High-voltage power distribution system of pure electric direct-current high-voltage electric drive mine truck

Abstract

The utility model relates to the technical field of power distribution systems, in particular to a high-voltage power distribution system of a pure electric direct-current high-voltage electric drive mine truck, which comprises a charging seat and a battery heating film in the power distribution system, and the charging seat and the battery heating film are both connected with a battery, a high-voltage box and a step-down converter through wire harnesses. The high-voltage box is connected with the two single main drives, and the two single main drives are connected with motors. The step-down converter is connected with a motor set, a PTC, an air conditioner and two water cooling units through wires, and the motor set comprises a steering oil pump motor, a brake air pump motor and a DCDC output machine.

Description

TECHNICAL FIELD

[0001] The utility model relates to the technical field of power distribution system, concretely to a high voltage power distribution system of pure electric direct current high voltage electric drive mine truck. BACKGROUND

[0002] The pure electric mine truck is a large engineering vehicle driven by a battery and a motor, and is mainly used for material transportation in mines and other places. It realizes the electrification of the power system on the basis of the traditional fuel mine truck, has the remarkable characteristics of environmental protection, energy saving and high efficiency, and is an important direction of green transformation in the mine transportation field.

[0003] However, the large electric vehicle in the prior art usually needs to be assembled with a power battery (group) with super large capacity, high voltage, large current and multiple branches. The conventional technology adopts a power supply system with a rated voltage of 650V direct current and a full charge voltage of 750V direct current, an IGBT module with a withstand voltage level of 1200V and a supporting drive system for a motor controller MCU, and the highest allowable voltage of the MCU itself is 750V direct current. This power supply system itself is used on the pure electric mine truck product, and the overall system driving efficiency is low, the line heating loss is large, and the traditional power supply system cannot adapt to the rated 800V and the highest voltage 1000V direct current charging system. UTILITY MODEL CONTENTS

[0004] The utility model aims at providing a high voltage power distribution system of pure electric direct current high voltage electric drive mine truck to solve the problems in the above background technology.

[0005] To achieve the above-mentioned purpose, the utility model provides the following technical scheme:

[0006] A high voltage power distribution system of pure electric direct current high voltage electric drive mine truck, including the charging seat and battery heating film in the power distribution system, the charging seat and battery heating film all are connected with the battery, high voltage box and step-down converter through the wire harness, the high voltage box is connected with two single main drives respectively, and the two single main drives are all connected with the motor;

[0007] The step-down converter is connected with the motor set, PTC, air conditioner and two water cooling units through wires respectively, and the motor set includes a steering oil pump motor, a brake air pump motor and a DCDC output machine.

[0008] As a preferred scheme of the utility model, the battery output end is a 869.4V rated voltage platform, and the peak voltage is 985V direct current.

[0009] As a preferred scheme of the utility model, the power of the step-down converter (5) is 50kw, the rated 869V is reduced to 600V direct current, and the power supply is provided for the electric accessory controller.

[0010] As the preferred scheme of the utility model, the matching motor controller MCU adopts the next generation 1400V SiC-Mosfet or 1700V Si-IGBT high-efficiency electric control device, and the overall product voltage of MCU is raised to 1000V rated DC voltage.

[0011] As the preferred scheme of the utility model, the heavy charging system of the power distribution system adopts a 360kw DC charging pile, a double-pile parallel charging scheme, and simultaneously realizes four-gun charging compatible with the national standard 800A, 720kw supercharging, and double-gun liquid-cooled charging 800-1000A DC supercharging.

[0012] As the preferred scheme of the utility model, the high-voltage box is respectively connected with a power battery and a six-in-one module, and the six-in-one module is respectively electrically connected with a cooling unit, a steering pump, a pumping pump, a DCDC module, a compressor and a driving motor.

[0013] As the preferred scheme of the utility model, the battery capacity is 698.99kwh, the rated voltage is 869.4v, the electric control is 1700V / 900A, the peak current is 500Arms, the driving motor is 500kw / 800kw motor, and the peak torque is 2400Nm.

