SYSTEM AND METHOD FOR ALL ELECTRICAL OPERATION OF A MINING HAUL TRUCK
A mining haul truck driven by electrical wheel motors is operated with all electrical power sources; that is, without a diesel engine. While travelling on the loading site, the mining haul truck is powered by an on-board energy storage system, which may include a bank of ultracapacitors. The mining haul truck then moves to the bottom of a trolley ramp and is coupled to trolley lines. While travelling uphill, the mining haul truck is powered by the trolley lines, and the on-board energy storage system is charged by the trolley lines. When the mining haul truck reaches the top of the trolley ramp, the mining haul truck is uncoupled from the trolley lines. While travelling on the unloading site, the mining haul truck is powered by the on-board energy storage system. The on-board energy storage system may also be charged by retard energy generated by the wheel motors during braking.
The present application is a continuation of U.S. patent application Ser. No. 16/353,514 filed 14 Mar. 2019, which is a continuation of U.S. patent application Ser. No. 14/038,995 filed 27 Sep. 2013 in the U.S. Patent and Trademark Office, the content of which is hereby incorporated herein in their entirety.
BACKGROUND OF THE INVENTIONThe present invention relates generally to power systems for mining haul trucks, and more particularly to a system and method for all electrical operation of a mining haul truck.
Mining haul trucks are typically equipped with electrical drive motors. Under demanding conditions, such as travel on an uphill grade, electrical power can be supplied by a trolley line. The mining haul truck draws electrical power from the trolley line via a pantograph. Under some travel conditions, such as inside a mining pit, around a crusher, and on level surfaces, however, the mining haul truck operates independently of a trolley line. Electrical power is then supplied by an electrical generator powered by a diesel engine. Diesel engines require delivery and storage of a supply of fuel and require regular maintenance. The exhaust gases from diesel engines, furthermore, contribute to air pollution.
BRIEF SUMMARY OF THE INVENTIONIn an embodiment of the invention, a mining haul truck driven by electrical motors is operated from all electrical power sources, without the need for a diesel engine driving a generator. When the mining haul truck is travelling on substantially flat ground, electrical power is supplied by an on-board energy storage system. When the mining haul truck is travelling along an uphill grade, electrical power is supplied by trolley lines. The on-board energy storage system is also charged with electrical power from the trolley lines. In an embodiment of the invention, the on-board energy storage system is charged with retard energy captured from the electrical motors during braking.
These and other advantages of the invention will be apparent to those of ordinary skill in the art by reference to the following detailed description and the accompanying drawings.
In the power system shown in
The inputs of the inverters 210 and the inverters 218 can also be connected to DC power supplied by the electric substation 250 via the trolley line 230 and the trolley line 232. A trolley line is also referred to as an overhead line. Electrical connection of the mining haul truck to the trolley line 230 and the trolley line 232 is implemented via the pantograph arm 234 and the pantograph arm 236, respectively. The throw switch 240 connects/disconnects the inputs of the inverters 210 and the inverters 218 to the trolley line 230 and the trolley line 232. There is also an auxiliary breaker 238. As mentioned above, when the mining haul truck is powered by the trolley power system, the diesel engine 202 is typically disconnected from the generator 206 via the coupling 204.
In the uphill direction, the region 321 and the region 351 are connected by the trolley ramp 371, along which electrical power is available from the trolley lines 370 (for simplicity, the trolley lines 370 refer to a pair of trolley lines). In the downhill direction, the region 351 and the region 321 are connected by the trolley ramp 361, along which electrical power is available from the trolley lines 360. The trolley lines 370 and the trolley lines 360 are supported overhead by the support arms 312 mounted on the support poles 310.
In an embodiment of the invention, the mining haul truck is equipped with an on-board energy storage system (OBESS) that provides electrical power when the mining haul truck is operating within region 321 or within region 351. A diesel engine and generator are not needed. An OBESS refers to an energy storage system that travels with the mining haul truck (for example, mounted on the mining haul truck or attached to the mining haul truck or mounted on a trailer attached to the mining haul truck). In an embodiment of the invention, an OBESS includes a bank of ultracapacitors, a bank of batteries, or a bank of ultracapacitors and a bank of batteries. Further details of an OBESS are provided below. All electrical operation of the mining haul truck is first described.
