Systems, methods, and apparatuses for storing energy in a mining machine.

DIVISIONAL SUB-DIRECTOR OF PATENT FUND EXAMINATION OF MECHANICAL, ELECTRICAL AND INDUSTRIAL DESIGNS AND USEFUL MODELS

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PEDRO DAVID FRAGOSO LÓPEZ

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PEDRO DAVID FRAGOSO LQPEZ | 00001000000405457619 | Administration Service

Tax | 1052 || MX / 2019/73764 | MX / a / 2017/015307 | PCT patent title | 1223 | GAGV | Page (s) 2 | dgxweaTvKyokw + rKwbZg / BgcC4o =

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MX2019 / 73764

SYSTEMS METHODS, AND APPLIANCES FOR ENERGY STORAGE IN AN EXTRACTION MACHINE

RELATED APPLICATIONS

This application claims priority to the US provisional patent application. No. 62 / 167,814, filed on May 28, 2015. The content of both provisional applications is incorporated by reference herein.

BACKGROUND OF THE INVENTION

The embodiments of the invention provide extraction machines that include an energy storage device, such as a steering wheel. In particular, some embodiments of the invention provide the use of a flywheel energy storage system on an articulated front end loading machine and rubber tires with a switched reluctance transmission system.

BRIEF DESCRIPTION OF THE INVENTION

Extraction equipment commonly works in highly cyclic applications, where address changes and routine start and stop activities are frequent. These cyclic actions can be used to excavate, load, move and dispatch minerals.

For rubber pneumatic loaders or trucks, these cycles can occur in a period of approximately 30 seconds up to approximately 3 to 4 minutes, depending on the application. Variations between the cycle periods of different applications can be attributed to the length of the path (the distance the machine travels between the point where the machine collects the material and the point where the machine dumps the material).

For example, for a surface front end loader that loads trucks in an outdoor mine, the travel length can be approximately 30 meters. Consequently, if the front end loader has a machine speed of less than about 15 kilometers per hour (kph), the front end loader can cycle in less than 30 seconds. However, for an underground loader operating in a block or panel cave, the length of the route can exceed approximately 300 meters. Therefore, if the underground loader has a machine speed of approximately 20 kph, the underground loader can cycle in approximately 4 minutes.

Similarly, transport equipment, such as transport cars, repeatedly completes the task of recovering material from an extraction machine, transporting the material to a crushing or material handling solution, such as a conveyor, and then returning to the Extraction machine to pick up another load.

Large shovels and excavator dredgers also work cyclically. For example, excavator shovels and dredgers dig and turn in a cyclic movement where the machine's swing direction is reversed to return to a starting position while accelerating and decelerating a large mass of the vehicle.

Consequently, there are opportunities to improve the efficiency of the cyclic operation of the extraction equipment through the use of energy storage. An opportunity includes capturing kinetic energy in machine movement, storing energy and using stored energy for the next phase of cycle movement. Another opportunity includes smoothing the maximum power load of an energy source by storing energy from the energy source at times of low load and using stored energy to help the energy source to boost the maximum load. This functionality allows the power source, which can be a diesel engine, a transformer or a tracking cable, to be reduced by reducing installation and maintenance costs. There is also the opportunity, through the same efficiency gain, to improve the overall performance of a type of machine, for a given energy consumption.

Accordingly, the embodiments of the invention use an energy storage device that includes a steering wheel or other form of kinetic energy storage system (KESS). The KESS can be used with switched reluctance (SR) technology to store energy in kinetic form for later use. Thus, the embodiments of the invention incorporate one or more KESS in a high power mining traction application, which can be used in surface machines and underground machines incorporating SR technology.

In some embodiments, machines incorporating a KESS as described herein may include a diesel engine as a primary energy source. In this mode, the KESS performs an energy weighting and impulse function using both braking energy and diesel engine output stem energy. However, it should be understood that KESS can also be used with other sources of energy (not diesel). As described in more detail below, the KESS can assist the engine during load peaks and can be removed from the engine during load dives. Therefore, with a KESS of adequate size, the KESS can be used to achieve averaged total power, in which an engine runs continuously at an almost constant load (eg, without variation). The use of the average power provided by the KESS makes it possible to reduce the size of the engine. Similarly, energy averaging can prolong engine life and maximize fuel economy by running the engine in a constant state of output.

In addition, in some embodiments, the diesel engine can be replaced with a different power source, such as a battery. In particular, the average total power provided by a KESS traction system (developed with a diesel engine) can optimize a battery solution for some machines, such as a cargo haul dump (LHD) or a shuttle wagon. It should be understood that other energy sources, such as fuel cells, could also be used as an alternative to a diesel engine (for example, due to the energy density of liquid fuel storage on batteries).

For example, some modes provide a transport vehicle that includes a bi-directional electric bus, a power source, a motor, a kinetic energy storage system and a controller. The power source is coupled to the bidirectional electric bus through a first power converter. The motor is coupled to the bidirectional electric bus through a second power converter. The engine runs on available energy on the bidirectional electric bus and operates a transmission mechanism included in the transport vehicle. The kinetic energy storage system is coupled to the bidirectional electric bus through a third power converter and includes a steering wheel and a switched reluctance motor. The controller is configured to communicate with the kinetic energy storage system and the power source. The controller is configured to operate the kinetic energy storage system as a primary power source for the two-way electric bus and to operate the power source as a secondary power source for the two-way electric bus when the kinetic energy storage system does not It can meet a power demand on the two-way electric bus.

Other modalities provide a method to operate a tow vehicle. The method includes determining, with a controller configured to communicate with a kinetic energy storage system and a power source included in the cargo transport vehicle, a power demand in a bidirectional electric bus included in the cargo transport vehicle and determine, with the controller, the energy available through the kinetic energy storage system. The method also includes operating, with the controller, the kinetic energy storage system as the primary energy source for the bi-directional electric bus when the energy available through the kinetic energy storage system satisfies the energy demand and operates, with the controller, The power source as a secondary power source for the bi-directional electric bus when the energy available through the kinetic energy storage system cannot meet the energy demand.

