A 15-ton battery-powered drive system for a scraper and a scraper thereof

Abstract

The utility model relates to the field of engineering machinery, especially a 15-ton battery scraper power drive system and scraper thereof. The system comprises a battery energy storage module, a power drive module, a control system and a thermal management system: the battery energy storage module contains a battery pack and a BMS battery management system, ensuring power supply and safety; the power drive module adopts an independent drive structure of double permanent magnet synchronous motor + double gearbox, realizing differentiated power output of left and right drive wheels; the control system coordinates each module through a VCU main controller, supporting working condition adaptive power distribution and fault redundant switching; the thermal management system integrates motor cooling, battery thermal management, hydraulic oil cooling and air conditioning refrigeration circuit, realizing energy cascade utilization. The utility model improves the reliability and energy efficiency of the scraper, reduces operating costs, completely eliminates exhaust pollution and most of the noise of the internal combustion engine, realizes zero emission and reduces noise, and improves the underground working environment.

Description

Technical Field

[0001] This utility model relates to the field of engineering machinery, and in particular to a 15-ton battery-powered loader power drive system and the loader itself. Background Technology

[0002] In underground mining, internal combustion engine-driven loaders are one of the core production equipment. However, with the increase in mining depth and stricter environmental protection requirements, the drawbacks of internal combustion engine loaders have become increasingly apparent: First, their exhaust gases contain a large number of harmful substances, seriously polluting the air in the confined underground space and endangering the health of workers; second, internal combustion engines have low energy conversion efficiency, with more than 60% of fuel energy being dissipated as heat, causing a sharp increase in the underground ambient temperature and greatly increasing the load and energy consumption of the mine ventilation system; third, internal combustion engines generate enormous noise, worsening the working environment; and finally, diesel fuel is expensive, and engine maintenance is frequent, resulting in high overall operating costs.

[0003] Currently, although there have been attempts to adopt electric motors or alternative fuels, these solutions suffer from problems such as poor mobility, complex infrastructure, or incomplete emission reduction. Therefore, there is an urgent need for a new type of power solution for loaders that can completely solve these problems. Summary of the Invention

[0004] The purpose of this utility model is to overcome the shortcomings of the existing technology and provide a 15-ton battery-powered loader power drive system, including: A battery energy storage module, comprising a battery pack and a battery management system (BMS), wherein the BMS is used to monitor the status of the battery pack. The power drive module includes two permanent magnet synchronous motors, two motor controllers electrically connected to the permanent magnet synchronous motors, and two gearboxes connected to the output shafts of the permanent magnet synchronous motors. The outputs of the two gearboxes drive the left and right drive wheels respectively, achieving independent drive. The control system is communicatively connected to the battery energy storage module and the power drive module, and is used to control the power distribution and operating status of the vehicle. Thermal management system, the system comprising: A motor cooling circuit is used to circulate coolant to cool the permanent magnet synchronous motor and the motor controller; The battery thermal management circuit is used to regulate the temperature of the power battery pack of the loader; Hydraulic oil cooling circuit, used to cool the hydraulic oil in the hydraulic system of the loader.

[0005] Furthermore, the control system can control two permanent magnet synchronous motors to work simultaneously or only one of them to work according to the working condition command, and automatically switch to the other drive system to maintain vehicle operation when a failure is detected in one of the drive systems.

[0006] Furthermore, the thermal management system also includes an air conditioning refrigeration circuit. The evaporator of the air conditioning refrigeration circuit is provided with a first branch air duct and a second branch air duct. The first branch air duct leads to the cab of the loader, and the second branch air duct leads to the battery energy storage module. The direction of the cold air flow is controlled by a damper.

[0007] Furthermore, an oil cooler is provided on the hydraulic oil cooling circuit, and part of the cold air from the second branch air duct is guided to the oil cooler to cool the hydraulic oil.

[0008] Furthermore, the thermal management system also includes a plate heat exchanger connected between the motor cooling circuit and the battery thermal management circuit for heat exchange between the motor cooling circuit and the battery thermal management circuit.

[0009] Furthermore, the control system includes a VCU main controller, a human-machine interface, and an autonomous driving subsystem. The VCU main controller coordinates the work of each module, and the autonomous driving subsystem supports remote control or automatic operation.

[0010] The present invention also proposes a power drive system for a 15-ton battery loader.