Refer to travel scenario shown in
Position P 331 is the exit for the trolley ramp 371. The mining haul truck 302 is then uncoupled from the trolley lines 370. Powered by the OBESS, the mining haul truck 302 travels to position P 333 and then to the unloading site 339, where the mining haul truck 302 unloads the payload 304. The mining haul truck then departs the unloading site 339 at position P 335 and moves to position P 337, the entrance to the trolley ramp 361. The mining haul truck 302 is coupled to the trolley lines 360. Under trolley power, the mining haul truck 302 moves down the trolley ramp 361 (shown as position P 363) and arrives at position P 307. While the mining haul truck 302 is coupled to the trolley lines 360, trolley power is used to recharge the OBESS.
Position 307 is the exit for the trolley ramp 361. The mining haul truck 302 is then uncoupled from the trolley lines 360. Powered by the OBESS, the mining haul truck 302 moves to the position P 301 to start another work cycle.
Refer to travel scenario shown in
In the uphill direction, the region 451 and the region 421 are connected by the trolley ramp 471, along which trolley power is available from the trolley lines 470. In the downhill direction, the region 421 and the region 451 are connected by the trolley ramp 461, along which trolley power is available from the trolley lines 460. The trolley lines 470 and the trolley lines 460 are supported overhead by the support arms 412 mounted on the support poles 410.
Powered by an OBESS, the mining haul truck 302 starts in region 421 at position P 401 and moves to the loading site 409. At the loading site 409, an electric shovel (not shown) fills the payload 404 (such as ore) onto the mining haul truck 302, which then leaves the loading site 409 at position P 403. The mining haul truck 302 then moves to position P 405, the entrance to the trolley ramp 461. The mining haul truck 302 is coupled to the trolley lines 460. Under trolley power, the mining haul truck 302 moves down the trolley ramp 461 (shown as position P 463) and arrives at position P 431. While the mining haul truck 302 is coupled to the trolley lines 460, trolley power is used to recharge the OBESS.
Position P 431 is the exit for the trolley ramp 461. The mining haul truck 302 is then uncoupled from the trolley lines 460. Powered by the OBESS, the mining haul truck 302 travels to position P 433 and then to the unloading site 439, where the mining haul truck 302 unloads the payload 404. The mining haul truck 302 then departs the unloading site 439 at position P 435 and moves to position P 437, the entrance to the trolley ramp 471. The mining haul truck 302 is coupled to the trolley lines 470. Under trolley power, the mining haul truck 302 moves up the trolley ramp 471 (shown as position P 473) and arrives at position P 407. While the mining haul truck 302 is coupled to the trolley lines 470, trolley power is used to recharge the OBESS.
Position P 407 is the exit for the trolley ramp 471. The mining haul truck 302 is then uncoupled from the trolley lines 470. Powered by the OBESS, the mining haul truck 302 moves to the position P 401 to start another work cycle.
A method for all electrical operation of a mining haul truck is summarized in the flowchart of
In step 510, the mining haul truck is coupled to the trolley lines 1. In step 512, powered by the trolley lines 1, the mining haul truck departs region 1. In step 514, powered by the trolley lines 1, the mining haul truck travels along the trolley ramp 1. The OBESS is charged by electrical power from the trolley lines 1. In step 516, powered by the trolley lines 1, the mining haul truck arrives at region 2.
In step 518, the mining haul truck is uncoupled from the trolley lines 1. In step 520, powered by the OBESS, the mining haul truck travels within the region 2 (for example, travels to an unloading site and dumps the payload). In step 522, powered by the OBESS, the mining haul truck travels to the trolley ramp 2.