Additional embodiments provide a cargo transport vehicle that includes a mobile wagon in at least one direction, an actuator for moving the wafer in at least one direction, an operator control that includes a selection mechanism and a controller. The controller is configured to receive an input that represents the selection of the selection mechanism. In response to the input, the controller is configured to determine a current position of the wafer, retrieve a predetermined transport position of a memory, compare the current position of the wafer with the predetermined transport position and, when the current position of the nozzle differs from the predetermined transport position, the actuator automatically operates to move the nozzle to the predetermined transport position.

Other modalities provide a method to automatically operate a cargo transport vehicle. The method includes receiving, with a controller, an input that represents the selection of a selection mechanism. The method also includes, in response to the receipt of the entry, determining, with the controller, a current position of a cargo vehicle carrier, and recovering, with the controller, a predetermined transport position of a memory. The method also includes comparing, with the controller, the current position of the wafer with the predetermined hauling position and, when the current position of the wafer differs from the predetermined hauling position, automatically controlling, with the controller, an actuator to move the wafer to the default transport position.

Other aspects of the invention will be apparent when considering the detailed description, the accompanying drawings and the attached appendices.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 illustrates an energy curve for a mechanical transmission system.

Figure 2 illustrates an energy curve for a switched reluctance transmission system f'SR).

Figure 3 schematically illustrates the system architecture for a diesel hybrid SR surface loader.

Figure 4 is a graph of an efficiency curve of the SR machine.

Figures 5 and 6 illustrate energy curves for an SR transmission system with a kinetic energy storage system (KESS).

Figure 7 illustrates an energy curve for an SR transmission system with a KESS and a battery or fuel cell.

Figure 8 schematically illustrates the system architecture for an SR transmission system with a KESS.

Figure 9 illustrates a control curve for a KESS.

Figure 10 is a perspective view of the extraction equipment, specifically, a front end loader.

Figure 11 schematically illustrates functional elements of the extraction equipment of Figure 10.

Figure 12 schematically illustrates a controller included in the extraction equipment of Figure 10.

Figure 13 schematically illustrates a flow of potential energy within the equipment of Figure 10.

Figure 14 schematically illustrates an energy flow within the equipment of Figure 10 for loading the kinetic energy storage system.

Figure 15 schematically illustrates an energy flow in the equipment of the figure to perform the propulsion using the kinetic energy storage system.

Figure 16 schematically illustrates an energy flow in the equipment of the figure to perform the propulsion without using the kinetic energy storage system.

Figure 17 schematically illustrates a flow of energy in the equipment of Figure 10 for light braking.

Figure 18 schematically illustrates an energy flow in the equipment of the figure to perform heavy braking and load the kinetic energy storage system.

Figure 19 schematically illustrates an energy flow in the equipment of the figure for heavy braking without loading the kinetic energy storage system.

Figure 20 schematically illustrates an extraction machine that includes multiple kinetic energy storage systems.

Figure 21 illustrates a cargo drag dump (LHD) with a fork placed in a dump position.

Figure 22 illustrates the LHD of Figure 20 with the wand in an excavation position.

Figure 23 illustrates the LHD of Figure 20 with the carriage placed in the transport position.

DETAILED DESCRIPTION OF THE INVENTION

Before explaining in detail any of the embodiments of the invention, it should be understood that the invention is not limited in its application to the construction details and the arrangement of the components presented in the following description or that are illustrated in the drawings companions The invention may have other modalities and may be practiced or carried out in various ways. Also, it is understood that the wording and terminology used herein are intended for description and should not be considered limiting. The use of the phrases that it includes, that it understands or that it has and variations of the same in the present means that they cover the articles listed below and their equivalent, as well as additional articles. Unless specified or otherwise limited, the terms mounted, connected, supported and coupled and variations thereof, are widely used and encompass direct and indirect mounts, connections, brackets and couplings.

In addition, it should be understood that embodiments of the invention may include hardware, software and electronic components or modules that, for discussion purposes, may be illustrated and described as if most of the components were implemented only in the hardware. However, one skilled in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, aspects of the invention can be implemented in the software (for example, stored in the non-transient medium readable by computer) executable by one or more processing units, such as a microprocessor, circuits i

Integrated application specific (ASIC) or other electronic device. As such, it should be noted that a plurality of hardware and software based devices can be used, as well as a plurality of different structural components to implement the invention. For example, the controllers described in the specification may include one or more processors or processing units, one or more computer-readable media modules, one or more input / output interfaces and several connections (for example, a system bus) that connect the components.

As indicated above, the embodiments of the invention incorporate one or more kinetic energy storage systems (KESS) in a traction train of the machine (for example, high power), which can be used in extraction machines (by for example, surface and underground extraction machines) that incorporate SR technology. Accordingly, the embodiments of the invention can use KESS with an electric transmission system. Electric drive systems can burn 30% to 40% less fuel than an equivalent mechanical unit. These fuel savings can be achieved through differences in the respective drive trains of the equipment and relative efficiencies. In particular, the mechanical drive systems currently used in surface extraction applications employ a conventional mechanical drive train, with a torque converter, semi-automatic or automatic transmission / transfer case and differentials. Mechanical drive systems, however, may be inefficient due to the operation of the torque converter and may require a large motor to deliver a high power output even if the motor does not run consistently at a maximum output level. For example, Figure 1 illustrates an energy curve for a mechanical transmission system.

Switching reluctance electric drive systems provide additional efficiency advantages over mechanical drive transmission systems. For example, a switched reluctance transmission system may allow the engine to reduce due to the ability of the system to maintain the engine speed at a maximum output level. For example, Figure 2 illustrates an energy curve for a switched reluctance transmission system. Additionally, Figure 3 schematically illustrates a surface loader with a diesel hybrid SR drive. As described above, surface loaders operate or perform substantially cyclic operations. For example, a surface loader cycle can include approximately four changes in the machine direction during a cycle that can last approximately 40 seconds.

In particular, as illustrated in Figure 3, the surface loader includes a motor 10 combined with a motor / generator 12 (for example, an SR motor / generator) and a traction system 13. The traction system 13 ¡ Illustrated in Figure 1 includes four SR 14 motors. Each SR 14 motor can supply electric power to a wheel of the loader. The SR 14 motors and the motor / generator 12 are connected by an electric bus 16 (for example, a direct current bus (CD)). One or more converters 18 connect the motor / generator 12 to the electric bus 16. Similarly, one or more converters 18 connect the motors of SR 14 to the electric bus 16. The converters 18 can convert the energy supplied by the motor / generator 12 in energy supplied on the electric bus 16. Similarly, the converters 18 can convert the energy supplied through the electric bus 16 into energy usable by the SR 14 motors.

