Mining machine and energy storage system for same

• US 9,764,634 B2
• Filed: 05/27/2016
• Issued: 09/19/2017
• Est. Priority Date: 05/28/2015
• Status: Active Grant

• Current Assignee: Joy Global Longview Operations LLC (Mitsui & Company Limited)
• Original Assignee: Joy Global Longview Operations LLC (Mitsui & Company Limited)
• Inventors: Dorsett, William A., Dillinger, James B., Lyten, Michael John, Barr, Marcus N., Neilson, Bradley Maxwell, Owings, Don F.
• Primary Examiner(s): Gurari, Erez
• Application Number:
  US15/166,976
• Publication Number:
  US 20160347167A1
• Time in Patent Office: 480 Days
• CPC Class Codes: B60K 6/30 characterised by chargeable mechanical accumulators, e.g. flywheels
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60K 7/0007 the motor being electric
• CPC Class Codes: B60L 15/2018 for braking on a slope
• CPC Class Codes: B60L 2200/40 Working vehicles
• CPC Class Codes: B60L 2200/42 Fork lift trucks
• CPC Class Codes: B60L 2220/42 with use of more than one motor
• CPC Class Codes: B60L 2220/46 Wheel motors, i.e. motor connected to only one wheel
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/30 using propulsion power stored mechanically, e.g. in fly-wheels
• CPC Class Codes: B60L 50/60 using power supplied by batteries in combination with fuel cells B60L50/75
• CPC Class Codes: B60L 7/08 Controlling the braking effect B60L7/04, B60L7/06 take precedence
• CPC Class Codes: B60T 1/02 acting by retarding wheels
• CPC Class Codes: B60T 1/10 by utilising wheel movement for accumulating energy, e.g. driving air compressors
• CPC Class Codes: B60T 13/586 the retarders being of the electric type
• CPC Class Codes: B60T 2270/60 Regenerative braking
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 20/10 Controlling the power contribution of each of the prime movers to meet required power demand
• CPC Class Codes: B60Y 2200/415 : Wheel loaders
• CPC Class Codes: B60Y 2200/92 : Hybrid vehicles
• CPC Class Codes: E02F 3/3417 : Buckets emptying by tilting E02F3/342, E02F3/345 take precedence
• CPC Class Codes: E02F 3/431 : for bucket-arms, front-end loaders, dumpers or the like
• CPC Class Codes: E02F 9/2041 : Automatic repositioning of implements, i.e. memorising determined positions of the implement for dipper-arms or bucket-arms E02F3/434, E02F3/437, E02F3/438, E02F3/439 take precedence
• CPC Class Codes: E02F 9/205 : Remotely operated machines, e.g. unmanned vehicles E02F3/8866 takes precedence
• CPC Class Codes: E02F 9/2075 : of the hybrid type for vehicles in general B60W20/00
• CPC Class Codes: E02F 9/2091 : Control of energy storage means for electrical energy, e.g. battery or capacitors energy recovery arrangements in hydraulic or pneumatic drives E02F9/2217
• CPC Class Codes: E02F 9/2217 : with energy recovery arrangements, e.g. using accumulators, flywheels
• CPC Class Codes: E21C 33/02 : with equipment for loading or unloading the machine on to or from the truck
• CPC Class Codes: F16D 61/00 : Brakes with means for making the energy absorbed available for use F16D57/00 takes precedence
• CPC Class Codes: H02K 7/025 : for power storage
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y10S 903/96 : having chargeable mechanical accumulator

Abstract

A mobile mining machine includes a plurality of traction elements, a plurality of motors, a power source in electrical communication with the plurality of motors, and an energy storage system in electrical communication with the plurality of motors and the power source. Each of the motors is coupled to an associated one of the plurality of traction elements. Each of the motors is driven by the associated traction element in a first mode, and drives the associated traction element in a second mode. The energy storage system includes a shaft, a rotor secured to the shaft, a stator extending around the rotor, and a flywheel coupled to the shaft for rotation therewith. In the first mode, rotation of the motors causes rotation of the flywheel to store kinetic energy. In the second mode, rotation of the rotor and the flywheel discharges kinetic energy to drive the motors.

