Automated Battery Exchange System for Underground Mining Haulers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in underground mining is the inefficiency of recharging battery-powered ore hauler vehicles due to their continuous motion and unpredictable mechanical loads, making it impractical to provide battery charging stations at loading and unloading locations, which hinders the adoption of zero-emission vehicles.
Innovation Solution
An automated energy storage device exchange and rapid charging system that includes a central pillar, carriers, and a controller to facilitate the swapping and recharging of energy storage devices, allowing for quick detachment and reinstallation of batteries using a coupling interface with complementary shapes and energy transfer connectors, enabling automated swapping and charging without the need for continuous charging stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If battery-powered ore hauler vehicles are used for zero-emission operations, then air quality and environmental cleanliness are improved, but operational efficiency deteriorates due to excessive downtime for recharging
Solution Approach 1:
The battery system is segmented into removable energy storage devices that can be independently exchanged. The battery is divided into modular units that can be quickly detached and replaced without requiring the vehicle to remain stationary for extended recharging periods, thus maintaining operational efficiency while achieving zero-emission operations
Solution Approach 2:
Charged energy storage devices are prepared in advance at the charging station before being needed. The system performs preliminary charging actions off-site, allowing vehicles to quickly swap pre-charged batteries rather than waiting for in-situ recharging, thereby eliminating excessive downtime and maintaining high productivity
2Duration of action of moving object
If battery charging stations are provided at loading and unloading locations, then operational continuity is improved, but device complexity and cost increase
Solution Approach 1:
The charging function is extracted from the vehicle operation cycle and relocated to a separate, dedicated charging station. Energy storage devices are removed from vehicles and charged independently at centralized stations, eliminating the need for complex on-site charging infrastructure at multiple loading/unloading locations while maintaining operational continuity through rapid battery exchange
Solution Approach 2:
A centralized charging station serves as an intermediary between power sources and vehicles. Instead of equipping multiple locations with charging infrastructure, a single intermediary charging station prepares charged batteries in advance, which are then distributed to vehicles as needed, simplifying the overall system complexity while ensuring operational continuity
3Power
If high capacity batteries are used to power ore hauler for heavy loads, then vehicle capability is improved, but recharging time increases significantly
Solution Approach 1:
The high-capacity battery system is segmented into modular energy storage devices that can be independently exchanged. This segmentation allows the vehicle to use high-capacity batteries for heavy loads while enabling rapid replacement of depleted units with pre-charged modules, eliminating the time penalty associated with recharging large battery capacities
Solution Approach 2:
The system performs preliminary charging of battery modules in advance at dedicated charging stations. High-capacity batteries are charged completely before being installed in vehicles, so that when vehicles need power, they receive fully charged high-capacity units without experiencing recharging delays during operational cycles
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for the efficient swapping and rapid charging of batteries in ore hauler vehicles, reducing downtime and enabling the use of zero-emission vehicles in underground mining operations, thereby improving operational efficiency and air quality.
Implementation Method 1
at least one motor; and a controller configured to operate with the at least one motor to: rotate the carrier around the working axis
Data Source
AI summary
An apparatus for energy storage device exchange includes a central pillar; a first carrier that is mounted on the central pillar for motion generally parallel to and around a generally vertical working axis, and that is configured to engage a lifting structure of an energy storage device; at least one motor; and a controller configured to operate with the at least one motor to: rotate the first carrier around the working axis to a removal position adjacent to the lifting structure of the energy storage device mounted on a vehicle; engage the first carrier with the lifting structure and lift the energy storage device generally along the working axis; rotate the first carrier around the working axis to a deposit position adjacent to an energy storage device receptacle; and lower the first carrier generally along the working axis to deposit the energy storage device at the energy storage device receptacle.