In the system illustrated in Figure 3, the revolutions per minute (RPM) of the engine 10 are independent of the speed of the traction motor provided through the SR 14 engines. In other words, each SR 14 engine can extract or provide rotational energy to the motor drive line at any speed with little penalty in terms of loss of efficiency. In some embodiments, engine speed 10 may be adjusted to operate at the lowest RPM at which engine horsepower is available.

The speed setting of the motor 10 (at the peak of the power curve) facilitates the opportunity to increase the speed of the motor 10 above the adjusted speed of the regulator (above the motor speed), which makes the injectors of fuel stop supplying fuel to the engine 10 and allows the transmission line to be used as a steering wheel to store braking energy. Mechanical drive systems are ineffective in passing energy from the motor drive shaft to the wheels, particularly when there is a high speed difference (for example, due to the operation of the torque converter under high differential speed conditions). The engine in mechanically driven machines will commonly be under high load at speeds below the maximum horsepower curve; which means they are burning fuel at less than maximum engine efficiency. Because mechanical drive systems typically require high power at non-optimal engine RPMs, engines can be oversized in relative terms, where the rating of the engine plate is similar but a larger volumetric capacity of the engine is required. Larger engines lead to a machine design that has higher operating and reconstruction costs in addition to higher friction losses.

Figure 4 illustrates an SR machine efficiency curve. An SR system can provide full torque to the wheels during a blockage, consuming only about 10% of engine power. This may occur due to the low reactive losses of the SR system. For example, the only significant losses may be the copper losses caused by the internal resistance of the motor coils and the current that passes through them. Consequently, the SR machine (motor or generator) can have an almost flat efficiency curve in its speed range as illustrated in Figure 4 above.

A mechanical transmission train by comparison is commonly at a full horsepower outlet during a blockage. The torque converter requires this power to produce torque. Most of these horsepower is lost as heat, which is a byproduct of the torque production process. In addition, a torque converter is inefficient as long as there is a significant slip or speed differential between the input and output axes.

Indeed, both systems have zero percent efficiency during a blockage since the energy output of a stationary axis is zero. In this condition, the transmission efficiency could be measured as a function of the output torque versus energy consumption. However, in this scenario, the SR transmission system is more efficient in the production of torque per unit of power consumed compared to the typical mechanical transmission line. In addition, in a mechanical drive machine, conventional brakes are used. These brakes are typically multi-pack wet disc brakes. Like all mechanical brakes, these devices convert kinetic energy into heat. The heat in a multi-disc brake is transferred to the hydraulic oil and dissipated by means of a radiator cooling system.

In SR drive machines, such as surface loaders, braking energy is diverted to the engine transmission line. In some embodiments, this braking energy is used as described below. In particular, the braking energy can first supply the parasitic losses around the machine. These include, for example, the motor fan and other cooling fans, air conditioning and battery charging alternator. These systems are low power compared to the braking energy that is being diverted, so much remains to be done.

Then the loads of the operating hydraulic systems can receive energy. This includes the hydraulic functions of forklift, forklift and steering. Any remaining energy can be used to contribute energy to the drive train. For example, the SR generator, which now acts as an engine, contributes with driving force to the drive train to a point where the engine regulator can reduce or cut off the fuel supply to the injectors. At this point, the engine may not consume fuel and the SR generator compensates for friction losses and wind resistance of the engine. In these modes, the engine speed can be increased to the mechanical limit of the engine, at which time the engine becomes an energy storage device (a steering wheel), although with poor efficiency due to the friction of the engine and the wind effect Motor speed overload (for example, approximately 300 RPM) above the cut-off point of the regulator can be used in the next propulsion phase to increase the power available to the traction system above the plate rating the motor. The use of the transmission line as an energy storage device as described above provides an energy storage option when the speed of the machine cycle is fast (e.g., less than about 50 seconds) and the energy storage capacity is low since the energy stored in the transmission line can be reused by the traction system before it is consumed by engine friction and wind effects losses. Consequently, this energy storage option can be used in high altitude surface loaders where there is less total oxygen available for engine combustion. For example, at high altitude, turbocharges of larger diameter are generally required to supply air to the engine. These turbo charges take a long time to turn at a working speed due to the larger mass of inertia. This time restriction affects the response time of the engine. Therefore, a KESS can complement the power needs of the traction system while turbo loads reach a working speed.

However, for underground extraction, as an alternative or in combination with energy storage in the engine transmission line, a KESS can be used to store the braking energy. The KESS provides gains in fuel efficiency and, consequently, reduces emissions. In particular, the KESS provides a storage solution of greater duration, greater capacity and greater efficiency than the storage solution of the transmission line used in surface loaders as described in the previous paragraph. For example, Figure 5 illustrates an energy curve for a switched reluctance transmission system that includes a KESS. As illustrated in Figure 5, the KESS may provide an increase in power to complement the motor output, may allow the motor to be reduced, or a combination thereof. For example, Figure 6 illustrates an energy curve for a switched reluctance transmission system that includes a KESS greater than the KESS shown in Figure 5. As illustrated in Figure 6, the larger KESS can provide an average maximum engine power while providing a high maximum power to the traction system. Additionally, Figure 7 illustrates an energy curve for a switched reluctance transmission system that includes a KESS and a battery (for example, a sodium battery), a fuel cell or both. As illustrated in Figure 7, alternative power supply technologies, such as fuel cell technologies and battery technologies, can be used with a weighted power source.

The operating profiles of an underground extraction machine are significantly different from the operating profiles of a surface extraction machine, such as a loader, a shovel and the like. For example, a surface operating profile is commonly short, where the machine finds four changes of direction in a 40-second cycle period and spends approximately 8 to 10 seconds on the load filled by the wafer. In contrast, there are two main modes of operation in the underground environment: (1) development and (2) production work. Both modes of operation differ from surface operation in terms of drag distance and resulting cycle time. For example, an underground machine can transport drag materials over distances of up to 200 meters in the development of the mine and more than 350 meters in production, and these distances result in cycle times that vary from about 2 to about 3 minutes.

