A method for calculating oil consumption of heavy load operation of a mine car
By installing sensors and current monitoring devices on the mining trucks, and combining them with onboard processors to analyze operating conditions and calculate fuel consumption for each condition, the problem of inaccurate fuel consumption monitoring of mining trucks is solved, and precise fuel consumption management and fuel economy analysis are achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SHANGHAI NEW POWER AUTOMOTIVE TECH CO LTD
- Filing Date
- 2026-03-31
- Publication Date
- 2026-07-21
AI Technical Summary
Existing technologies cannot accurately monitor and collect fuel consumption data for mining trucks under various operating conditions, resulting in inaccurate fuel consumption management and affecting vehicle management and upgrades.
Speed sensors, torque sensors, weighing devices, and current monitoring circuits are installed on the mining truck. The on-board processor analyzes the working conditions and records the current of the fuel injection pump solenoid valve, and calculates the fuel injection pump power and fuel consumption for each working condition.
It enables precise monitoring and statistics of fuel consumption of mining trucks under various operating conditions, supports fuel economy analysis, ensures the accuracy of fuel consumption data, and facilitates management and hardware upgrades.
Abstract
Description
Technical Field
[0001] This invention relates to the field of mining vehicle technology, specifically to a method for calculating fuel consumption during heavy-load mining operations. Background Technology
[0002] In the mining industry, fuel consumption of mining trucks often accounts for a large portion of the operating costs of mines, and how to reduce the fuel consumption of fuel-powered mining trucks has always been an urgent problem for mining companies.
[0003] When mining trucks travel in mining areas, their speeds change frequently over a certain distance, generally including: ① unloaded uphill; ② unloaded on a level slope or unloaded deceleration to the loading point; ③ idling while loading; ④ heavily loaded downhill; ⑤ heavily loaded on a level slope or heavily loaded and decelerated to the unloading point; ⑥ idling while unloading. The speed differences between these conditions are quite significant. However, the vehicle's fuel consumption meter can only display the fuel consumption for the entire journey, and it cannot display the fuel consumption when the mining truck is loaded separately. It is impossible to collect targeted fuel consumption data. As fuel consumption monitoring and management of vehicles become increasingly important, the fuel consumption meter alone cannot comprehensively and accurately monitor and evaluate fuel consumption, thus affecting subsequent vehicle management and upgrades. Summary of the Invention
[0004] The technical problem to be solved by this invention is that existing methods cannot accurately monitor and collect fuel consumption data for mining trucks under various operating conditions.
[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is to provide a method for calculating fuel consumption in heavy-load mining operations, comprising the following steps:
[0006] S1. Install a speed sensor and a torque sensor on the engine flywheel, install a current monitoring circuit at the fuel injection pump solenoid valve, install a weighing device on the vehicle axle, and connect the speed sensor, torque sensor, current monitoring circuit and weighing device to the vehicle processor. S2. After the engine starts, the speed sensor, torque sensor and weighing device monitor the engine speed Ni, torque Ti and vehicle load Xi respectively and transmit them to the on-board processor. The on-board processor analyzes the different working conditions of the vehicle based on different data and records the injection pump solenoid valve current Ii under the working conditions. S3. If N1 < Ni ≤ Nmax, T1 < Ti < Tmax, and Xi ≤ 0, then determine that the vehicle is in the "unloaded uphill" condition and record the current applied to the fuel injection pump solenoid valve as I1. Where N1 is the economical engine speed when the vehicle is running normally without load; Nmax is the maximum engine speed; T1 is the economical torque when the vehicle is running normally without load; and Tmax is the maximum engine torque. S4. If N1<Ni≤Nmax, Ti=T1, Xi≤0, then determine that the vehicle is in the "unloaded flat slope forward or unloaded deceleration to the loading point" working condition, and record the fuel injection pump solenoid valve applied current as I2. S5. If Nidle < Ni < N1, Ti = 0, Xi > 0, then determine that the vehicle is in the "idle loading" or "idle unloading" working condition, and record the current applied to the fuel injection pump solenoid valve as I3. Nidle is the lowest engine speed when the vehicle is idling. S6. If N1 < Ni ≤ Nmax, Ti = 0, Xi > 0, then determine that the vehicle is in the "heavy load downhill" condition and record the current applied to the fuel injection pump solenoid valve as I4. S7. If N1 < Ni ≤ Nmax, T1 < Ti < Tmax, Xi > 0, then determine that the vehicle is in the "heavy load on flat slope or heavy load deceleration to unloading point" working condition, and record the fuel injection pump solenoid valve current as I5. S8. The on-board processor calculates the fuel injection pump power Pi for each operating condition based on the applied current of the fuel injection pump solenoid valve under each operating condition. S9. Calculate the specific fuel consumption for each operating condition based on the fuel injection pump map.
