CN-121986034-A - Energy management system for mining truck

CN121986034ACN 121986034 ACN121986034 ACN 121986034ACN-121986034-A

Abstract

An energy management system for a mining truck may include an electrical power system to supplement a mechanical power system. The power system may include an energy storage system for providing power at a first voltage and a voltage transmission system for receiving power from the energy storage system. The voltage transfer system may include a first power converter for converting power to a second voltage, a converter cooling system for maintaining a temperature of the first power converter, and a second power converter for converting power to a third voltage. The energy management system may include an electrical conduit for coupling the electrical system with the mechanical power system, and a controller for controlling power output of the electrical system and the mechanical power system based on power demand, state of charge of the battery system, or engine speed.

Inventors

YU WENCHANG
ZHENG GUANGFEI
WU GANGE
WANG TAO
CHENG DEJUN
LI KE

Assignees

康明斯电力公司

Dates

Publication Date: 20260505
Application Date: 20230829

Claims (12)

1. An energy management system for a mining truck, the energy management system comprising: -an electrical power system configured to supplement a mechanical power system of the mining truck, the electrical power system comprising: An energy storage system for providing power at a first voltage, and -A voltage transmission system for receiving power at the first voltage from the energy storage system, the voltage transmission system comprising: -a first power converter for converting power from the energy storage system from the first voltage to a second voltage, the second voltage being greater than the first voltage, the second voltage being for powering the mining truck; A converter cooling system for maintaining the temperature of the first power converter within a converter temperature range, and -A second power converter for converting power from the energy storage system from the first voltage to a third voltage, the third voltage being less than the first voltage, power having the third voltage being used to power the converter cooling system; an electrical conduit electrically coupling the electrical power system with the mechanical power system, the power having the second voltage being transmitted to the mining truck via the electrical conduit, and -A hybrid control unit configured to control power output by the electric power system and the mechanical power system based on at least one of a power demand of the mining truck, a state of charge of the energy storage system, or an engine speed.
2. The energy management system of claim 1, wherein the hybrid control unit is further configured to: Detecting a fault associated with the energy management system; determining a level of the fault based on a predetermined threshold, and A control signal is generated based on the level of the fault, wherein the control signal causes at least one of the electrical power system or the mechanical power system to shut down.
3. The energy management system of claim 1, further comprising a low voltage interface to couple the hybrid control unit with a vehicle control unit of the mining truck, the hybrid control unit configured to: Receiving predefined vehicle information from the vehicle control unit via the low voltage interface, and Controlling an operating mode of the energy management system based on the predefined vehicle information.
4. The energy management system of claim 3, wherein the hybrid control unit is further configured to: Aggregating information from components of the energy management system to determine a status of the energy management system, and The state of the energy management system is sent to the vehicle control unit of the mining truck via the low voltage interface.
5. The energy management system of claim 1, wherein the hybrid control unit is further configured to: receiving inputs indicative of the power demand of the mining truck and the state of charge of the energy storage system; comparing the power demand with a power range and determining that the power demand is within the power range; Comparing the state of charge of the energy storage system with a charging range and determining that the state of charge is within the charging range; Determining an operating mode of the energy management system based on the power demand being within the power range and the state of charge being within the charge range, the operating mode including an alternator direct drive mode, and A control signal is generated to prevent the power system from providing power to the mining truck.
6. The energy management system of claim 1, wherein the hybrid control unit is further configured to: receiving inputs indicative of the power demand of the mining truck and the state of charge of the energy storage system; comparing the power demand to a power threshold and determining that the power demand exceeds the power threshold; Comparing the state of charge of the energy storage system with a charging range and determining that the state of charge is within the charging range; determining an operating mode of the energy management system based on the power demand exceeding the power threshold and the state of charge being within the charging range, the operating mode including a battery assist drive mode, and Control signals are generated to cause the electrical power system and the mechanical power system to provide power to the mining truck.
7. The energy management system of claim 1, wherein the hybrid control unit is further configured to: receiving inputs indicative of the power demand of the mining truck and the state of charge of the energy storage system; comparing the power demand to a power threshold and determining that the power demand is below the power threshold; comparing the state of charge of the energy storage system to a charge threshold and determining that the state of charge is below the charge threshold; Determining an operating mode of the energy management system based on the power demand being below the power threshold and the state of charge being below the charge threshold, the operating mode including a battery charge drive mode, and A control signal is generated to cause the electrical power system to draw power from the mechanical power system to charge the energy storage system.
8. The energy management system of claim 1, wherein the hybrid control unit is further configured to: receiving inputs indicative of the power demand of the mining truck and the state of charge of the energy storage system; identifying the power demand as negative or zero; Comparing the state of charge of the energy storage system with a charging range and determining that the state of charge is within the charging range; Determining an operating mode of the energy management system based on the power demand being negative or zero and the state of charge being within the charging range, the operating mode including a regenerative braking mode, and A control signal is generated to cause the power system to draw power from a high voltage bus into the energy storage system of the power system.
9. The energy management system of claim 1, wherein the hybrid control unit is configured to: monitoring the voltage of an electrical bus of the mechanical power system; Detecting when the voltage of the electrical bus reaches a threshold voltage, and And starting a turn-on sequence of the energy management system based on the voltage of the electrical bus reaching the threshold voltage.
10. The energy management system of claim 1, wherein the hybrid control unit is configured to: Receiving an input comprising information associated with at least one of the power demand of the mining truck, the state of charge of the energy storage system, or the engine speed; Determining an operating mode of the mining truck based on the input; distributing system power between the mechanical power system and the electrical power system based on the power demand and the operating mode of the mining truck, and Control signals are generated to cause the mechanical power system and the electrical power system to provide power based on power distributed between the mechanical power system and the electrical power system.
11. The energy management system of claim 1, wherein the hybrid control unit is further configured to: Receiving an input indicative of the engine speed of an engine of the mining truck; Determining a torque of the engine based on the engine speed; comparing the torque with a torque range and determining that the torque is outside the torque range, and A control signal is generated to cause the electric power system to provide power to the mining truck to return the torque of the engine to within the torque range.
12. A vehicle comprising the energy management system of any one of claims 1 to 11.

