life, ultimately overcoming the shortcomings of existing systems with frequent explosion hazards and a lifespan of only ≤500 cycles, achieving a 100% improvement in system reliability and ensuring stable rescue operations in high-risk mine scenarios.

[0039] In terms of energy utilization, the bidirectional DC / DC converter directly stabilizes the voltage during load fluctuations and recovers ≥80% of braking energy through duty cycle adjustment. This recovery mechanism is amplified to improve the overall efficiency of the motor from 80% to 90%, reducing the waste of existing regenerative energy and the heat loss caused by voltage fluctuations ≥5V. Ultimately, it achieves the advantages of a 20% increase in energy utilization and an indirect 15% extension of range, significantly reducing the energy consumption cost of the mission.

[0040] To address low-temperature adaptability, the thermal management system of this invention can directly raise the temperature to 25°C within 3 minutes in an environment of 5°C, maintaining a capacity retention rate of ≥85%. This thermal control effect further enhances the charging acceptance capability, overcomes the bottlenecks of existing capacity decay of 30% and charging time extension of 50%, and ultimately achieves the advantages of accelerated start-up response and continuous operation in northern mines during winter, ensuring the timeliness and environmental adaptability of disaster relief. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the hybrid energy storage module of the present invention;

[0042] Figure 2 This is a schematic diagram of the intelligent energy management unit of the present invention;

[0043] Figure 3 This is a schematic diagram of the bidirectional DC / DC converter of the present invention;

[0044] Figure 4 This is a schematic diagram of the security protection module of the present invention. Detailed Implementation

[0045] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0046] Please see Figure 1-4 The present invention provides a technical solution: The present invention provides a hybrid power supply system for mining robots consisting of a power battery and a supercapacitor. The system integrates a hybrid energy storage module, an intelligent energy management unit, a bidirectional DC / DC converter and a safety protection module to achieve the coordinated operation of the power battery and the supercapacitor, thereby solving problems such as the contradiction between the range and power of mining robots, high safety risks, low energy utilization and poor low temperature adaptability.

[0047] Specifically, the system operates on the principle of condition-adaptive energy allocation: the intelligent energy management unit monitors the load current in real time, identifies normal driving, high-power operation, or regenerative recovery status through current sensors, and controls the bidirectional DC / DC converter to adjust the energy flow; the hybrid energy storage module provides a stable voltage output, and the safety protection module ensures rapid circuit disconnection in case of abnormalities. The entire system is integrated into a dedicated compartment of the mining robot chassis, with a total weight not exceeding 50kg and dimensions of 500mm×400mm×200mm, supporting 72V DC bus output to the robot motor and control system.

[0048] The system consists of four main components: a hybrid energy storage module, an intelligent energy management unit, a bidirectional DC / DC converter, and a safety protection module. These components are mechanically connected via standardized interfaces (such as M8 bolts and JST connectors) and achieve electrical and signal interaction through a 72V DC bus and a CAN bus (1Mbps transmission rate). The hybrid energy storage module acts as the energy source, providing the base voltage; the intelligent energy management unit monitors and makes decisions, controlling the bidirectional DC / DC converter to distribute energy to the load; the safety protection module monitors in real time and disconnects the bus in case of abnormalities. The operational relationship is as follows: when the system starts up, the intelligent energy management unit initializes each module, and the hybrid energy storage module is pre-charged to 72V; during operation, energy flows unidirectionally or bidirectionally from the hybrid energy storage module through the bidirectional DC / DC converter, depending on the operating conditions; when the protection is triggered, the safety protection module initiates the disconnection to ensure system safety.

[0049] 1. Detailed structure and operation of hybrid energy storage modules

[0050] The hybrid energy storage module is responsible for storing and initially regulating energy, supporting continuous low-power output and high-power peak discharge. Its function is to achieve complementary energy density and power density through the parallel configuration of the power battery pack and supercapacitor pack, while the thermal management system maintains temperature stability. The module is housed in an aluminum alloy shell (3mm thick, 400mm×300mm×150mm) and fixed to the robot chassis with four M6 bolts.