[0011] Compared with the prior art, the beneficial effects of this utility model are: it completely eliminates exhaust pollution and most of the noise from internal combustion engines, achieving zero emissions and reducing noise, thus improving the working environment underground; the dual-motor drive architecture provides power redundancy, avoiding vehicle paralysis caused by single-point failure; the electric drive system is highly efficient, with heat dissipation far lower than that of internal combustion engines, significantly reducing mine ventilation costs, and electricity costs are far lower than diesel costs; moreover, the motor structure is simple, which also reduces maintenance costs. Attached Figure Description

[0012] Figure 1 This utility model provides a flowchart of a power drive system for a 15-ton battery-powered loader. Detailed Implementation To make the objectives and advantages of this utility model clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0013] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0014] It should be noted that in the description of this utility model, the terms "upper", "lower", "left", "right", "inner", "outer", etc., indicating the direction or positional relationship are based on the direction or positional relationship shown in the drawings. This is only for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this utility model.

[0015] Furthermore, it should be noted that, in the description of this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0016] The present application will be further described in detail below with reference to the accompanying drawings.

[0017] like Figure 1 As shown in the flowchart, a 15-ton battery-powered loader power drive system includes a battery energy storage module, a power drive module, a control system, and a thermal management system. The modules work together to achieve power supply and precise control of the entire vehicle.

[0018] The battery energy storage module provides the core electrical energy for the entire vehicle, including the battery pack and the BMS (Battery Management System). The battery pack uses high-energy-density lithium iron phosphate or ternary lithium batteries, configured according to the power requirements of the 15-ton loader, and achieves high-voltage DC output through series and parallel connections. The BMS acts as the "brain" of the battery pack, monitoring key status parameters in real time such as individual cell voltage, total voltage, charging and discharging current, temperature, and SOC (State of Charge). It also features overcharge, over-discharge, over-temperature, and overcurrent protection, as well as equalization control functions, ensuring safe and stable battery operation and extending its service life.

[0019] The power drive module adopts a dual-motor independent drive structure, including two permanent magnet synchronous motors, two motor controllers, and two gearboxes. Permanent magnet synchronous motors offer advantages such as high power density, high efficiency, and fast response speed. Each motor has a rated power of no less than 160kW, meeting the heavy-duty requirements of the loader for loading, climbing, and other demanding tasks. The two motor controllers are electrically connected to their respective permanent magnet synchronous motors, receiving command signals from the control system and converting the DC power output from the battery energy storage module into frequency- and voltage-adjustable AC power to achieve precise control of motor speed and torque. The two gearboxes, using either a fixed-shaft or planetary structure, are rigidly connected to the output shaft of the permanent magnet synchronous motors via flanges. Through gear reduction and torque amplification, they drive the left and right drive wheels of the loader respectively, forming independent drive units. This dual-drive structure enables differentiated power output to the left and right drive wheels, improving the overall machine's steering flexibility and providing a structural basis for fault redundancy.

[0020] The control system is the core of the vehicle control system. It establishes communication connections with the battery energy storage module and the power drive module via CAN bus or Ethernet to realize data interaction and command transmission, and is used to control the power distribution and operating status of the entire vehicle. Specifically, the control system includes the VCU main controller, the human-machine interface, and the autonomous driving subsystem: The VCU main controller, as the "central processing unit," receives status data (such as battery SOC, motor temperature, drive wheel speed, etc.) and operating condition commands (such as forward, reverse, steering, loading, etc.) from various modules, calculates the optimal power distribution scheme through built-in control strategies, and sends control commands to the motor controller, BMS, etc.; The human-machine interface uses a touch screen display, integrates operation buttons and status indicator lights, and realizes functions such as operation mode selection, parameter setting, and fault alarm, allowing the driver to keep track of the vehicle status in real time; The autonomous driving subsystem supports remote control or automatic operation. By integrating LiDAR, high-definition cameras, GPS / BeiDou positioning modules, and inertial navigation units, it realizes functions such as path planning, obstacle recognition, and automatic loading / unloading, which is suitable for unmanned operation in hazardous conditions and improves operational safety.

[0021] The control system also features intelligent power regulation and fault redundancy: based on operating conditions (such as light-load transport, heavy-load loading, hill climbing, etc.), the VCU main controller can control two permanent magnet synchronous motors to work simultaneously to output maximum power, or control only one of the permanent magnet synchronous motors to work to reduce energy consumption; when the system detects a fault in one of the drive systems (motor, controller, or gearbox), the VCU main controller immediately triggers the fault redundancy mechanism, automatically cuts off the power output of the faulty unit, and at the same time increases the power response speed of the other drive system to maintain basic vehicle operation and ensure continuous operation.

[0022] The thermal management system is an integrated multi-loop design that enables coordinated temperature control of the motor, battery, hydraulic oil, and cab, improving energy utilization and overall environmental adaptability. It includes a motor cooling circuit, a battery thermal management circuit, a hydraulic oil cooling circuit, and an air conditioning cooling circuit.