[0007] Optionally, in step S8, the fuel injection pump power Pi for each operating condition is obtained using an integral method: Pi=Ti∫(U×(Ii-I0))dt; Where Ti is the duration of each operating condition, which can be obtained from the timer built into the vehicle processor; I0 is the current applied to the fuel injection pump solenoid valve when the vehicle is running normally under no-load.
[0008] Optionally, steps S4, S5, and S7 each include two working conditions: the duration T2 of I2 is the sum of the durations of the "unloaded flat slope forward" working condition and the "unloaded deceleration to loading point" working condition; the duration T3 of I3 is the sum of the durations of the "idle loading" working condition and the "idle unloading" working condition; and the duration T5 of I5 is the sum of the durations of the "heavy load flat slope forward" working condition and the "heavy load deceleration to unloading point" working condition.
[0009] Optionally, in step S9, each point on the fuel injection pump map corresponds to a specific fuel consumption, and the specific fuel consumption for each operating condition is as follows: Ai = Pi × corresponding fuel consumption / 1000 Fuel consumption Ai is measured in kg / h; Pi in kW; and specific fuel consumption in g / kWh.
[0010] In summary, this invention judges the various working conditions of the mining car by measuring rotational speed, torque, and load, and calculates the specific fuel consumption for each working condition by measuring the current of the fuel injection pump. It clarifies the segmented fuel consumption of the mining car during operation, enabling precise monitoring of fuel consumption. This facilitates the identification of the mining car's economic fuel consumption zone and makes subsequent management and hardware upgrades of the mining car easier. Detailed Implementation
[0011] This invention discloses a method for calculating fuel consumption during heavy-load operations of mining trucks, comprising the following steps: S1. Install a speed sensor and a torque sensor on the engine flywheel, install a current monitoring circuit at the fuel injection pump solenoid valve, install a weighing device on the vehicle axle, and connect the speed sensor, torque sensor, current monitoring circuit and weighing device to the vehicle processor. S2. After the engine starts, the speed sensor, torque sensor and weighing device monitor the engine speed Ni, torque Ti and vehicle load Xi respectively and transmit them to the on-board processor. The on-board processor analyzes the different working conditions of the vehicle based on different data and records the injection pump solenoid valve current Ii under the working conditions. S3. If N1 < Ni ≤ Nmax, T1 < Ti < Tmax, and Xi ≤ 0, then determine that the vehicle is in the "unloaded uphill" condition and record the current applied to the fuel injection pump solenoid valve as I1. Where N1 is the economical engine speed when the vehicle is running normally without load; Nmax is the maximum engine speed; T1 is the economical torque when the vehicle is running normally without load; and Tmax is the maximum engine torque. S4. If N1<Ni≤Nmax, Ti=T1, Xi≤0, then determine that the vehicle is in the "unloaded flat slope forward or unloaded deceleration to the loading point" working condition, and record the fuel injection pump solenoid valve applied current as I2. S5. If Nidle < Ni < N1, Ti = 0, Xi > 0, then determine that the vehicle is in the "idle loading" or "idle unloading" working condition, and record the current applied to the fuel injection pump solenoid valve as I3. Nidle is the lowest engine speed when the vehicle is idling. S6. If N1 < Ni ≤ Nmax, Ti = 0, Xi > 0, then determine that the vehicle is in the "heavy load downhill" condition and record the current applied to the fuel injection pump solenoid valve as I4. S7. If N1 < Ni ≤ Nmax, T1 < Ti < Tmax, Xi > 0, then determine that the vehicle is in the "heavy load on flat slope or heavy load deceleration to unloading point" working condition, and record the fuel injection pump solenoid valve current as I5. S8. The on-board processor calculates the fuel injection pump power Pi for each operating condition based on the applied current of the fuel injection pump solenoid valve under each operating condition. Specifically, the fuel injection pump power Pi under each operating condition is obtained using an integral method: Pi=Ti∫(U×(Ii-I0))dt; Where Ti is the duration of each operating condition, which can be obtained from the timer built into the vehicle processor; I0 is the current applied to the fuel injection pump solenoid valve when the vehicle is running normally under no-load. S9. Calculate the specific fuel consumption for each operating condition based on the fuel injection pump map. Specifically, each point on the fuel injection pump map corresponds to a specific fuel consumption, and the specific fuel consumption for each operating condition is as follows: Ai = Pi × corresponding fuel consumption / 1000 Fuel consumption Ai is measured in kg / h; Pi in kW; and specific fuel consumption in g / kWh.