In step 524, the mining haul truck is coupled to the trolley lines 2. In step 526, powered by the trolley lines 2, the mining haul truck departs region 2. In step 528, powered by the trolley lines 2, the mining haul truck travels along the trolley ramp 2. The OBESS is charged by electrical power from the trolley lines 2. In step 530, powered by the trolley lines 2, the mining haul truck arrives at region 1. In step 532, the mining haul truck is uncoupled from the trolley lines 2. The mining haul truck has a charged OBESS and is ready to start another work cycle.
In an embodiment of the invention, the OBESS is charged with retard energy from the wheel motors. To slow down a moving mining haul truck, the mining haul truck drive system operates in a retard mode. Under normal operation, an electrical motor converts electrical energy into mechanical energy. The operating mode in which an electrical motor converts electrical energy into mechanical energy is referred to as the propel mode, and a time interval during which the electrical motor operates in a propel mode is referred to as a propel interval. An electrical motor can also be operated in reverse as a generator to convert mechanical energy into electrical energy (referred to as retard energy), which is fed into inverters. The operating mode in which the electrical motor converts mechanical energy into electrical energy is referred to as the retard mode, and a time interval during which the electrical motor operates in a retard mode is referred to as a retard interval.
Typically, braking choppers, connected to the inverters, channel the power into a power resistor grid that continuously dissipates the retard energy until the mining haul truck reaches standstill; that is, the retard energy is dissipated as waste heat. Braking is smooth, similar to the braking operation in a car, but without mechanical brake wear. Refer to the prior-art power system shown in
In an embodiment of the invention, however, an OBESS is integrated into the mining haul truck power system to recover and store the retard energy. In particular, when a mining haul truck is travelling downhill, substantial quantities of retard energy can be captured and stored (especially if the mining haul truck is carrying a heavy payload), since the mining haul truck is frequently braking, and therefore there are frequent intervals during which the wheel motors are operating in the retard mode. Depending on the terrain, retard energy can also be captured during the uphill trip; retard energy can also be captured while the mining haul truck is travelling on level ground.
The retard energy is then used to charge the OBESS. In an embodiment of the invention, the OBESS is implemented with an ultracapacitor system comprising an ultracapacitor bank. The amount of energy that can be stored in the ultracapacitor system depends on the size of the ultracapacitor bank. The OBESS can also be implemented with a rechargeable battery system comprising a battery bank. The amount of energy that can be stored in the battery system depends on the size of the battery bank. The OBESS can also be implemented with combinations of ultracapacitor banks and battery banks. Storage capacity requirements are described below.
An ultracapacitor can provide high power densities. For increased electrical energy storage, multiple ultracapacitors can be connected in series and parallel to form an ultracapacitor bank. Electrical current flowing into an ultracapacitor charges the ultracapacitor, and electrical energy is stored via charge separation at an electrode-electrolyte interface. The stored electrical energy can then later be used to output an electrical current. To maximize the lifetime of an ultracapacitor, the ultracapacitor is not fully discharged. Typically, the ultracapacitor is discharged until its voltage drops to a minimum user-defined lower voltage limit. The lower voltage limit, for example, can be one-half of the initial fully-charged voltage.
The ultracapacitor electrical energy storage unit 614 is managed by the ultracapacitor energy management controller 612. The ultracapacitor energy management controller 612 can also receive motor drive system data 628, which characterizes operation of the motor drive system 630. The motor drive system data 628 includes, for example, DC link voltage, current, and temperature. In response to control signals or control commands from the ultracapacitor energy management controller 612, the ultracapacitor electrical energy storage unit 614 can (a) transmit electrical energy to the wheel motors, (b) receive electrical energy from the trolley DC power system, or (c) receive retard electrical energy from the wheel motors. If the ultracapacitor bank becomes fully charged, excess retard energy can be dissipated in the grid resistors. Excess retard energy can also be transmitted via the trolley lines and stored in an auxiliary energy storage system or transmitted via the trolley lines and returned to the utility grid via a bidirectional electric substation (as described in US Patent Application Publication No. 2011/0094841).