In addition, in underground extraction environments, the production environment is predominantly flat. For example, the maximum ratings seen in this operation are around 1 in 50. As described above, underground machines can transport material over distances greater than 350 meters. In addition, in the production cycle, the machines will generally complete two trams forward and two trams backwards. In addition, in many mines, a production loader can visit many extraction points at different distances from the crusher to collect the ore. Consequently, the nature of this cycle may depend on the design of the mine and the distance of the ore to the loading hopper of the crushing plant.

Depending on this type of environment, an opportunity to store energy in the production cycle is during braking events. To maximize productivity, the underground machine should be able to accelerate and decelerate rapidly. Consequently, during deceleration, the energy taken from traction motors can be captured for later reuse by a KESS. In addition, when the engine is in a low demand situation, part of its available power could be used to supply power to the KESS. As noted above, the use of energy stored in this way allows the diesel engine to be reduced by averaging the engine's output power during a cycle. In addition to reducing the engine, which reduces costs, the magnitude of the reduced size can also result, in some embodiments, to a smaller block size engine, which provides additional performance gains as the costs are further reduced. friction and wind effect losses.

The KESS used in these situations may be able to store the energy of one or two braking events (for example, approximately 1.2 megajoules (MJ) per event) with high power capacity (for example, approximately 500 kilowatts (KW)) for allow the KESS to fill or empty in a matter of seconds. The KESS can also be configured to provide efficient energy absorption and release and retain stored energy with minimal loss over time.

With respect to the development environment, a greater percentage of development work occurs around the road or decline of entry to the mine. These decreases are typically on a slope of approximately 1 in 5.5. When working in the development environment, the underground machine excavates from the bottom of the slope, where the road extends, through drilling and explosion techniques. Then, the machine prepares the inclined drag between approximately 256 to approximately 200 meters where the machine unloads the material or loads it into a truck. The underground machine returns to the excavation face, which implies driving along the slope of approximately 200 meters while braking to manage the speed.

The uphill drag is turned on with an intensive engine and causes an impact on the life of the transmission while the return to the downward slope commonly places great strain on the brakes. A KESS that stores the braking energy generated on the downward slope that runs towards the excavation face (for example, giving up to 10 MJ) can provide a significant boost to the engine in the path of the upward slope.

Figure 8 illustrates an SR transmission system with a KESS 30. The KESS 30 includes an SR 30a transmission engine and a steering wheel 30b. In the configuration illustrated in Figure 8, the KESS 30 can be configured to store braking energy as the machine slows down (the speed of a transmission mechanism decreases) according to the operator's command. The energy can be maintained in the KESS 30 for several minutes. When the operator orders the machine to accelerate, the KESS 30 releases energy to the traction system, which complements the energy supplied by an engine (for example, a diesel engine) through an engine / generator. In some embodiments, this release of energy from the KESS 30 allows the machine to have a maximum available power of approximately twice the power of the engine alone.

There may be periods during the operating cycle when the engine is not running at full load. During these periods, engine power can be used to recharge the KESS 30. This functionality can ensure that the KESS 30 is charged or full before an acceleration event.

In some embodiments, the speed of the KESS 30 may be weakly linked to the speed of the machine. For example, as the machine accelerates (the speed of a transmission mechanism increases), the KESS 30 may slow down (the rotation speed of the flywheel 122 may decrease) as a melt of the energy release of the KESS 30. Conversely, as the machine slows down (the speed of a transmission mechanism decreases), the KESS 30 can be loaded and consequently accelerate (the rotation speed of the flywheel 122 increases). An advantage of this operation of the KESS 30 is that the gyroscopic forces of the KESS 30 will be lower when the machine is at high speed and rapid movement or in contact with the wall could result in a significant support or housing overload. In some embodiments, a target machine speed of an operator control can be received.

For example, in some embodiments, the speed of rotation of the KESS 30 (the speed of rotation of the steering wheel 30b) and therefore, the energy stored within the KESS 30 is controlled as a function of the speed of the machine. For example, Figure 9 illustrates a control curve comparing a machine speed to a rotation speed of KESS 30. Line 90 indicates a target speed of KESS 30 for a given machine speed and the area 92 surrounding line 90 indicates an allowable range of variation around the target speed. The relationship illustrated in Figure 9 can be used to provide handling of the gyroscopic forces of the KESS 30 which can be very high when the high angular machine speed (speed of the change of direction) coincides with the high rotation speed of the KESS 30. The shape of the curve also takes into account the energy required to accelerate and decelerate the machine and can be defined for the specific equipment and application.

As described in more detail below, in some embodiments, as the speed of the machine increases (during acceleration) energy is taken from the KESS 30 and is provided to traction motors by placing the energy in a bidirectional bus (for for example, a CD bus) feeding the traction motors. This power supply reduces the rotation speed of the KESS 30. When the traction system requires more power than the KESS 30 provides, a diesel engine can provide supplementary power. Similarly, when the KESS 30 provides more energy than is required by traction motors, excess energy can dissipate through the brakes.

Similarly, as the machine speed decreases (during deceleration), the KESS 30 is ordered to increase the speed, and the energy required to increase the speed of the KESS 30 is taken from the bidirectional bus. This energy is supplied by traction motors operated in a braking mode of operation. In some embodiments, when the KESS 30 does not receive enough power from the traction motors during the operating braking mode to meet the requirements of the speed curve, the energy can be accepted from the diesel engine by means of a generator. Similarly, when the KESS 30 receives an excess of energy, the energy can go in the route of the engine transmission line through the generator to overcome any loss of the transmission line and loss of engine fuel. Any additional excess energy can dissipate through the brakes as heat.

Consequently, as described above, the KESS 30 can supply or collect power from the bidirectional bus as determined by the control curve illustrated in Figure 9. The motor, through the generator functionality, can supply power only when there is a deficit between the energy supplied by the KESS 30 and the energy demanded by traction motors. The variation between supply and demand is a function of the operating conditions in which the machine is located. For example, the degree or slope and the rolling resistance of the access on which the machine operates can alter the supply and demand balance between the KESS 30 and the traction motors when the traction motors operate in propulsion mode and mode. of braking that alerts the amount of energy demanded or supplied. Consequently, in rudimentary terms, the KESS 30 can be the main power source for the bidirectional bus and the motor can be a secondary power source for the bidirectional bus, such as when the KESS 30 cannot meet a power demand in the bidirectional electric bus.