[0023] The motor cooling circuit adopts liquid cooling heat dissipation, which consists of a cooling water pump, radiator, fan and connecting pipes. The coolant (using ethylene glycol aqueous solution) circulates in the circuit, flows through the water jacket of the permanent magnet synchronous motor and the heat dissipation cavity of the motor controller, absorbs the heat generated during motor operation, and then exchanges heat with the outside air through the radiator. After cooling down, it re-enters the heat dissipation cycle to ensure that the operating temperature of the motor and controller is maintained in the optimal range of 25-65℃. The battery thermal management circuit achieves bidirectional heating or cooling regulation based on battery charging / discharging and ambient temperature requirements. The circuit integrates an electric heater, a plate heat exchanger, and a circulating water pump. When the ambient temperature is below 5℃, the electric heater activates to heat the coolant, raising the battery pack temperature via the heat exchange plates within the battery pack. When the battery temperature exceeds 35℃, heat exchange occurs between the plate heat exchanger and the motor cooling circuit. Waste heat recovery from the motor or cooling from the subsequent air conditioning circuit is utilized to cool the battery pack, ensuring the battery operating temperature is maintained between 15-35℃, thus guaranteeing charging / discharging performance and safety. Because the hydraulic oil in the hydraulic system of a loader (responsible for lifting, tilting, and other actions of the bucket) is prone to overheating during high-frequency operation, an oil cooler is installed in the hydraulic oil cooling circuit as a core heat dissipation component. When the hydraulic oil flows through the oil cooler, it exchanges heat with the cooling medium to achieve temperature control and prevent the hydraulic oil from deteriorating due to high temperature, which could lead to damage to the seals or a decrease in system efficiency.

[0024] The air conditioning refrigeration circuit consists of a compressor, condenser, evaporator, and throttling element, used for cooling the cab and providing auxiliary heat dissipation. The evaporator outlet has a first branch air duct and a second branch air duct. The first branch air duct leads to the cab via a duct, directly providing the driver with a comfortable working environment. The second branch air duct leads to the power battery pack of the battery energy storage module, and the direction of the cold air flow is controlled by an electric damper to achieve active cooling of the power battery pack. Furthermore, a branch of the second branch air duct leads to the oil cooler of the hydraulic oil cooling circuit, guiding some of the cold air to the surface of the oil cooler. Forced convection improves the heat dissipation efficiency of the hydraulic oil, achieving cascaded utilization of cooling capacity.

[0025] This invention is not limited to the specific embodiments described above. Any modifications made by those skilled in the art based on the above concept without creative effort are within the protection scope of this invention.

Claims

1. A power drive system for a 15-ton battery-powered loader, characterized in that, include: A battery energy storage module, comprising a battery pack and a battery management system (BMS), wherein the BMS is used to monitor the status of the battery pack. The power drive module includes two permanent magnet synchronous motors, two motor controllers electrically connected to the permanent magnet synchronous motors, and two gearboxes connected to the output shafts of the permanent magnet synchronous motors. The outputs of the two gearboxes drive the left and right drive wheels respectively, and the left and right drive wheels are driven independently. The control system is communicatively connected to the battery energy storage module and the power drive module, and is used to control the power distribution and operating status of the vehicle. Thermal management system, the system comprising: A motor cooling circuit is used to circulate coolant to cool the permanent magnet synchronous motor and the motor controller; The battery thermal management circuit is used to regulate the temperature of the power battery pack of the loader; Hydraulic oil cooling circuit, used to cool the hydraulic oil in the hydraulic system of the loader.

2. The system according to claim 1, characterized in that, The control system can control two permanent magnet synchronous motors to work simultaneously or only one of them to work according to the working condition command, and automatically switch to the other drive system to maintain vehicle operation when a failure is detected in one of the drive systems.

3. The system according to claim 1, characterized in that, The thermal management system also includes an air conditioning refrigeration circuit. The evaporator of the air conditioning refrigeration circuit is provided with a first branch air duct and a second branch air duct. The first branch air duct leads to the cab of the loader, and the second branch air duct leads to the battery energy storage module. The direction of the cold air flow is controlled by a damper.

4. The system according to claim 3, characterized in that, An oil cooler is provided on the hydraulic oil cooling circuit, and part of the cold air from the second branch air duct is guided to the oil cooler to cool the hydraulic oil.

5. The system according to claim 1, characterized in that, The thermal management system also includes a plate heat exchanger connected between the motor cooling circuit and the battery thermal management circuit for heat exchange between the motor cooling circuit and the battery thermal management circuit.

6. The system according to claim 1, characterized in that, The control system includes a VCU main controller, a human-machine interface, and an autonomous driving subsystem. The VCU main controller coordinates the work of each module, and the autonomous driving subsystem supports remote control or automatic operation.

7. A 15-ton battery loader, characterized in that, It is equipped with the power drive system according to any one of claims 1-6.

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