An embodiment of a computational system for implementing the ultracapacitor energy management controller 612 (
The computational system 1002 comprises the computer 1006, which includes a processor [referred to as the central processing unit (CPU) 1008], memory 1010, and a data storage device 1012. The data storage device 1012 comprises at least one persistent, tangible computer readable medium, such as non-volatile semiconductor memory, a magnetic hard drive, and a compact disc read only memory. In an embodiment of the invention, the computer 1006 is implemented as an integrated device.
The computational system 1002 can further comprise a user input/output interface 1014, which interfaces the computer 1006 to a user input/output device 1022. Examples of the input/output device 1022 include a keyboard, a mouse, and a local access terminal. Data, including computer executable code, can be transferred to and from the computer 1006 via the input/output interface 1014.
The computational system 1002 can further comprise a communications network interface 1016, which interfaces the computer 1006 with a remote access network 1024. Examples of the remote access network 1024 include a local area network and a wide area network (communications links can be wireless). A user can access the computer 1006 via a remote access terminal (not shown). Data, including computer executable code, can be transferred to and from the computer 1006 via the communications network interface 1016.
The computational system 1002 can further comprise the ultracapacitor electrical energy storage unit interface 1018, which interfaces the computer 1006 with the ultracapacitor electrical energy storage unit 614 (see
As is well known, a computer operates under control of computer software, which defines the overall operation of the computer and applications. The CPU 1008 controls the overall operation of the computer and applications by executing computer program instructions that define the overall operation and applications. The computer program instructions can be stored in the data storage device 1012 and loaded into memory 1010 when execution of the program instructions is desired.
The method steps shown in the flowchart in
Required storage capacity of the OBESS can be estimated from calculations. For example, assume the following haul profile (travel scenario similar to that shown in
-
- 500 m, flat: shovel (loading site) to trolley ramp, loaded
- 2000 m, 10% grade: trolley ramp, loaded
- 500 m, flat: trolley ramp to dump (unloading site), loaded
- 500 m, flat: dump to trolley ramp, empty
- 2000 m, −10% grade: trolley ramp, empty
- 500 m, flat: trolley ramp to shovel, empty.
Each leg of the profile specifies (a) the distance travelled, (b) slope of ground, (c) travel path, and (d) payload status of the mining haul truck. The weight of the empty mining haul truck is assumed to be 160,000 kg; and the weight of the loaded mining haul truck is assumed to be 400,000 kg.
The speed and acceleration for the mining haul truck running on the above profile is shown in
From
Selection of the appropriate energy storage device is important. Mines are often located in remote locations with extreme climatic conditions. Extreme cold conditions with temperatures below −20° C. pose particular challenges. In addition, mining haul trucks are subjected to extreme shocks and vibrations. Appropriate candidates for energy storage are traction grade ultracapacitors and traction grade batteries.
Refer back to the travel scenarios shown in
Embodiments of the invention can be retrofitted into an existing mining haul truck that has a diesel engine and a generator. The diesel engine can be retained for operation under fault conditions or used to charge the OBESS while idling. In other embodiments of the invention, a mining haul truck is not equipped with a diesel engine and generator: the mining haul truck is propelled by electrical power supplied by trolley lines alone, an OBESS alone, or a combination of trolley lines and an OBESS.
Embodiments of the invention have been described with reference to a mining haul truck. One skilled in the art can develop embodiments of the invention for other vehicles driven by electrical motors.
The foregoing Detailed Description is to be understood as being in every respect illustrative and exemplary, but not restrictive, and the scope of the invention disclosed herein is not to be determined from the Detailed Description, but rather from the claims as interpreted according to the full breadth permitted by the patent laws. It is to be understood that the embodiments shown and described herein are only illustrative of the principles of the present invention and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention. Those skilled in the art could implement various other feature combinations without departing from the scope and spirit of the invention.
Claims
1.-20. (canceled)
21. An on-board energy storage system that travels with a mining haul truck, the on-board energy storage system comprising:
- an electrical energy storage unit, and
- an energy management controller configured to manage the electrical energy storage unit,
- wherein the energy management controller is configured to receive electrical data that characterize operation of a drive system configured to power electrical wheel motors of the mining haul truck.