Consequently, in the underground extraction space, a benefit of the KESS 30 is that the maximum engine horsepower in that environment can be reduced. This can be an important factor since engine horsepower can be a determining factor in the ventilation requirements of an underground mine, which is an important capital expense for the customer. For example, many jurisdictions use plate motor horsepower as the basis for ventilation air flow in performance standards.

For surface machines, a KESS provides benefits in high altitude situations where the engine response is diminished due to thinner air (less total oxygen is available for engine combustion). For example, to overcome the problem of fine air, engine manufacturers generally increase the diameter of turbochargers. This increased diameter increases the inertia of the turbochargers resulting in turbo lag resulting in the longer turbo delay (waiting time for the turbocharger to generate speed and momentum). The KESS can be used to provide a complementary power source to the machine while increasing engine horsepower. For example, the KESS can be used to gently load the engine to provide a transmission line response and, therefore, better operating performance, provide energy boost from the braking energy that could otherwise dissipate as heat or A combination of them.

It should be understood that the size of the KESS (for example, energy capacity and power rating) is based on the requirements of the application. For example, some applications may use a KESS solution as a low capacity and high power solution or other combinations of capacity and power depending on the operational needs of the machine. For example, when a machine provides maximum power for extended periods, the machine may be equipped with a KESS that provides a high energy storage capacity and a high nominal power.

For example, Figure 10 illustrates extraction equipment 100 according to an embodiment of the invention. The extraction equipment 100 may be an underground extraction machine (for example, a continuous miner, a drag system, a long wall shearer, a loader, and the like) or a surface extraction machine (for example, a loader of wheels, a hybrid shovel, an excavator dredger miner, and the like). The extraction equipment 100 may include a frame 101 and a traction system 102, such as a plurality of wheels rotatably coupled to the frame 105. The extraction equipment 100 may also include other mobile systems and components, such as a cable reel or A swing system. In the mode illustrated in Figure 10, the extraction equipment 100 is a load, drag, discharge (LHD) commonly used in underground mining environments.

As illustrated in Figure 11, the extraction equipment 100 includes a generator / engine 103. The generator / engine 103 may include a diesel engine that emits mechanical energy and a generator that converts the mechanical energy emitted by the engine into electrical energy . In some embodiments, the generator includes an SR generator. In some embodiments, the generator can be used as an engine that increases engine speed (for example, to use the engine as an energy storage device used separately or in combination with the kinetic energy storage system described below) .

It should be understood that in some embodiments, the extraction equipment 100 includes one or more generators turned on by one or more engines.

The generator / motor 103 also provides mechanical power (shown in solid lines in Figure 11) to the hydraulic pumps 104, which can drive the work hydraulics and the cooling fans and parasites 107 that use hydraulic power (shown in broken lines in Figure 11). In particular, the rotation energy is passed through the generator and is provided to the hydraulic pumps 104 through a mechanical connection between the hydraulic pumps 104 and the generator / motor 103. The generator / motor 103 also provides electrical power ( shown in solid lines in Figure 11) to a bidirectional electric bus 106 (for example, a direct current capacitive bus (CD)). The bidirectional electric bus 106 supplies electric power to one or more traction motors 108 (for example, SR motors). For example, as illustrated in Figure 11, the extraction equipment 100 includes a left front drive motor 108A, a right front drive motor 108B, a left rear drive motor 108C, and a right rear drive motor 108D. Each traction motor 108 drives a wheel or other drive mechanism included in the traction system 102. In particular, each traction motor 108 converts the electric power received on the bidirectional electric bus 106 into rotational energy to drive a drive mechanism. . In some embodiments, one or more of the traction motors 108 include SR motors.

In some embodiments, the bidirectional electric bus 106 is in communication with one or more converters 110. The converters 110 may be configured to transmit power through the bidirectional electric bus 106 or to receive power from the bidirectional electric bus 106 (for example, to use bidirectional electric bus 106 as bidirectional bus). Each converter 110 can be used as a CD to CD converter, a CD to AC inverter, an AC to CD rectifier or another type of power converter. Alternatively or in addition, a converter 110 may be used as a motor controller for a traction motor 108. For example, the converter 110 may be configured to detect characteristics of a traction motor 108 and respond to the detected characteristics. In some embodiments, one or more of the converters 110 use electrical switching devices of a bipolar isolated gate transistor (IGBT). In some embodiments, a plurality of converters (eg, parallel) can be used for a component coupled to the bidirectional electric bus 106. For example, the KESS 120 may be associated with one or more parallel converters that regulate the power in the KESS 120 or outside the KESS 120. Also, in some embodiments, the KESS 120 may be associated with one or more parallel converters that regulate the power in the KESS 120 and the parallel converters that regulate the energy outside the KESS 120. The use of a plurality of parallel converters may affect the performance of the KESS 120 (for example, faster loading, faster unloading, increased loading potential, increased discharge potential, or a combination thereof).

As illustrated in Figure 11, each traction motor 108 is associated with a braking grid 112. The braking grid 112 converts the kinetic energy of the traction motor into thermal energy (heat) during braking of the extraction equipment 100.

