Vector Drive Control for Mining Machine Digging
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Solution Overview
Problem
Industrial machines like electric mining shovels face inefficiencies in digging operations due to suboptimal control of dig force vectors, leading to reduced performance and structural damage from events like boom-jacking and motor stalling.
Innovation Solution
Implementing a vector control system that dynamically adjusts the torque limits of motors to optimize dig force magnitude and angle, using sensors to track attachment position and dynamic forces, and controlling torque to maintain optimal force vectors within predetermined boundaries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fixed torque limits are used for motors during digging operations, then motor protection is simplified, but digging performance is suboptimal and structural damage occurs
Solution Approach 1:
The patent implements dynamic torque limit adjustment based on real-time dig force vector calculations. The controller continuously computes optimal torque limits for hoist and crowd motors by analyzing attachment position, dig force magnitude, and dig force angle, replacing fixed torque limits with dynamically adapted limits that prevent structural damage while maximizing digging performance
Solution Approach 2:
The system uses feedback from sensors tracking attachment position and motor parameters to continuously calculate and adjust torque limits. The controller receives real-time data on dig force vectors and uses this feedback to modify motor torque limits dynamically, creating a closed-loop control system that adapts to changing digging conditions
2Force
If torque limits are increased beyond traditional fixed limits, then dig force magnitude is maximized, but structural components may be damaged
Solution Approach 1:
The patent changes the torque limit parameter dynamically based on calculated dig force vectors. By adjusting torque limits as a variable parameter rather than a fixed value, the system allows higher torque when digging conditions permit (maximizing dig force) while reducing torque limits when structural stress becomes excessive, thereby optimizing both digging performance and structural protection
3Use of energy by moving object
If traditional fixed torque control is used, then control system is simple, but energy efficiency is reduced and motor stalling occurs
Solution Approach 1:
The patent replaces traditional mechanical torque control with an electronic vector control system that calculates optimal torque limits based on dig force vectors. This substitution of control methodology enables energy-efficient operation by preventing motor stalling and optimizing torque application, while the added electronic control complexity is justified by the significant energy savings and performance improvements
Data Source
AI summary
A method of controlling a digging operation of an industrial machine, the industrial machine including a dipper and an actuator. The method including determining a force associated with the actuator; determining a dig force vector for the dipper based on the force associated with the actuator, the dig force vector including a dig force angle and a dig force magnitude; determining a characteristic of the industrial machine; and controlling, using a processor, the dig force vector based on the characteristic of the industrial machine, the dig force vector being controlled by controlling at least one of the force associated with the actuator and an angle of the dipper.