[0051] The exploded structural breakdown of the hybrid energy storage module is described as follows: The power battery pack is located at the bottom, comprising 20 series-10-parallel lithium iron phosphate battery cells (each cell 3.2V, 20Ah, aluminum casing), connected in series and parallel via laser-welded copper busbars (10mm wide, 2mm thick) to form a battery pack with a total voltage of 72V and a capacity of 200Ah. A supercapacitor pack is stacked on top, comprising 10 series activated carbon supercapacitor cells (each cell 7.2V, 50F, cylindrical casing), connected in parallel to a copper busbar (200mm long) via screws (M4 specification). A thermal management system surrounds two groups, including a liquid cooling plate (aluminum, 4mm channel diameter, 1L / min flow rate) and a heating film (PTC material, 100W power). The liquid cooling plate is bonded to the battery / capacitor surface with thermally conductive adhesive. The outer casing is sealed with snap-fit ​​fasteners. Side connection details include: T-shaped connection interfaces between the copper busbars and the busbars for total output.

[0052] The components of a power battery pack include individual battery cells and copper busbars. These components are welded together to form a battery pack, which functions to provide high-capacity continuous discharge (50A). The operational relationship is as follows: individual cells are connected in series to increase voltage, and connected in parallel to increase capacity. The copper busbars transmit current to the module output. The components of a supercapacitor pack include supercapacitor cells, screws, and copper busbars. The function is instantaneous high-power discharge (150A, 10s). The operational relationship is as follows: individual cells are connected in series to match voltage, screws are used to fix them to the busbars, and the busbars are connected in parallel with the battery copper busbars to a bidirectional DC / DC converter. The components of a thermal management system include a liquid cooling plate, a heating film, and thermally conductive adhesive. The function is PID control of temperature (25-40℃). The operational relationship is as follows: the liquid cooling plate circulates coolant (inlet and outlet pipes), the heating film is activated at low temperatures, and the thermally conductive adhesive conducts heat to the battery / capacitor surface.

[0053] The circuit principle of the hybrid energy storage module is described as follows: The positive terminal of the power battery pack is connected to the main bus via a diode (Schottky type, to prevent reverse charging). The supercapacitor bank is connected in parallel to the same bus. The temperature sensor (NTC type) of the thermal management system is connected to the PID controller, which outputs a PWM signal to control the liquid cooling pump and heating film. The power path is connected with solid lines, and the control signal is connected with dashed lines. All components are integrated through standardized interfaces.

[0054] 2. Detailed structure and operation of the intelligent energy management unit

[0055] The intelligent energy management unit is responsible for identifying operating conditions and making energy allocation decisions. Its function is to switch power supply modes in real time through algorithms to ensure efficient energy utilization. This unit uses a microcontroller (STM32F4 series) as its core, is packaged in an aluminum box (150mm×100mm×50mm), and is fixed to the top of the hybrid energy storage module with four M5 bolts.

[0056] The internal structure of the intelligent energy management unit is described as follows: a current sensor (Hall effect type, 1kHz sampling rate) is connected in series with the bus and outputs an analog signal to the ADC interface; a microcontroller processes the data and controls the relays via GPIO pins; a CAN transceiver connects to the CAN bus. All interfaces include a power input (5V drawn from the battery pack).

[0057] The operating condition identification and energy allocation process of the intelligent energy management unit is described as follows: From system startup, the current I is collected; if 30A ≤ I ≤ 50A, it enters normal mode: battery powered, DC / DC off; if I ≥ 80A, it enters high-power mode: parallel power supply, duty cycle 80%; if I < 0, it enters regeneration mode: energy to capacitor, duty cycle 20%; the process then loops back to monitoring. Decisions are executed in a conditional branching manner, with each step based on a threshold judgment.

[0058] The current sensor monitors the load current. Its operation is as follows: it connects to the bus in series and outputs to the microcontroller's ADC. The microcontroller consists of a CPU core, memory, and an algorithm module (embedded with C code). Its function is to execute the allocation strategy. Its operation is as follows: after receiving a signal, it uses GPIO to drive a relay to switch paths and uses CAN to notify the safety module.

[0059] 3. Detailed structure and operation of the bidirectional DC / DC converter

[0060] The bidirectional DC / DC converter enables bidirectional energy conversion and adjusts voltage matching according to the duty cycle, supporting 95% efficiency. This converter employs a phase-shifted full-bridge topology and is encapsulated in a heat sink housing (aluminum profile, dimensions 200mm × 150mm × 80mm), secured to the chassis with thermal grease.