The extraction equipment 100 also includes a kinetic energy storage system (KESS) 120. The KESS 120 may include a flywheel 122 and a motor / generator 124. In some embodiments, the motor / generator 124 includes a variable speed motor, such as a variable speed SR motor / generator. For example, the act of storing and retrieving energy from a KESS is associated with the acceleration and slowdown of the rotating mass. Consequently, the wide range of power and constant speed of an SR motor is very suitable for the KESS. The flywheel 122 is mechanically coupled to the motor / generator 124. The motor / generator 124 is configured to receive electrical power from the bidirectional electric bus 106 and generate rotation energy towards the flywheel 122, and, alternatively, to receive rotational energy from the flywheel. 122 and the electric power output to the bidirectional electric. bus 106. Consequently, upon receiving electric power, the motor / generator 124 rotates the flywheel 122 to store kinetic energy. The stored energy can be collected from the KESS 120 using rotation energy of the flywheel 122 to rotate a rotor included in the motor / generator 124, which converts the rotation energy into electrical energy that can be supplied to the bidirectional electric bus 106. In some embodiments, the flywheel 122 included in the KESS 120 has a rotation speed of about 0 to about 6500 RPM, which allows the KESS 120 to provide output power up to about 4000 horsepower (hp) per second (about 3 MJ). In other embodiments, the flywheel 112 has a rotation speed of about 3000 RPM at about 10,000 RPM or about 5000 RPM at about 8000 RPM. Similarly, in some embodiments, the KESS 120 provides an energy production of about 1 MJ to about 15 MJ or from about 2 MJ to about 7 MJ. As indicated above, the power output of the KESS 120 may depend on the configuration of the one or more converters that couple the KESS 120 to the bidirectional electric bus 106.

Although not illustrated in Figure 11, the extraction equipment 100 also includes one or more controllers that manage the operation of the generator / motor 103 and the KESS 120. In particular, the extraction equipment 100 may include a controller that issues commands to the KESS 120, which includes commands related to the torque in the motor / generator 124 for storing energy or extracting energy from the KESS 120. Similarly, the equipment may include a controller that issues commands to the generator / engine 103 in relation to the output levels of the engine, the generator or both. In addition, the extraction equipment 100 may include a controller that issues commands to the traction motors 108 that drive the traction system 102. It should be understood that this functionality can be performed by a single controller or a plurality of controllers. In addition, in some embodiments, the functionality or potion thereof may be performed by one or more controllers located remotely from the extraction equipment 100, such as in a remote control station for the extraction equipment 100. In some embodiments, The functionality performed by the controller described here can be included in another component. For example, the controller may be included in KESS 120 (for example, within a common housing).

In some embodiments, as described above with respect to Figure 9, the extraction equipment 100 may include a controller that issues orders to the KESS 120 and the generator / motor 103 to supply or collect energy based on the speed of the extraction equipment 100 In particular, as described in more detail below, the controller can issue orders to the KESS 120 and the generator / motor 103 to use the KESS 120 as the primary power source for the bidirectional electric bus 106.

Figure 12 illustrates an example of a controller 150 included in the extraction equipment 100. As illustrated in Figure 12, the controller 150 includes an electronic processor 152 (for example, one or more microprocessors, specific application integrated circuits ( ASIC), or other electronic devices), a non-transient computer readable memory 154, and an input / output interface 156. It should be understood that controller 150 may induce additional components to those illustrated in Figure 12 and the configuration of the components illustrated in Figure 12 are provided as a single example. Memory 154 stores instructions executable by electronic processor 152 to issue commands as indicated above (for example, through input / output interface 156). For example, controller 150 may issue commands to control the energy flows described below with respect to Figures 13 to 19. The controller 150 can also use the input / output interface 158 to receive information (for example, operating parameters, such as machine speed, addressing address, bus voltage, engine speed sensors, motor load, load of the traction system or command functions, load of the hydraulic system or command functions, and the like) that the controller 150 can use to determine when and what type of commands to issue. For example, in some embodiments, the controller 150 controls the KESS 120 based on one or more measured signals, received or calculated for the extraction equipment 100. It should be understood that the input / output interface 156 can communicate with the components outside the controller 150 (for example, KESS 120, generator / motor 103, a motor controller and the like) over a wired or wireless connection, which includes local area networks and controller area networks.

Figure 13 illustrates the potential energy flows within the extraction equipment 100. In particular, as illustrated in Figure 13, the hydraulic pumps 104 consume energy provided by the generator / motor 103. However, the generator / motor 103 also it can receive power from the bidirectional electric bus 106 (for example, during braking events). In addition, each traction motor 108 can receive power from the bidirectional electric bus 106 and supply power to the bidirectional electric bus 106. In addition, the KESS 120 can receive power from the bidirectional electric bus 106 and supply power to the bidirectional electric bus 106. On the contrary, the brakes 112 only consume energy from the bidirectional electric bus 106.

Figure 14 illustrates the energy flow in the extraction equipment 100 for charging the KESS 120. In particular, as illustrated in Figure 14, the power supplied by the generator / motor 103 is provided to the bidirectional electric bus 106, which It supplies power to charge the KESS 120. In some modes, the KESS 120 is charged during commissioning of the extraction equipment 100. However, in other embodiments, the KESS 120 can be charged during low load times in the generator / motor 103.

Figure 15 illustrates the flow of energy in the extraction equipment 100 for propulsion without using the KESS 120. In particular, after the KESS 120 is charged, the KESS 120 can supply power to the bidirectional electric bus 106. The power is consumed by traction motors 108. In some embodiments, the KESS 120 acts as the main or master energy source for traction motors 108. If the KESS 120 cannot fully supply the traction motors 108 with the necessary power, the traction motors 108 can receive power from the generator / motor 103, which, as illustrated in Figure 15, also supplies power to the bidirectional electric bus 106 Consequently, in this arrangement, the KESS 120 is the main energy supplier for the traction system 102 with the generator / motor 103 providing a backup supply. The KESS 120 is a more receptive power source than the generator / motor 103. Accordingly, by first using the most sensitive power source, the traction system 102 can increase the speed faster than a system of power would allow. conventional transmission In addition, the use of the KESS 120 as the main energy supplier can reduce the need to operate the generator / motor 103 at full capacity. In particular, as described above, using the KESS 120 as the main source of energy to the traction system 102 may allow the generator / engine 103 to operate at a more stable output, which saves fuel and reduces the engine output requirements.

Accordingly, during operation of the extraction equipment 100, the controller 150 can be configured to determine a power demand in the bidirectional electric bus 106 and determine the power available through the KESS 120. When the power available through the KESS 120 satisfies the energy demand, the controller 150 can be configured to operate the KESS 120 as a primary power source for the bidirectional electric bus 106 (for example, controlling a rotation speed of the flywheel 122 included in KESS 120). However, when the power available through the KESS 120 cannot meet the energy demand, the controller 150 can operate the generator / motor 103 as a secondary power source (for example, with any power available from the KESS 120) for the bidirectional electric bus 106 to meet the energy demand.