[0014] Compared with the prior art, the utility model has the beneficial effects that: in view of the problems in the background art, the application realizes that the energy consumption of the whole vehicle is reduced by more than 10% under the same heavy load uphill working condition compared with the original vehicle of the same level, and the motor and key technology of the AC 460VAC and above voltage platform are realized. The motor of 460VAC and above voltage is 21% higher in voltage and 21% lower in current compared with the 380VAC motor under the condition of the same power and electromagnetic torque output. The overall I2*R loss distribution on the motor, controller and cable harness will be greatly reduced. The 800V high-voltage platform technology is continuously heating up in the market. The pure electric commercial vehicle is currently in the technical reserve or prototype development stage of the 800V and above high-voltage platform. According to the characteristics of the pure electric mine truck transportation scene of heavy load uphill and downhill, it is required to continuously reduce the energy consumption of the vehicle, improve the safety and stability of the vehicle, and the super-fast charging system under the condition of large power, so as to improve the voltage of the vehicle end, improve the charging efficiency, and realize the operation frequency demand of the customer. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 It is the circuit system diagram of the utility model.

[0016] In the figure: 1, charging seat; 2, battery heating film; 3, battery; 4, high-voltage box; 5, voltage converter. DETAILED DESCRIPTION

[0017] The technical scheme in the utility model embodiment will be clearly and completely described below with reference to the utility model embodiments.

[0018] Embodiment 1

[0019] Please refer to Figure 1 The utility model provides a technical scheme: a high voltage power distribution system of a pure electric direct current high voltage electric drive mine truck, including a charging seat 1 and a battery heating film 2 in the power distribution system, the charging seat 1 and the battery heating film 2 are connected with a battery 3, a high voltage box 4 and a step-down converter 5 through a wire harness, the high voltage box 4 is connected with two single main drives respectively, and the two single main drives are both connected with a motor.

[0020] The step-down converter 5 is connected with a motor set, a PTC, an air conditioner and two water cooling units through wires respectively, and the motor set includes a steering oil pump motor, a brake air pump motor and a DCDC output machine.

[0021] The matched motor controller adopts an IGBT module with a voltage resistance level of 1700V direct current, improves the voltage resistance requirement of overall internal devices, adopts a 50kw power step-down DCDC, realizes step-down from a rated 869V to 600V direct current, and powers an electric accessory controller; the charging system adopts a 360kw direct current charging pile, a double pile parallel charging scheme, realizes 600kw direct current supercharging, synchronously realizes four gun charging compatible with national standard 800A, 720kw supercharging, and double gun liquid cooling charging 800-1000A direct current supercharging. Realize that the battery charging is from the electric quantity soc20% to soc90%, and the charging time is within 50 minutes; and realize that the vehicle energy consumption is reduced by 10% or more than the original vehicle model with the same level of electric quantity under the same heavy load uphill working condition; AC 460VAC and above voltage platform motor and key technology. The motor with 460VAC and above voltage is compared with the 380VAC motor, and under the condition of the same power and electromagnetic torque output, the voltage is increased by 21%, and the current is decreased by 21%. The overall I2*R loss distribution on the motor, the controller and the cable wire harness will be greatly reduced.

[0022] All electrical elements in the embodiment are controlled through a conventional controller.

[0023] The battery 3 adopts 3 branches, 3*(3*AD02+AD04) boxes, and the electric quantity is 698.99kwh, and the rated voltage 869.4v meets the power requirement of the mine truck.

[0024] Embodiment, please refer to Figure 1, the battery 3 output end is 869.4V rated voltage platform, peak voltage 985V DC, the power of the voltage converter 5 is 50kw, and the rated 869V is reduced to 600V DC to power the electric accessory controller, and the supporting motor controller MCU adopts the next generation 1400V Si C-Mosfet or 1700V Si-IGBT high-efficiency electric control device, and the overall product voltage of the MCU is raised to 1000V rated DC voltage, and the power distribution system adopts a power of 360kw DC charging pile, a double-pile parallel charging scheme, and simultaneously realizes four-gun charging compatible with the national standard 800A, 720kw supercharging, and double-gun liquid-cooled charging 800-1000A DC supercharging, the high-voltage box (4) is connected with the power battery and the six-in-one module respectively, and the six-in-one module is electrically connected with the cooling unit, the steering pump, the inflator pump, the DCDC module, the compressor and the driving motor respectively. The battery (3) has an electric quantity of 698.99kwh and a rated voltage of 869.4v; the electric control is 1700V / 900A, and the peak current is 500Arms; and the driving motor is 500kw / 800kw motor, and the peak torque is 2400Nm.

[0025] Embodiment 2, the basic technical scheme adopted is basically the same as that of embodiment 1, and the difference lies in that a waterway arrangement technical architecture is provided, and the specific embodiments are as follows:

[0026] Power battery cooling waterway arrangement and battery box waterway design: in the 800V platform 105T and 130T vehicle models, the power battery adopts a liquid cooling mode, and a cooling water pipe is arranged in each battery box to circulate the cooling liquid to cool the battery. For example, the 3-branch battery box of the 105T vehicle model and the 4-branch battery box of the 130T vehicle model are designed to have a reasonable cooling water pipe layout to ensure that the heat generated by the battery during high-power charging and discharging can be dissipated in time.