22. The system of claim 21,
- wherein the electrical data include direct current (DC) link voltage data, current data and temperature data.
23. The system of claim 21,
- wherein the on-board energy storage system is configured to integrate with a trolley power system.
24. The system of claim 23,
- wherein, in response to control signals or control commands from the energy management controller, the electrical energy storage unit is configured to
- transmit electrical energy to the electrical wheel motors,
- receive electrical energy from the trolley power system, or
- receive retard electrical energy from the electrical wheel motors.
25. The system of claim 21,
- wherein the on-board energy storage system comprises a bank of ultracapacitors, or a bank of batteries, or combinations of ultracapacitor banks and battery banks.
26. The system of claim 25,
- wherein the bank of ultracapacitors and the bank of batteries comprise traction grade ultracapacitors and traction grade batteries.
27. The system of claim 21,
- wherein the on-board energy storage system is mounted on the mining haul truck or attached to the mining haul truck or mounted on a trailer attached to the mining haul truck.
28. The system of claim 21,
- wherein the on-board energy storage system is configured to recover and store retard energy from the electrical wheel motors generated during braking of the mining haul truck.
29. The system of claim 21,
- wherein the energy management controller comprises a processor, a memory, and a data storage device, an electrical storage unit interface for interfacing with the electrical storage unit, and a drive system interface configured to receive the electrical data.
30. The system of claim 21,
- wherein the management controller comprises a communications network interface for communicating with a remote access network, and
- wherein the management controller is accessible via the remote access network.
31. The system of claim 21,
- wherein the on-board energy storage system is configured to be retrofitted into an existing mining haul truck that has a diesel engine and a generator, wherein the diesel engine is retained for operation under fault conditions or for charging while the mining haul truck is idling.
32. A method for supplying electrical power to electrical wheel motors on an all electrically powered mining haul truck, the method comprising:
- receiving, by an electrical energy storage unit, control signals or control commands from an energy management controller, and
- in response to the control signals or control commands, by the electrical energy storage unit, transmitting electrical energy to the electrical wheel motors, or receiving electrical energy from a trolley power system, or receiving retard electrical energy from the electrical wheel motors.
33. The method of claim 32, comprising:
- receiving, by the energy management controller, electrical data that characterize operation of a drive system configured to power the electrical wheel motors of the mining haul truck.
34. The method of claim 33,
- wherein the electrical data include DC link voltage data, current data and temperature data.
35. The method of claim 32,
- wherein the electrical energy storage unit comprises a bank of ultracapacitors, or a bank of batteries, or combinations of ultracapacitor banks and battery banks.
36. The method of claim 33, comprising:
- recovering and storing retard energy from the electrical wheel motors generated during braking of the mining haul truck.
37. The method of claim 32, comprising:
- supplying electrical energy to the electrical wheel motors from the trolley power system while the mining haul truck is travelling on an uphill grade; and
- charging the electrical energy storage unit with electrical energy from the trolley power system while the mining haul truck is travelling on the uphill grade.
38. The method of claim 32, further comprising:
- supplying electrical energy to the electrical wheel motors from the trolley power system while the mining haul truck is travelling on a downhill grade; and
- charging the electrical energy storage system with electrical power from the trolley power system while the mining haul truck is travelling on the downhill grade.
39. A method for determining a storage capacity of an electrical energy storage unit on a mining haul truck, the method comprising:
- determining a haul profile, the haul profile including multiple profile legs, wherein each profile leg comprises travel distance, slope of ground, travel path and payload status of the mining haul truck, and
- determining speed and acceleration for the mining haul truck for the haul profile, and
- calculating the storage capacity of the electrical energy storage unit based on the haul profile, speed, and acceleration.
40. The method of claim 39, further comprising:
- determining a weight of the mining haul track in an empty state and in a loaded state, wherein calculating of the storage capacity is further based on the weight of the mining haul truck.
Type: Application
Filed: Oct 27, 2022
Publication Date: Mar 9, 2023
Inventor: Joy Mazumdar (Norcross, GA)
Application Number: 18/050,076