Description

Energy management system for mining truck Technical Field The present disclosure relates to systems and methods for integrating an electrical power system with a mechanical power system of a vehicle. Background In a vehicle, a powertrain or powertrain system refers to a component that provides power to propel the vehicle. These components may include an engine, generator, rectifier, motor controller, drive motor, and/or final drive (FINAL DRIVE), among potentially other components/systems. For internal combustion engines, the engine combusts fuel to produce mechanical power in the form of a rotating crankshaft. The generator receives the rotating crankshaft and manipulates the engine speed (i.e., rotation of the crankshaft) to control the output voltage of a bus bar, which is also coupled to the motor controller. The electrical power is received by a drive motor that converts the electrical power to mechanical power to move the vehicle. Summary of The Invention One embodiment of the present invention relates to an energy management system for a mining truck. The energy management system includes an electrical power system configured to supplement a mechanical power system of the mining truck. The power system includes an energy storage system that provides power at a first voltage. The power system includes a first power converter to convert power from the energy storage system from a first voltage to a second voltage. The second voltage is greater than the first voltage. The second voltage may power a mining truck. The power system includes a thermal control system to maintain a temperature of the first power converter within a converter temperature range. The power system includes a second power converter to convert power from the energy storage system from the first voltage to a third voltage. The third voltage is less than the first voltage. The third voltage may power the thermal control system. The energy management system includes a conduit (conduit) that electrically couples the electrical power system with the mechanical power system. The second voltage may be transmitted to the mining truck via a conduit. The energy management system includes a controller configured to control power output by the electric power system and the mechanical power system based on at least one of a power demand of the mining truck, a state of charge of the energy storage system, or an engine speed. One embodiment of the invention is directed to an energy management system wherein the hybrid control unit is further configured to detect a fault associated with the energy management system, determine a level of the fault based on a predetermined threshold, and generate a control signal based on the level of the fault. The control signal causes at least one of the electrical system or the mechanical power system to shut down. One embodiment of the present invention is directed to an energy management system that further includes a low voltage interface to couple the hybrid control unit with a vehicle control unit of a mining truck. The hybrid control unit is configured to receive predefined vehicle information from the vehicle control unit via the low-voltage interface and to control an operational mode of the energy management system based on the predefined vehicle information. One embodiment of the invention is directed to an energy management system wherein the hybrid control unit is further configured to aggregate information from components of the energy management system to determine a status of the energy management system and transmit the status of the energy management system to a vehicle control unit of the mining truck via the low-pressure interface. One embodiment of the invention is directed to an energy management system wherein the hybrid control unit is further configured to receive an input indicative of a power demand of the mining truck and a state of charge of the energy storage system, compare the power demand to a power range and determine that the power demand is within the power range, compare the state of charge of the energy storage system to a charge range and determine that the state of charge is within the charge range, determine an operating mode of the energy management system based on the power demand being within the power range and the state of charge being within the charge range, the operating mode including an alternator direct drive mode, and generate a control signal to prevent the power system from providing power to the mining truck. One embodiment of the invention is directed to an energy management system wherein the hybrid control unit is further configured to receive an input indicative of a power demand of the mining truck and a state of charge of the energy storage system, compare the power demand to a power threshold and determine that the power demand exceeds the power threshold, compare the state of charge of the energy storage system to a range of charge and determine that