[0061] The circuit principle of the bidirectional DC / DC converter is described as follows: The input terminal is connected to a hybrid energy storage module. The full-bridge circuit includes four MOSFET switches (IRF series, 600V / 50A), a phase-shifting transformer (iron core EE type, turns ratio 1:1), an output filter inductor (100μH), and a capacitor (1000μF). The PWM driver receives signals from the intelligent unit and controls the duty cycle. The power path is connected with solid lines, and the control signal is connected with dashed lines. All component labels are covered.

[0062] The phase-shifted full-bridge converter functions as a bidirectional isolated converter, operating as follows: at high power, it operates with an 80% duty cycle for deep capacitor discharge; during regeneration, it operates with a 20% duty cycle for current-limited charging. The PWM driver is connected to a microcontroller for real-time adjustment.

[0063] 4. Detailed structure and operation of the safety protection module

[0064] The safety protection module provides multi-layered protection and functions to monitor anomalies and respond quickly (≤20ms). This module is integrated into the PCB board (100mm × 80mm) and mounted on the system sidewall via a slot.

[0065] The circuit description of the safety protection module is as follows: a voltage sensor (accuracy 0.1V) is connected in parallel with a battery and a capacitor; a current sensor is connected in series with the bus; and a temperature sensor is connected to the thermal management unit. A comparator output drives a relay, and a CAN interface notifies the outside world. Abnormal thresholds include voltage 78V, current 120A, and temperature 60℃.

[0066] The multi-parameter monitoring circuit functions to acquire data in real time. Its operation is as follows: when a threshold is exceeded, the comparator triggers a relay to disconnect the bus. The equalization circuit (including resistors, 1A) is connected to individual battery cells and activates when the voltage difference is ≥50mV.

[0067] System overall working sequence and integration

[0068] The system's operating timing is described as follows: The time axis moves from 0 to 20 seconds; the current I suddenly increases from 40A to 100A and then reverses to -20A; the duty cycle is adjusted accordingly to 80% or 20%; the capacitor's SOC decreases from 50% to 30% and then rises again; the temperature is controlled within 40℃. Switching points are based on operating condition thresholds to ensure synchronized operation.

[0069] Based on the above structural description, the technical solution of this invention achieves the following objectives: the hybrid energy storage and converter work together to cut off power bottlenecks, the management unit optimizes allocation, the protection module enhances safety, and a closed-loop system is formed.

[0070] 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. A hybrid power supply system for a mining robot, characterized in that, include: Hybrid energy storage module: As an energy source, it is used to store and initially regulate energy, supporting continuous low-power output and high-power peak discharge; Bidirectional DC / DC converter: used to achieve bidirectional energy conversion, adjusting voltage matching according to duty cycle; Intelligent energy management unit: used for operating condition identification and energy allocation decision-making, real-time monitoring of load current and control of bidirectional DC / DC converter to adjust energy flow direction; Safety protection module: used for real-time monitoring of multiple parameters, quickly disconnecting the circuit and issuing a notification when the system malfunctions; The hybrid energy storage module, bidirectional DC / DC converter, intelligent energy management unit, and safety protection module are mechanically connected through standardized interfaces and achieve electrical and signal interaction through a 72V DC bus and a CAN bus with a transmission rate of 1Mbps.

2. The hybrid power supply system for a mining robot according to claim 1, characterized in that: The hybrid energy storage module includes a power battery pack, a supercapacitor pack, and a thermal management system, all of which are integrated into an aluminum alloy shell and fixed to the robot chassis with bolts. The power battery pack is located at the bottom of the aluminum alloy casing and is stacked with the supercapacitor pack. The thermal management system is arranged around the power battery pack and the supercapacitor pack. The positive terminal of the power battery pack is connected to the main bus through a Schottky diode, and the supercapacitor pack is connected in parallel to the same main bus.