Figure 16 illustrates the power flow in the extraction equipment 100 to perform the propulsion without using the KESS 120. In this situation, the traction motors 108 consume energy from the bidirectional electric bus 106, which is supplied only by the generator / engine 103. This situation can be used when the KESS 120 is not loaded, is malfunctioning or is not present.

Figure 17 illustrates the power flow in the extraction equipment 100 for light braking. As illustrated in Figure 17, during braking of the traction system 102, the traction motors 108 act as generators and supply electric power to the bidirectional electric bus 106. In the situation illustrated in Figure 17 (light braking), the The energy supplied by the traction motors 108 can be supplied to the generator included in the generator / motor 103. The generator can use the energy received to accelerate the transmission line between the generator / engine 103 and the hydraulic pumps 104 (for example, accelerate the engine to a set speed point where it is ordered that the fuel injectors stop supplying fuel to the motor). In some situations, when the transmission line is being motivated by the generator included in the generator / engine 103, the generator / engine 103 reduces fuel consumption (for example, to operate at a zero fuel level).

Similarly, Figure 18 illustrates the power flow in the extraction equipment 100 to perform strong braking and load the KESS 120. As illustrated in Figure 18, in these situations, the traction motors 108 act as generators and supply electric power to the bidirectional electric bus 106. In the situation illustrated in Figure 18 (strong braking), the power generator by the traction motors 108 and supplied to the bidirectional electric bus 106 can be supplied to the generator included in the generator / motor 103 and to the KESS 120.

Figure 19 illustrates the flow of energy in the extraction equipment 100 to perform a heavy interruption without charging the KESS 120 (for example, the KESS 120 is full, malfunctions or does not represent it). As illustrated in Figure 19, in these situations, traction motors 108 have generators and supply electric power to the bidirectional electric bus 106. Part of the power supplied is provided to the generator included in the generator / motor 103. However, part of the power supplied is also supplied to one or more of the brakes 112, which convert the energy into heat.

It should be understood that other modes of operation can be used with the KESS 120. For example, in some embodiments, the generator / motor 103 can be used as the primary power source of the traction system 102 and the KESS 120 can provide a supply of backup power In this configuration, a controller can be configured to issue commands to the KESS 120 that can be based on the operating speed of the traction system 102.

In addition, in some embodiments, a user interface is provided for the extraction equipment 100 that allows an operator to configure the KESS 120. In some embodiments, the user interface can also display (for example, textually or graphically) the actual amount of energy stored in KESS 120.

It should also be understood that more than one KESS 120 can be used for a particular extraction machine depending on the power needs of the machine and the characteristics of the KESS 120. In addition, in some embodiments, multiple KESS 120 can be used to reduce the effects Gyros associated with a KESS (steering wheel rotation). For example, two separate KESS 120 (a first KESS 120 and a second KESS 120) may be contained within a single housing with the handwheels 122 which reduce in rotation the gyroscopic effects on the machine. For example, a first KESS 120 may include a first steering wheel 122 that rotates in a first direction, and a second KESS 120 may include a second steering wheel 122 that rotates in a second direction opposite the first direction. Similarly, four KESS 120 (a first KESS 120, a second KESS 120, a third KESS 120 and a fourth KESS 120) can be placed in four cardinal directions along a plane to reduce gyroscopic effects. For example, as illustrated in Figure 20, the first KESS 120 may be positioned in a first cardinal direction along a plane, the second KESS 120 may be positioned in a second cardinal direction along the plane, the third KESS 120 may be positioned in a third cardinal direction along the plane, and the fourth KESS 120 may be positioned in a fourth cardinal direction along a plane.

As indicated above, the extraction equipment 100 may include a cargo transport vehicle, such as an LHD commonly used in underground mining environments. As illustrated in Figure 20, an LHD 200 includes a carriage 202 supported by one or more arms 204, wherein the carriage 202 moves in at least one direction (eg, a horizontal height, an angle from a horizontal position, or the combination thereof). The nozzle 202 can be moved using one or more actuators (changing the position of the nozzle 202, the arms 204, or both), such as one or more hydraulic actuators, rams and the like, included in the LHD 200. The nozzle 202 can move based on the input received from an operator control, such as a joystick, lever, button, touch screen and the like Included in the LHD 200. A controller, such as the controller 150 described above or a separate, similar controller, included in the LHD 200 can receive the input and control the one or more actuators accordingly (for example, when issuing orders to the one or more actuators). In some modes, the controller is also configured to provide automatic return to excavation functionality.

For example, when the nozzle 202 of the LHD 200 is in a position without excavation (for example, an unloading position as illustrated in Figure 21), an operator operating the LHD 200 can press a selection mechanism (for example , the selection mechanism to be transported again), like a button, located in an operator control included in the LHD 200 (for example, a right or left hand lever of the LHD 200, a touch screen and the like) or a remote control station for the LHD 200. When the operator selects this selection mechanism, the controller 150 receives a signal from the selection mechanism (for example, directly or on one or more networks) and, in response, automatically controls one or more actuators associated with the nozzle 202 to relocate the nozzle 202 at a predetermined digging position (for example, a predetermined height, a predetermined angle or the combination thereof) (see, for example, Figure 22). As illustrated in Figure 22, the position of return to excavation can be defined as the booth 202 that is approximately horizontal with the earth or the material being excavated.

For example, controller 150 can access the predetermined digging position from a memory (such as memory 154 included in controller 150) and compare the predetermined digging position stored to a current position of the nozzle 202. As described previously, the controller 150 may use data collected by one or more sensors to determine the current position of the carrier 202. When the positions are different, the controller 150 can control the one or more actuators to change the current position of the nozzle 202 to match the predetermined stored excavation position. For example, when the current height of the nozzle 202 is greater than the height included in the predetermined digging position, the controller 150 can control the one or more actuators to lower the nozzle 202. Similarly, when the current angle of the nozzle 202 is greater than the angle included in the predetermined digging position, the controller 150 can control the one or more actuators to lower the nozzle 202.