[0027] Connection of battery box and integrated thermal management unit: the cooling water pipe of the power battery is connected with the integrated thermal management unit of the vehicle. In the high-voltage topology diagram, it can be seen that water cooling 1 (10 square, integrated thermal management unit connected with snow source) is connected with the cooling water pipe of the battery box, and the integrated thermal management unit controls the temperature of the battery through the cooling liquid circulation system to keep the battery within the optimal working temperature range.

[0028] High-voltage system cooling waterway arrangement and high-voltage box cooling: as the core component of the high-voltage power distribution system, the cooling waterway arrangement of the high-voltage box is also very important. In the 1000V platform vehicle high-voltage topology diagram, the high-voltage box (BDU) is connected with water cooling 1, and the heat generated by the high-voltage box during operation is taken away through the circulation of the cooling liquid to ensure the stable operation of the high-voltage box.

[0029] Motor Controller Cooling: The motor controller (such as the MCU in the high-voltage platform five-in-one) generates a large amount of heat during operation, requiring an effective cooling system. In the high-voltage topology diagram, it can be seen that the motor controller is connected to the water cooling 2 (16 square, plugging), and the cooling liquid circulates in the radiator of the motor controller, reducing its operating temperature and ensuring the efficient operation of the motor controller.

[0030] Vehicle Cooling Water Circuit Integration and Cooling Liquid Circulation System: The entire mine truck's cooling water circuit forms a complete circulation system, including the cooling water pipes of key components such as power batteries, high-voltage boxes, motor controllers, and the main pipes connecting these components. The cooling liquid circulates in the system under the action of the water pump, and after being cooled by the radiator, it enters each component again for cooling.

[0031] Radiator and Fan Arrangement: In the overall arrangement scheme of the vehicle, the arrangement of the radiator and fan needs to consider the cooling effect and space utilization. For example, in the arrangement scheme of the 130T vehicle model, the position of the radiator and fan is designed to ensure that there is enough air flow through the radiator to improve cooling efficiency, while not affecting the arrangement of other components of the vehicle and driving performance.

[0032] Necessary Explanation of Water Pipe Arrangement Method and Characteristics, Water Pipe Layout: The arrangement of water pipes on the vehicle should avoid sharp bends and intersections as much as possible to reduce the resistance of cooling liquid flow. In the power battery arrangement scheme, the water pipe is drawn out from the battery box and follows the vehicle body frame or a specially designed pipe to connect to the integrated thermal management unit and other cooling components.

[0033] Water Pipe Fixing and Protection: Water pipes need to be fixed on the vehicle body through clamps, supports, and other methods to prevent loosening or damage due to vibration during vehicle driving. At the same time, the water pipe should have protective measures outside to avoid contact with high-temperature components or sharp objects and prevent cooling liquid leakage.

[0034] Water Pipe Interface Design: The water pipe interface should use reliable sealing technology to ensure that the cooling liquid does not leak at the interface. In the high-voltage topology diagram, it can be seen that the cooling water pipe interfaces of each component are designed with sealing rings or other sealing devices to ensure the sealing of the system.

[0035] Optimization and Adjustment of Water Circuit Arrangement Necessary Explanation, Adjustment of Water Circuit Arrangement According to Vehicle Model: For different tonnage and configuration of mine truck models, the water circuit arrangement scheme needs to be adjusted accordingly. For example, the 130T vehicle model has larger battery capacity and more components, so its cooling water pipe diameter, length, and layout may need to be more optimized than the 105T vehicle model to meet higher cooling requirements.

[0036] Consider the special arrangement of the extended range vehicle: in the extended range vehicle, due to the small gap between the range extender and the motor, the water pipe arrangement needs to be more compact and reasonable. In the arrangement scheme of the 130T extended range vehicle, the layout and interface position of the water pipe need to fully consider the space limitation to ensure that the installation and operation of the range extender and the motor are not affected.

[0037] Through the above water route arrangement scheme, the high-voltage power distribution system and related components of the pure electric direct-current high-voltage electric drive mining truck can be effectively cooled, and the stable operation and performance of the vehicle under various working conditions can be ensured.

