Electric Compressor Drive for Rock Drilling Rig Fuel Reduction
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Solution Overview
Problem
Rock drilling rigs experience significant loading and increased fuel consumption due to the compressor system, which is typically driven by the combustion engine, leading to inefficient energy use and potential overproduction of compressed air.
Innovation Solution
The implementation of an electrically driven compressor system, utilizing stored energy from batteries or energy storage, allowing independent operation of the compressor and adjusting power output based on drilling needs, thereby reducing the load on the combustion engine and optimizing fuel consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the compressor is driven by the combustion engine, then the compressor can operate continuously, but the fuel consumption and engine loading increase significantly
Solution Approach 1:
The battery stores electrical energy in advance during periods when compressed air is not needed or when the engine is under light load, so that the compressor can be powered by the battery during drilling operations without increasing fuel consumption. This preliminary energy storage resolves the contradiction by decoupling compressor operation from continuous engine running.
Solution Approach 2:
The system dynamically switches between engine-driven generator mode and battery-driven compressor mode based on real-time energy availability and drilling requirements. This dynamic operation allows the compressor to run continuously when needed while the engine operates only when necessary for power generation, optimizing fuel consumption while maintaining operational continuity.
2Reliability
If the compressor runs continuously to ensure pressurized air availability, then air supply reliability is maintained, but unnecessary compressed air production increases energy waste
Solution Approach 1:
The control system continuously monitors the drilling unit's compressed air consumption and adjusts the compressor operation accordingly. When drilling is active, the compressor runs on battery power to meet the increased demand. When drilling stops or air consumption drops, the compressor reduces or stops operation, preventing unnecessary energy waste while ensuring air availability during actual drilling operations.
3Power
If a high-power combustion engine is used to drive the compressor, then sufficient power is available, but the engine size and cost increase
Solution Approach 1:
The power supply system is segmented into two independent sources: a compact battery-electric system dedicated to the compressor and a smaller combustion engine-generator system for auxiliary power needs. This segmentation allows the use of a much smaller, less expensive combustion engine while the battery handles the high-power compressor loads, resolving the contradiction between power availability and engine size.
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 decreases fuel consumption and engine loading by allowing precise control of compressed air production, enabling the use of smaller, less expensive engines and reducing unnecessary air production during non-drilling operations, thus enhancing energy efficiency and reducing costs.
Implementation Method 1
the electric compressor drive motor is driven only by means of electric energy received from the energy storage
Implementation Method 2
The compressor is driven by one or more electric motors
Data Source
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AI summary
The invention relates to a rock drilling rig and a method of driving a compressor. The rock drilling rig (1) is combustion engine (DI) operated and is provided with a flushing system (FS) including a compressor (CO) for producing pressurized air. The compressor is driven by an electric drive motor (CM). The combustion engine is connected to drive a generator (GEN) which produces electric energy that is stored in an energy storage (BAT). The stored electric energy can be utilized in driving the compressor.