Safety protection system for eddy current retarder of pure electric mining wide-body vehicle
By installing an eddy current retarder on the transmission shaft of a pure electric mining wide-body vehicle and connecting it with the vehicle controller and battery system, the problems of degraded motor braking capacity and motor overspeed loss in traditional technology are solved, and more reliable braking capacity and motor operation safety are achieved.
Patent Information
- Application Number
- CN202421572596.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-07-04
- Publication Date
- 2025-04-22
- Estimated Expiration
- 2034-07-04
AI Technical Summary
In the heavy-duty downhill conditions of traditional pure electric mining wide-body vehicles, the braking capacity of the motor decreases, and there is a risk that the motor will lose control of the vehicle after the speeding motor.
A safety protection system for eddy current retarder is designed. By installing an eddy current retarder on the transmission shaft, and connecting it with the vehicle controller VCU and 24V lead-acid battery, the eddy current retarder consumes battery power or motor feedback when needed, and generates reverse torque to achieve retarding.
It effectively solves the problem of limited energy return charge when the battery system is high, ensures the overall braking capacity under serious faults, avoids the motor speeding and vehicle out of control, and prevents excessive charge current from being too high when the battery is full or heavy load goes downhill, ensuring that the motor braking is available.
Smart Images
Figure CN222780276U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of mining equipment, in particular to a safety protection system for an eddy current retarder of a pure electric wide-body mining vehicle. Background Art
[0002] The traditional pure electric wide-body mining vehicle transmission structure is powered by an electric motor only, which is driven by a high-voltage 618V system. During long, heavy-load downhill conditions, the motor is always in an energy feedback state. When the battery charge exceeds 90%, the BMS will limit energy feedback, resulting in a decrease in the braking capacity of the entire motor, and even a risk of the motor overspeeding and the vehicle losing control. Utility Model Content
[0003] The utility model aims to provide a safety protection system for an eddy current retarder of a pure electric wide-body mining vehicle, so as to solve the problems raised in the above-mentioned background technology.
[0004] To achieve the above-mentioned purpose, the utility model provides the following technical solutions: a pure electric wide-body mining vehicle eddy current retarder safety protection system, comprising a vehicle controller VCU, a 24V lead-acid battery, an electric transmission system and a transmission structure, the 24V lead-acid battery and the electric transmission system are both connected to the vehicle controller VCU, the electric transmission system comprises a bidirectionally connected motor controller MCU and a high-voltage distribution box PDU, the output end of the high-voltage distribution box PDU is electrically connected to the input end of the 24V lead-acid battery, the transmission structure comprises a motor, a gearbox, a drive shaft and an axle bidirectionally connected in sequence, the motor, the gearbox and the drive shaft are all electrically connected to the vehicle controller VCU, the motor is bidirectionally connected to the motor controller MCU, an eddy current retarder is provided on the drive shaft, and the eddy current retarder is connected to the 24V lead-acid battery.
[0005] The following improvements are made in the present application scheme: the eddy current retarder includes a controller, an electric retarder, a temperature control probe, a connector C1, a connector C2, a battery and a main power switch; pin 1 of the controller is grounded, the negative pole of the battery is connected in series with the main power switch, a fuse FU is connected in series between the positive pole of the battery and pin 2 of the controller, the electric retarder, the temperature control probe and the connector C1 are connected in series between pins 3 to 6 of the controller and pins 7 to 8, one end of channel 1 of the connector C2 is connected to pin 9 of the controller, and the other end is connected to an external high-power controller, one end of channel 2 is connected to pin 10 of the controller, and the other end is connected to CAN_L, one end of channel 3 is connected to pin 11 of the controller, and the other end is connected to CAN_H, one end of channel 4 is connected to pin 12 of the controller, and the other end is grounded.
[0006] The following improvement is made in the present application scheme: the motor, motor controller MCU, high-voltage distribution box PDU and power battery BMS are bidirectionally connected in sequence through high-voltage lines.
[0007] The following improvement is made in the present application scheme: the 24V lead-acid battery is respectively connected to the vehicle controller VCU, the high-voltage distribution box PDU and the eddy current retarder through a 24V low-voltage line.
[0008] The following improvement is made in the present application: the vehicle controller VCU is connected to the electric drive system as well as the motor, gearbox and drive shaft through a low-voltage signal line.
[0009] The following improvements are made in the present application scheme: the electric transmission system also includes a power battery BMS, which is bidirectionally connected to the high-voltage distribution box PDU. When the whole machine is driven, the electric energy of the BMS battery system supplies power to the motor, and the motor transmits power to the gearbox. The gearbox transmits the power of the corresponding gear to the drive shaft. The drive shaft is equipped with a retarder, and the kinetic energy of the drive shaft is transmitted to the axle to drive the vehicle forward. When the whole machine is braked or the retarder is turned on, the axle power is reversely transmitted to the drive shaft, and then reversely transmitted to the motor. The reversible nature of the motor's work is used to convert the received kinetic energy into electrical energy, and then the electrical energy is fed back to the PDU for redistribution.