In some embodiments, the controller 150 may repeatedly compare a current position of the booth 202 with the predetermined digging position stored while the booth 202 is moved until the positions align. Alternatively or in addition, the controller 150 may initially compare a current position of the nozzle 202 with the predetermined excavation position stored and determine an amount of movement necessary to align the nozzle 202 with the predetermined excavation position stored. The controller 150 can then order the movement of the nozzle 202 based on the determined distance. Accordingly, in any of the configurations, the controller 150 translates a difference between the current position and the position stored in an order or a series of orders to one or more actuators that simulate commands received from an operator control. Consequently, the use of the selection mechanism allows the operator to concentrate on driving the LHD 200 without also having to perform multiple joystick movements to return the wand 202 to an excavation position.

In some embodiments, an operator can manually adjust the predetermined transport position (for example, the predetermined height, the predetermined angle or the combination thereof) to suit the operator's preferences or operating environment. For example, the operator may be able to signal when the nozzle 202 is in a desired digging position (for example, by selecting a selection mechanism or operating an operator control). The controller 150 receives the input from the operator and saves the current position of the carrier 202 (for example, the current height, the current angle or the combination thereof). The controller 150 can determine the current position based on data collected by one or more sensors that communicate with the controller 150 (for example, a pressure sensor, an encoder, an inclinometer and the like). The stored location information can be retrieved and applied when the operator subsequently selects the return transport mechanism. In some embodiments, the modified predetermined digging position can be stored as an absolute position (for example, a height and an angle). However, alternatively or in addition, the modified predetermined excavation position can be stored as a displacement to the predetermined excavation position (for example, a height displacement and an angle displacement). In some embodiments, the modified excavation position may be restored to the predetermined excavation position after the LHD 200 shuts down and restarts. In other embodiments, the modified excavation position may be at rest in the predetermined excavation position (for example, in response to the selection of a reset to default selection mechanism).

Alternatively or in addition, the controller 150 included in the LHD 200 can provide automatic return carrying functionality. For example, when the nozzle 202 of the LHD 200 is in a position without excavation (for example, an unloading position as illustrated in Figure 21), an operator operating the LHD 200 can press a selection mechanism (for example , the selection mechanism to return to transport), like a button, located in an operator control included in the LHD 200 (for example, a right or left hand lever of the LHD 200, a touch screen and the like) or a remote control station for the LHD 200. When the operator selects this selection mechanism, the controller 150 receives a signal from the selection mechanism (for example, directly or on one or more networks) and, in response, automatically controls one or more actuators associated with the nozzle 202 to relocate the nozzle 202 to a predetermined transport position (for example, a predetermined height, a predetermined angle or the combination thereof) (see, for example, Figure 23).

For example, the controller 150 can access the predetermined transport position from a memory (such as the memory 154 included in the controller 150) and compare the predetermined transport position stored to a current position of the carrier 202. As described above. , controller 150 may use data collected by one or more sensors to determine the current position of the carrier 202. When the positions are different, the controller 150 can control the one or more actuators to change the current position of the carrier 202 to match the stored predetermined transport position. For example, when the actual height of the booth 202 is less than the height included in the predetermined transport position, the controller 150 can control the one or more actuators to raise the booth 202. Similarly, when the actual height of the nozzle 202 is less than the angle included in the predetermined transport position, the controller 150 can control the one or more actuators to raise the nozzle 202.

In some embodiments, the controller 150 may repeatedly compare a current position of the container 202 with the predetermined transport position stored while the bucket 202 is moving until the positions are aligned. Alternatively or in addition, the controller 150 may initially compare a current position of the carrier 202 with the predetermined carry position stored and determine an amount of movement necessary to align the location 202 with the predetermined carry position stored. The controller 150 can then order the movement of the nozzle 202 based on the determined distance. Accordingly, in any of the configurations, the controller 150 translates a difference between the current position and the position stored in an order or a series of orders to one or more actuators that simulate commands received from an operator control. Consequently, the use of the selection mechanism allows the operator to concentrate on driving the LHD 200 without also having to perform multiple joystick movements to return the wand 202 to a transport position.

In some embodiments, an operator can manually adjust the predetermined transport position (for example, the predetermined height, the predetermined angle or the combination thereof) to suit the operator's preferences or operating environment. For example, the operator may be able to signal when the carrier 202 is in a desired transport position (for example, by selecting a selection mechanism or operating an operator control). The controller 150 receives the input from the operator and saves the current position of the carrier 202 (for example, the current height, the current angle or the combination thereof). The controller 150 can determine the current position based on data collected by one or more sensors that communicate with the controller 150 (for example, a pressure sensor, an encoder, an inclinometer and the like). The stored location information can be retrieved and applied when the operator subsequently selects the return transport mechanism. In some embodiments, the modified predetermined transport position can be stored as an absolute position (for example, a height and an angle). However, alternatively or in addition, the modified predetermined transport position can be stored as a displacement to the predetermined transport position (for example, a height displacement and an angle displacement). In some embodiments, the modified transport position may be restored to the predetermined transport position after the LHD 200 is turned off and restarted. In other embodiments, the modified transport position may be at rest in the predetermined transport position (for example, in response to the selection of a reset to default selection mechanism).

As illustrated in Figure 23, the transport position can be defined when the carrier 202 is rolled back and the arms 204 are low (the carrier 202 is low and is engaged to place the carrier 202 in a very stable position so that the machine can drive long distances commonly performed using LHD). In particular, the transport position and, subsequently, the automatic return to transport functionality can provide benefits in situations in which, once the operator fills the booth 202 or dumps the booth 202, the operator must drive the LHD 200 to great distance (for example, greater than approximately 152.4 meters). For example, surface wheel loaders typically travel less than 91.44 meters during a round trip between a haul truck and an excavator. This distance generally does not guarantee placing the wafer in a transport position. On the contrary, when traveling this distance, the arms of the surface loader can be used to fully lift the carriage or return the carriage to an excavation position. On the contrary, the return distances of LHD are usually 304.8 meters or more. Accordingly, the automatic return-to-transport functionality provides benefits for long-distance LHDs where it is undesirable (for example, for stability purposes) to drive with the fork 202 completely elevated.

Therefore, the embodiments of the invention provide, among other things, a kinetic energy storage system for an extraction machine. The kinetic energy storage system can be used to power a traction system of the extraction machine using the energy stored during engine starting, low engine load and braking events.

Several features and advantages of the invention are set forth in the following claims.