Mining Vehicle Brake Operation Guiding Method
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Solution Overview
Problem
In electrically-driven mining vehicles, the frequent use of mechanical brake devices leads to excessive wear of brake pads, as their braking performance differs significantly from regenerative brake devices, especially at high speeds, necessitating a method to reduce mechanical brake usage.
Innovation Solution
An electrically-driven mining vehicle equipped with an obstacle detector, speed detector, alarm system, and vehicle control device that determines collision risks and outputs warnings to operators to use either the regenerative brake or cooperative brake pedals based on calculated collision avoidance limits, minimizing mechanical brake activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the mechanical brake device is frequently used for stopping the vehicle, then the stopping performance is improved, but the brake pad wear increases
Solution Approach 1:
The braking function is segmented into two distinct systems: regenerative braking for normal stopping operations and mechanical braking for emergency situations. The control device separates the braking demands by detecting obstacle distance and vehicle speed, directing normal braking to the regenerative system and reserving mechanical braking only for critical scenarios, thereby reducing brake pad wear while maintaining stopping performance.
Solution Approach 2:
The system changes the operational parameters of the braking system based on detected conditions. When obstacle distance and vehicle speed indicate a non-critical situation, the regenerative brake is activated with higher braking force. Only when parameters indicate emergency conditions does the mechanical brake engage, optimizing the distribution of braking efforts to minimize wear.
2Loss of substance
If the regenerative brake device is used for normal stopping, then the mechanical brake wear is reduced, but the braking performance at high speed is insufficient
Solution Approach 1:
The control device dynamically adjusts the braking strategy based on real-time detection of vehicle speed and obstacle distance. At high speeds with sufficient stopping distance, the system dynamically selects regenerative braking to reduce wear. When speed increases or distance decreases, the system dynamically transitions to or combines with mechanical braking to ensure adequate stopping performance.
Solution Approach 2:
The system creates a hybrid braking approach where the regenerative brake handles the majority of braking demands under normal conditions, copying the stopping function. The mechanical brake serves as a backup copy that activates only when the regenerative system's performance becomes insufficient at high speeds, ensuring both wear reduction and adequate performance.
3Speed
If the cooperative braking is operated, then the stopping distance is reduced, but the mechanical brake usage frequency increases
Solution Approach 1:
The control device continuously monitors obstacle distance and vehicle speed, providing feedback to determine the appropriate braking mode. This feedback mechanism allows the system to assess whether cooperative braking is truly necessary or if regenerative braking alone suffices, reducing unnecessary mechanical brake activation while maintaining adequate stopping distances.
Solution Approach 2:
The system performs preliminary assessment of the braking situation by detecting obstacle distance and vehicle speed before activating any braking mode. This preliminary action allows the control device to predict whether cooperative braking will be needed, and if not, to prepare for regenerative braking only, thereby preventing unnecessary mechanical brake usage while ensuring stopping distance requirements are met.
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 approach decreases the frequency of mechanical brake use, reducing brake pad wear by optimizing the operation of regenerative and mechanical brakes based on speed and collision risk assessments, thereby extending brake pad life.
Implementation Method 1
an obstacle detector that detects a relative distance from the electrically-driven mining vehicle to an obstacle forward in a traveling direction and a relative speed of the obstacle to the electrically-driven mining vehicle
Implementation Method 2
a regenerative brake device used in normally stopping the vehicle
Data Source
Figure 1
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AI summary
An electrically-driven mining vehicle includes an obstacle detector, a speed detector, and an alarm. The alarm outputs a first warning, which urges an operator of the electrically-driven mining vehicle to operate a regenerative brake pedal that actuates only the regenerative brake device, and a second warning, which urges the operator to operate a cooperative brake pedal that uses the regenerative brake device and the mechanical brake device in combination. If the travel speed of the vehicle is included in a low speed range in which no difference can be considered to exist in distance between a first braking distance upon actuation of only the regenerative brake device and a second braking distance upon operation of a cooperative braking, a signal for performing the first warning is outputted earlier by at least a warning time interval.