[0010] Compared with the prior art, the utility model provides a safety protection system for an eddy current retarder of a pure electric wide-body mining vehicle, which has the following beneficial effects:
[0011] The utility model adopts a transmission structure composed of a motor, a gearbox, a transmission shaft plus a retarder, and an axle. The power sources of this power transmission mode are the motor and the retarder. The eddy current retarder is assembled on the transmission shaft and directly acts on the transmission shaft. When the retarder needs to intervene, the VCU automatically wakes up the retarder, consumes the 24V lead-acid battery, thereby consuming the electric energy of the power battery, or directly consumes the excess power fed back by the motor to generate a torque opposite to the driving direction, thereby achieving the purpose of deceleration, and effectively solves the problem of limited energy recharge of the battery system under high power and continuous heavy load conditions, ensuring the braking ability of the entire machine under severe faults and avoiding the vehicle from losing control due to overspeeding of the motor; at the same time, when the power battery is fully charged or the recharge current is large when going downhill, the excess power can be directly consumed to prevent the recharge current from being too large, ensuring that the motor braking is available and not restricted (when the power battery limits the recharge current, the motor braking is weak). BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Figure 1 It is a structural block diagram of the utility model;
[0013] Figure 2 is the circuit diagram of the eddy current retarder;
[0014] Figure 3 It is the circuit diagram of the eddy current retarder and the vehicle controller VCU;
[0015] Figure 4 This is a logic schematic diagram of the utility model.
[0016] In the figure: 1. High voltage line; 2. 24V low voltage line; 3. Low voltage signal line. DETAILED DESCRIPTION
[0017] The technical scheme in the embodiment of the present invention will be described below in conjunction with the accompanying drawings in the embodiment of the present invention:
[0018] like Figure 1 As shown, a pure electric wide-body mining vehicle electric eddy current retarder safety protection system includes a vehicle controller VCU, a 24V lead-acid battery, an electric transmission system and a transmission structure. The 24V lead-acid battery and the electric transmission system are both connected to the vehicle controller VCU, and the 24V lead-acid battery adopts a 24V lead-acid battery; the electric transmission system includes a motor controller MCU, a high-voltage distribution box PDU and a power battery BMS which are bidirectionally connected in sequence, the output end of the high-voltage distribution box PDU is electrically connected to the input end of the 24V lead-acid battery, the transmission structure includes a motor, a gearbox, a transmission shaft and axle which are bidirectionally connected in sequence, and the electric transmission system includes a motor, a gearbox, a transmission shaft and axle which are bidirectionally connected in sequence. The engine, gearbox and drive shaft are all electrically connected to the vehicle controller VCU, the motor is bidirectionally connected to the motor controller MCU, and an eddy current retarder is provided on the drive shaft. The eddy current retarder is designed based on the electromagnetic principle. When the retarder is working, the coil is energized to generate a strong magnetic field, and the rotor rotates with the drive shaft, cutting the magnetic lines of force in the magnetic field to generate eddy currents in the rotor disk. The magnetic field of the eddy current interacts with the magnetic field of the stator coil to generate a resistance torque, thereby achieving a deceleration effect. The retarder automatically starts when the conditions are met to ensure the normal operation of the motor and ensure that the motor's anti-drag feedback power is effective, and at the same time brakes in conjunction with the motor.
[0019] like Figure 2 and 3As shown, the eddy current retarder includes a controller, an electric retarder, a temperature control probe, a connector C1, a connector C2, a battery and a main power switch. Pin 1 of the controller is grounded, the negative pole of the battery is connected in series with the main power switch, a fuse FU is connected in series between the positive pole of the battery and pin 2 of the controller, the electric retarder, the temperature control probe and the connector C1 are connected in series between pins 3 to 6 of the controller and pins 7 to 8, pins 3 to 6 correspond to the four gears of the electric retarder in sequence, pins 7 to 8 correspond to the two channels of the temperature control probe in sequence, one end of channel 1 of the connector C2 is connected to pin 9 of the controller, and the other end is connected to an external high-power controller, and one end of channel 2 is connected to the controller One end of channel 3 is connected to pin 11 of the controller, and the other end is connected to CAN_H. One end of channel 4 is connected to pin 12 of the controller and the other end is grounded. At the same time, the eddy current retarder is connected to the 24V lead-acid battery; the motor, motor controller MCU, high-voltage distribution box PDU and power battery BMS are bidirectionally connected in sequence through the high-voltage line 1, the 24V lead-acid battery is respectively connected to the vehicle controller VCU, the high-voltage distribution box PDU and the eddy current retarder through the 24V low-voltage line 2, and the vehicle controller VCU is connected to the electric transmission system as well as the motor, gearbox and drive shaft through the low-voltage signal line 3.