[0012] In a specific implementation, steps S4, S5, and S7 each include two working conditions: the duration T2 of I2 is the sum of the durations of the "unloaded flat slope forward" working condition and the "unloaded deceleration to loading point" working condition; the duration T3 of I3 is the sum of the durations of the "idle loading" working condition and the "idle unloading" working condition; and the duration T5 of I5 is the sum of the durations of the "heavy load flat slope forward" working condition and the "heavy load deceleration to unloading point" working condition. The duration of each working condition can be obtained by accumulating the timer or by having the operator hold a timer. The current monitoring circuit has a "shunt + detection amplifier + MCU" structure, which can output the monitored current in real time; The weighing device is a common weighing instrument, which only determines whether a load is being carried out, without needing to measure the specific load.
[0013] In addition, this invention can also calculate the fuel consumption of mining cars under heavy load: A 重 =A3+A4+A5=P3×corresponding fuel consumption / 1000+P4×corresponding fuel consumption / 1000+P5×corresponding fuel consumption / 1000=∫U((I3-I0)T3+(I4-I0)T4+(I5-I0)T5)dt.
[0014] This invention can specifically calculate and present the actual load and fuel consumption of mining trucks during actual operation, which is beneficial for analyzing and identifying the fuel economy of mining trucks. At the same time, it can also calculate the fuel consumption of mining trucks throughout the entire operation and compare it with the fuel consumption data in the instrument panel to determine whether the instrument record is accurate.
[0015] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.
Claims
1. A method for calculating fuel consumption during heavy-load mining operations, characterized in that, Includes the following steps: S1. Install a speed sensor and a torque sensor on the engine flywheel, install a current monitoring circuit at the fuel injection pump solenoid valve, install a weighing device on the vehicle axle, and connect the speed sensor, torque sensor, current monitoring circuit and weighing device to the vehicle processor. S2. After the engine starts, the speed sensor, torque sensor and weighing device monitor the engine speed Ni, torque Ti and vehicle load Xi respectively and transmit them to the on-board processor. The on-board processor analyzes the vehicle's operating conditions based on different data and records the injection pump solenoid valve current Ii under the operating conditions. S3. If N1 < Ni ≤ Nmax, T1 < Ti < Tmax, and Xi ≤ 0, then determine that the vehicle is in the "unloaded uphill" condition and record the current applied to the fuel injection pump solenoid valve as I1. Where N1 is the economical engine speed when the vehicle is running normally without load; Nmax is the maximum engine speed; T1 is the economical torque when the vehicle is running normally without load; and Tmax is the maximum engine torque. S4. If N1<Ni≤Nmax, Ti=T1, Xi≤0, then determine that the vehicle is in the "unloaded flat slope forward or unloaded deceleration to loading point" working condition, and record the fuel injection pump solenoid valve applied current as I2. S5. If Nidle < Ni < N1, Ti = 0, Xi > 0, then determine that the vehicle is in the "idle loading" or "idle unloading" working condition, and record the current applied to the fuel injection pump solenoid valve as I3. Nidle is the lowest engine speed when the vehicle is idling. S6. If N1 < Ni ≤ Nmax, Ti = 0, Xi > 0, then determine that the vehicle is in the "heavy load downhill" condition and record the current applied to the fuel injection pump solenoid valve as I4. S7. If N1 < Ni ≤ Nmax, T1 < Ti < Tmax, Xi > 0, then determine that the vehicle is in the "heavy load on flat slope or heavy load deceleration to unloading point" working condition, and record the fuel injection pump solenoid valve current as I5. S8. The on-board processor calculates the fuel injection pump power Pi for each operating condition based on the applied current of the fuel injection pump solenoid valve under each operating condition. S9. Calculate the specific fuel consumption for each operating condition based on the fuel injection pump map.
2. The method for calculating fuel consumption for heavy-load mining car operations according to claim 1, characterized in that, In step S8, the fuel injection pump power Pi under each operating condition is obtained by integration: Pi=Ti∫(U×(Ii-I0))dt; Where Ti is the duration of each operating condition, which can be obtained from the timer built into the vehicle processor; I0 is the current applied to the fuel injection pump solenoid valve when the vehicle is running normally under no-load.
3. The method for calculating fuel consumption for heavy-load mining car operations according to claim 2, characterized in that, Steps S4, S5, and S7 each include two working conditions: the duration T2 of I2 is the sum of the durations of the "unloaded flat slope forward" working condition and the "unloaded deceleration to loading point" working condition; the duration T3 of I3 is the sum of the durations of the "idle loading" working condition and the "idle unloading" working condition; and the duration T5 of I5 is the sum of the durations of the "heavy load flat slope forward" working condition and the "heavy load deceleration to unloading point" working condition.
4. The method for calculating fuel consumption for heavy-load mining car operations according to claim 3, characterized in that, In step S9, each point on the fuel injection pump map corresponds to a specific fuel consumption, and the specific fuel consumption for each operating condition is as follows: Ai = Pi × corresponding fuel consumption / 1000 Fuel consumption Ai is measured in kg / h; Pi in kW; and specific fuel consumption in g / kWh.