ENERGY MANAGEMENT SYSTEM FOR MACHINERY PERFORMING A PREDICTABLE WORK CYCLE

• US 20140083089A1
• Filed: 09/23/2013
• Published: 03/27/2014
• Est. Priority Date: 09/21/2012
• Status: Active Grant

• Current Assignee: Harnischfeger Technologies Inc. (Mitsui & Company Limited)
• Original Assignee: Harnischfeger Technologies Inc. (Mitsui & Company Limited)
• Inventors: Wutke, Joe, Dorsett, William A., Barr, Marcus N., Sorgee, Jason
• Granted Patent: US 10,132,335 B2
• Time in Patent Office: Days
• US Class Current: 60/327
• CPC Class Codes: E02F 3/437 providing automatic sequences of movements, e.g. linear excavation, keeping dipper angle constant
• CPC Class Codes: E02F 9/2075 of the hybrid type for vehicles in general B60W20/00
• CPC Class Codes: E02F 9/265 with follow-up actions (e.g. control signals sent to actuate the work tool)
• CPC Class Codes: F15B 15/18 Combined units comprising both motor and pump

Abstract

Industrial machines and methods of operating the same. One industrial machine includes at least one controller that is configured to (1) detect an occurrence of a regenerative work cycle segment within a repetitive work cycle performed by the industrial machine and including a plurality of work cycle segments and (2) modify operation of at least one power source included in the industrial machine for the regenerative work cycle segment (i.e., prior to and/or during the regenerative work cycle segment).

Claims

1. An industrial machine comprising:

at least one controller configured to (1) detect an occurrence of a regenerative work cycle segment within a repetitive work cycle performed by the industrial machine and including a plurality of work cycle segments and (2) modify operation of at least one power source included in the industrial machine for the regenerative work cycle segment.

2. The industrial machine of claim 1, wherein the power source includes an engine.

3. The industrial machine of claim 2, wherein the at least one controller is configured to modify operation of the at least one power source by increasing a speed of the engine.

4. The industrial machine of claim 2, wherein the at least one controller is configured to modify operation of the at least one power source by decreasing the speed of the engine.

5. The industrial machine of claim 1, wherein the at least one controller is configured to modify operation of the at least one power source prior to a start of the regenerative work cycle segment.

6. The industrial machine of claim 1, wherein the at least one controller is configured to detect the occurrence of a regenerative work cycle segment by detecting a current work cycle segment and identifying whether the current work cycle segment is a regenerative work cycle segment.

7. The industrial machine of claim 1, wherein the at least one controller is configured to detect the occurrence of a regenerative work cycle segment by detecting a current work cycle segment, predicting a subsequent work cycle segment based on the current work cycle segment and the repetitive work cycle, and identifying whether the subsequent work cycle segment is a regenerative work cycle segment.

8. The industrial machine of claim 1, wherein the controller is further configured to modify a bi-directional power bus for the regenerative work cycle segment.

9. The industrial machine of claim 8, wherein the controller is configured to modify the bi-directional power bus by reducing a voltage of the bi-directional power bus.

10. The industrial machine of claim 1, further comprising a dipper controlled by an operator to perform the repetitive work cycle.

11. The industrial machine of claim 10, further comprising at least one sensor configured to detect a position of the dipper.

12. The industrial machine of claim 11, wherein the at least one sensor includes at least one of a crowd sensor, a swing sensor, and a hoist sensor.

13. The industrial machine of claim 10, wherein the controller is configured to detect the occurrence of a regenerative work cycle segment based on information from the at least one sensor.

14. The industrial machine of claim 10, further comprising an operator interface configured to receive at least one motion command from an operator.

15. The industrial machine of claim 14, wherein the at least one motion command includes at least one of a crowd control, a swing control, a hoist control, and a door control from an operator.

16. The industrial machine of claim 14, wherein the controller is configured to detect the occurrence of a regenerative work cycle segment based on the at least one motion command.

17. The industrial machine of claim 11, wherein the plurality of work cycle segments includes a dig segment, a swing segment, a dump segment, and a return segment.

18. A method of operating an industrial machine, the method comprising:

detecting, by a controller, an occurrence of a regenerative work cycle segment within a repetitive work cycle performed by the industrial machine, the repetitive work cycle including a plurality of work cycle segments; and

modifying, by the controller, operation of the industrial machine for the regenerative work cycle.

19. The method of claim 18, wherein detecting an occurrence of a regenerative work cycle segment includes detecting a current work cycle segment and identifying whether the current work cycle segment is a regenerative work cycle segment.

20. The method of claim 18, wherein detecting an occurrence of a regenerative work cycle segment includes detecting a current work cycle segment, predicting a subsequent work cycle segment based on the current work cycle segment and the repetitive work cycle, and identifying whether the subsequent work cycle segment is a regenerative work cycle segment.

21. The method of claim 18, wherein modifying operation of the industrial machine includes modifying operation of the industrial machine prior to a start of the regenerative work cycle segment.

22. The method of claim 18, wherein modifying operation of the industrial machine includes modifying operation of at least one engine included in the industrial machine.

23. The method of claim 22, wherein modifying operation of the at least one engine includes increasing a speed of the at least one engine.

24. The method of claim 22, wherein modifying operation of the at least one engine includes decreasing a speed of the at least one engine.

25. The method of claim 18, wherein modifying operation of the industrial machine includes modifying operation of at least one bi-directional power bus included in the industrial machine.

26. The method of claim 25, wherein modifying operation of the at least one bi-directional power bus includes lowering a voltage of the at least one bi-directional power bus.

27. The method of claim 18, further comprising returning the shovel to non-modified operation after an end of the regenerative work cycle segment.

28. An energy management system comprising:

a bi-directional power bus;

a power conversion unit receiving electrical power from the bi-directional power bus and generating regulated electrical energy;

an actuator receiving regulated electrical energy from the power conversion unit to operate at least one tool within a repetitive work cycle having a plurality of work cycle segments;

an engine;

a motor-generator coupled to and driven by the engine, the motor/generator generating electrical energy and supplying the electrical power to the bi-directional power bus; and

a controller configured to (1) detect an occurrence of one of the plurality of work cycle segments during which regenerative power is generated and (2) modify operation of at least one of the engine and the bi-directional power bus for the one of the plurality of work cycle segments based on the regenerative power.

29. The energy management system of claim 28, wherein the controller is configured to modify operation of at least one of the engine and the bi-directional power bus by increasing a speed of the engine.

30. The energy management system of claim 28, wherein the controller is configured to modify operation of at least one of the engine and the bi-directional power bus by decreasing a speed of the engine.

31. The energy management system of claim 28, wherein the controller is configured to modify operation of at least one of the engine and the bi-directional power bus by lowering a voltage of the at least one bi-directional power bus.

32. The energy management system of claim 28, wherein the motor-generator drives the engine during the one of the plurality of work cycle segments.