[0020] The motor is driven by a high-voltage 618V system, and the eddy current retarder is driven by a low-voltage 24V system. The eddy current retarder is powered by a low-voltage system and works in coordination with the drive motor of the high-voltage system without affecting each other. The system is relatively independent, and a failure of the high-voltage system will not affect its normal operation. Its operating conditions are easy to meet, and the system operation is more stable.
[0021] Working principle: Figure 4As shown, the eddy current retarder is controlled by the vehicle controller VCU command. When the vehicle controller VCU detects that the relevant working conditions are met, it sends a command to turn it on; when the vehicle controller VCU detects that the relevant conditions are not met, it turns off the retarder. The conditions that meet the relevant working conditions include when the maximum recharge allowable current of the battery system is less than 600A, and when the motor starts to recharge energy, the eddy current retarder starts automatically, and as the brake pedal is deeply stepped on, the retarder changes from low gear to high gear. When the brake pedal opening is 0-20%, the retarder opens 1st gear, when the brake pedal opening is 20-40%, the retarder opens 2nd gear, when the brake pedal opening is 40-60%, the retarder opens 3rd gear, when the brake pedal opening is 60-100%, the retarder opens 4th gear, and the maximum torque of the retarder is 3300N.m, the requested torque of the first gear is -17%, the requested torque of the second gear is -34%, the requested torque of the third gear is -52%, and the requested torque of the third gear is -52%. The requested torque for the fourth gear is -80%; when the retarder lever is open (the retarder is generally opened when going downhill with a heavy load) and in the gear shift gap, the eddy current retarder automatically starts to ensure that there is power in the gear shift gap, ensure a smooth gear shift process, and enhance the driving experience; when the vehicle speed is greater than 30KM / H and the brake pedal opening is greater than 60%, the eddy current retarder automatically opens and is in the highest gear; when a serious fault occurs in the whole machine and the high voltage is applied, the drive motor is in a shutdown state; when the drive motor stops abnormally or does not respond to the requested torque, the eddy current retarder will start automatically and open to the maximum gear to ensure that the vehicle has a certain braking torque so that the whole machine can slow down and stop smoothly.
[0022] The above embodiments are only some embodiments of the utility model, not all embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.
Claims
1. A pure electric wide-body mining vehicle eddy current retarder safety protection system, comprising a vehicle controller VCU, a 24V lead-acid battery, an electric transmission system and a transmission structure, wherein the 24V lead-acid battery and the electric transmission system are both connected to the vehicle controller VCU, and characterized in that: The electric transmission system includes a motor controller MCU and a high-voltage distribution box PDU that are bidirectionally connected. The output end of the high-voltage distribution box PDU is electrically connected to the input end of a 24V lead-acid battery. The transmission structure includes a motor, a gearbox, a drive shaft and an axle that are bidirectionally connected in sequence. The motor, the gearbox and the drive shaft are all electrically connected to the vehicle controller VCU. The motor is bidirectionally connected to the motor controller MCU. An eddy current retarder is provided on the drive shaft, and the eddy current retarder is connected to a 24V lead-acid battery.
2. The eddy current retarder safety protection system for a pure electric wide-body mining vehicle according to claim 1 is characterized in that: The eddy current retarder includes a controller, an electric retarder, a temperature control probe, a connector C1, a connector C2, a battery and a main power switch. Pin 1 of the controller is grounded, the negative pole of the battery is connected in series with the main power switch, a fuse FU is connected in series between the positive pole of the battery and pin 2 of the controller, the electric retarder, the temperature control probe and the connector C1 are connected in series between pins 3 to 6 and pins 7 to 8 of the controller, one end of channel 1 of the connector C2 is connected to pin 9 of the controller, and the other end is connected to an external high-power controller, one end of channel 2 is connected to pin 10 of the controller, and the other end is connected to CAN_L, one end of channel 3 is connected to pin 11 of the controller, and the other end is connected to CAN_H, one end of channel 4 is connected to pin 12 of the controller, and the other end is grounded.
3. The eddy current retarder safety protection system for a pure electric wide-body mining vehicle according to claim 1 is characterized in that: The motor, the motor controller MCU, the high-voltage distribution box PDU and the power battery BMS are bidirectionally connected in sequence via a high-voltage line (1).
4. The eddy current retarder safety protection system for a pure electric wide-body mining vehicle according to claim 1 is characterized in that: The 24V lead-acid battery is respectively connected to the vehicle controller VCU, the high-voltage power distribution box PDU and the eddy current retarder via a 24V low-voltage line (2).
5. The eddy current retarder safety protection system for a pure electric wide-body mining vehicle according to claim 1 is characterized in that: The vehicle controller VCU is connected to the electric drive system, the motor, the gearbox and the drive shaft via a low-voltage signal line (3).
6. The eddy current retarder safety protection system for a pure electric wide-body mining vehicle according to claim 4 is characterized in that: The electric drive system also includes a power battery BMS, and the power battery BMS is bidirectionally connected to a high-voltage power distribution box PDU.