3. The hybrid power supply system for a mining robot according to claim 2, characterized in that: The power battery pack is formed by connecting 20 series-10 parallel lithium iron phosphate battery cells in series and parallel through laser welding copper busbars. The lithium iron phosphate battery cells are packaged in aluminum shells and have individual specifications of 3.2V and 20Ah. The total voltage of the power battery pack is 72V and the capacity is 200Ah. The supercapacitor bank consists of 10 strings of activated carbon supercapacitor cells, which are connected in parallel to the copper busbar by screws. The activated carbon supercapacitor cells are cylindrical and have a cell specification of 7.2V and 50F. The thermal management system includes a liquid cooling plate, a heating film, and thermally conductive adhesive. The liquid cooling plate is made of aluminum with a channel diameter of 4 mm and a flow rate of 1 L / min. The heating film is made of PTC material with a power of 100 W. The liquid cooling plate is attached to the surface of the power battery pack and the supercapacitor pack using thermally conductive adhesive. The thermal management system is equipped with an NTC-type temperature sensor and a PID controller. The temperature sensor is connected to the PID controller, and the PID controller outputs a PWM signal to control the liquid cooling pump and the heating film, maintaining the temperature of the power battery pack and the supercapacitor pack at 25–40 °C.

4. The hybrid power supply system for a mining robot according to claim 1, characterized in that: The intelligent energy management unit is based on an STM32F4 series microcontroller, encapsulated in an aluminum housing, and fixed above the hybrid energy storage module. The intelligent energy management unit includes a Hall-type current sensor, a microcontroller, and a CAN transceiver. The Hall-type current sensor has a sampling rate of 1kHz, is connected in series with a 72V DC bus, and outputs an analog signal to the ADC interface of the microcontroller. The CAN transceiver is connected to the CAN bus. The microcontroller controls the relay through GPIO pins, and the intelligent energy management unit draws 5V from the hybrid energy storage module as its power input.

5. A hybrid power supply system for a mining robot according to claim 4, characterized in that: The intelligent energy management unit has a built-in operating condition identification and energy allocation algorithm. The algorithm execution flow is as follows: After the system starts up, the Hall-type current sensor collects the load current I in real time; If 30A≤I≤50A, the system enters the normal power supply mode, where the power battery pack provides power independently and the bidirectional DC / DC converter is turned off. If I≥80A, the system enters high-power supply mode, with the power battery pack and supercapacitor pack connected in parallel for power supply, and the duty cycle of the bidirectional DC / DC converter adjusted to 80%. If I < 0A, the system enters regenerative energy recovery mode, transferring regenerative energy to the supercapacitor bank for storage, and the duty cycle of the bidirectional DC / DC converter is adjusted to 20%. After completing the mode switch, the loop returns to the load current acquisition step.

6. The hybrid power supply system for a mining robot according to claim 1, characterized in that: The bidirectional DC / DC converter adopts a phase-shifted full-bridge topology, is encapsulated in an aluminum profile heat sink housing, and is fixed to the robot chassis with thermal grease, with an energy conversion efficiency of ≥95%. The bidirectional DC / DC converter includes four IRF series MOSFET switches, an EE type iron core phase-shifting transformer, a 100μH output filter inductor, and a 1000μF filter capacitor. The bidirectional DC / DC converter is equipped with a PWM driver, which is connected to the microcontroller of the intelligent energy management unit. The PWM driver receives the control signal from the microcontroller and adjusts the duty cycle of the phase-shifted full-bridge topology. The duty cycle adjustment range is 0 to 100%.

7. A hybrid power supply system for a mining robot according to claim 1, characterized in that: The safety protection module is integrated on the PCB board, and the abnormal response time is ≤20ms; The safety protection module includes a voltage sensor, a current sensor, a temperature sensor, a comparator, a relay drive circuit, a CAN interface, and a battery equalization circuit. The voltage sensor has an accuracy of 0.1V and is connected in parallel across the power battery pack and the supercapacitor pack. The current sensor is connected in series with the 72V DC bus. The temperature sensor is connected to the thermal management system of the hybrid energy storage module. The comparator is connected to the voltage, current, and temperature sensors respectively, and its output is connected to the relay drive circuit. The CAN interface is connected to the CAN bus and is used to send abnormal notifications to the outside.

8. A hybrid power supply system for a mining robot according to claim 7, characterized in that: The safety protection module has preset system abnormal thresholds of 78V voltage, 120A current and 60℃ temperature. When the monitored parameters exceed any threshold, the comparator triggers the relay drive circuit to control the relay to disconnect the 72V DC bus. The battery balancing circuit includes a 1A balancing resistor connected to both ends of the individual cells in the power battery pack. When the voltage difference between the individual cells in the power battery pack is ≥50mV, the battery balancing circuit is automatically activated.

Images