[0038] The working process of the utility model: in use, the current enters the system from the charging seat 1, is distributed through the high-voltage box 4, and charges the battery 3. The high-voltage direct-current power output by the battery 3 is transmitted to the two single main drives through the wire harness to drive the motor to operate. At the same time, the electric energy of the battery 3 is also transmitted to the step-down converter 5 to reduce the voltage from 869V to 600V direct current, and to supply power to the motor set (including the steering oil pump motor, the brake air pump motor, the DCDC output machine), the PTC, the air conditioner and the two water cooling units and other low-voltage accessories.

[0039] In the low-temperature environment in winter, the battery heating film 2 starts to heat the battery 3, so that the battery works in the appropriate temperature range and maintains its performance and service life. Each component in the high-voltage power distribution system, such as the high-voltage box 4 and the motor controller, is cooled by the water cooling system. The cooling liquid circulates in the cooling water pipes of the power battery, the high-voltage box, the motor controller and other components under the drive of the water pump, absorbs and carries away the heat. Then, the cooling liquid is cooled by the radiator, and after the temperature is reduced, it enters the cycle again to ensure the stability and reliability of the system during high-power operation.

[0040] The cooling water circuit of the whole vehicle forms a complete circulation system, the water pipe arrangement is reasonable, the sharp bends and intersections are avoided, and the cooling liquid flow resistance is reduced. The water pipe is fixed on the vehicle body by means of clamp, support and other methods, and protective measures are taken to prevent the cooling liquid from leaking. The water pipe interface adopts reliable sealing technology to ensure the sealing of the system. According to different tonnage and configuration of the mining truck, the water route arrangement scheme is adjusted accordingly to meet the cooling demand. In the extended range vehicle, the water pipe arrangement is more compact and reasonable, fully considering the space limitation to ensure that the installation and operation of the range extender and the motor are not affected.

[0041] By optimizing the current, switching frequency and loss control, the overall efficiency of the electric control system is improved, the energy consumption of the whole vehicle is reduced by more than 10% compared with the original vehicle of the same level under the same heavy load uphill working condition, and the economy and environmental protection of the vehicle are improved.

[0042] Although the embodiments of the present application have been shown and described, it is to be understood that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present application, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-voltage power distribution system for a pure electric DC high-voltage driven mining truck, comprising a charging base (1) and a battery heating film (2) in the power distribution system, characterized in that: The charging base (1) and the battery heating film (2) are connected to the battery (3), the high voltage box (4) and the step-down converter (5) through wiring harnesses. The high voltage box (4) is connected to two single main drives respectively, and both single main drives are connected to motors. The step-down converter (5) is connected to a motor set, a PTC, an air conditioner and two water-cooled units via wires, and the motor set includes a steering oil pump motor, a brake air pump motor and a DC-DC output unit.

2. The high-voltage power distribution system for a pure electric DC high-voltage driven mining truck according to claim 1, characterized in that: The battery (3) has a rated voltage platform of 869.4V and a peak voltage of 985V DC at its output terminal.

3. The high-voltage power distribution system for a pure electric DC high-voltage driven mining truck according to claim 1, characterized in that: The step-down converter (5) has a power of 50kW and steps down the rated 869V to 600V DC to power the electrical accessory controller.

4. The high-voltage power distribution system for a pure electric DC high-voltage driven mining truck according to claim 1, characterized in that: The matching motor controller MCU adopts next-generation 1400V SiC-Mosfet or 1700V Si-IGBT high-efficiency electronic control devices, and the overall MCU product withstand voltage is increased to 1000V rated DC voltage.

5. The high-voltage power distribution system for a pure electric DC high-voltage driven mining truck according to claim 1, characterized in that: The power distribution system's heavy-duty charging system adopts a 360kW DC charging pile, a dual-pile parallel charging scheme, and simultaneously achieves four-gun charging compatible with the national standard 800A, 720kW supercharging, and dual-gun liquid-cooled charging 800~1000A DC supercharging.

6. The high-voltage power distribution system for a pure electric DC high-voltage driven mining truck according to claim 1, characterized in that: The high-voltage box (4) is connected to the power battery and the six-in-one module respectively, and the six-in-one module is electrically connected to the cooling unit, steering pump, air pump, DC-DC module, compressor and drive motor respectively.

7. The high-voltage power distribution system for a pure electric DC high-voltage driven mining truck according to claim 1, characterized in that: The battery (3) has a capacity of 698.99 kWh and a rated voltage of 869.4 V; the electronic control is 1700 V / 900 A with a peak current of 500 Arms; the drive motor is a 500 kW / 800 kW motor with a peak torque of 2400 Nm.

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