Claims

1. A mobile mining machine comprising:

a plurality of traction elements;

a plurality of motors, each motor being coupled to an associated one of the plurality of traction elements, each motor configured to be driven by the associated traction element in a first mode, each motor configured to drive the associated traction element in a second mode;

a switched reluctance motor in electrical communication with the plurality of motors; and

an energy storage system in electrical communication with the plurality of motors and the power source, the energy storage system including a shaft defining a shaft axis, a rotor secured to the shaft, a stator extending around the rotor and around the shaft axis, and a flywheel coupled to the shaft for rotation therewith,

wherein, in the first mode, rotation of the plurality of motors causes rotation of the flywheel to store kinetic energy,

wherein, in the second mode, rotation of the rotor and the flywheel discharges kinetic energy to drive the plurality of motors.

2. The mobile mining machine of claim 1, further comprising

a bi-directional electrical bus providing electrical communication between the motors, the power source, and the energy storage system;

and

a plurality of power converters, each power converter associated with one of the motors, the power source, and the energy storage system.

3. The mobile mining machine of claim 2, wherein in the first mode the rotation of the motors transmits electrical energy to the energy storage system via the bus, the electrical energy causing rotation of the flywheel, wherein in the second mode rotation of the rotor and the flywheel is converted to electrical energy and transmitted to the motors via the bus.

4. The mobile mining machine of claim 1, further comprising a plurality of braking mechanisms, each of the braking mechanisms associated with one of the motors, wherein when the speed of the motor is reduced, the motor supplies energy to the energy storage system.

5. The mobile mining machine of claim 4, wherein, in the first mode, when the energy storage system reaches a maximum storage capacity, additional energy created by the rotation of the plurality of motors is transmitted to one of the braking mechanisms and dissipated as heat.

6. The mobile mining machine of claim 1, wherein the switched reluctance motor is coupled to one of more hydraulic pumps for driving auxiliary actuators.

7. The mobile mining machine of claim 1, wherein, in the first mode, the switched reluctance motor may receive energy from the plurality of motors, the switched reluctance motor driving an engine at a constant speed to reduce fuel consumption.

8. The mobile mining machine of claim 1, wherein the flywheel may rotate at least 3000 revolutions per minute, and wherein the energy storage system outputs energy of at least approximately 1 megajoule.

9. The mobile mining machine of claim 1, wherein the flywheel includes a first portion and a second portion, the first portion extending radially outward from the shaft and defining a periphery spaced apart from the shaft, the second portion connected to the periphery and extending axially along a portion of the shaft.

10. The mobile mining machine of claim 9, wherein the second portion extends around the rotor and the stator.

11. A mobile haulage vehicle comprising:

a chassis;

a boom including a first end pivotably coupled to the chassis and a second end;

an attachment coupled to the second end of the boom; and

a drive system including,

a bi-directional electrical bus;

a plurality of traction elements supporting the chassis;

a plurality of motors, each motor being coupled to an associated one of the plurality of traction elements and in electrical communication with the bus, each motor configured to be driven by the associated traction element in a first mode, each motor configured to drive the associated traction element in a second mode;

a switched reluctance motor in electrical communication with the plurality of motors via the bus; and

an energy storage system in electrical communication with the plurality of motors and the switched reluctance motor via the bus, the energy storage system including a housing secured to the chassis, a shaft, a rotor secured to the shaft, a stator, and a flywheel coupled to the shaft for rotation therewith, the shaft defining a shaft axis and supported for rotation relative to the housing, the stator extending around the rotor and around the shaft axis,

wherein, in the first mode, rotation of the plurality of motors transmits electrical energy to the energy storage system via the bus, the electrical energy driving rotation of the flywheel to store kinetic energy,

wherein, in the second mode, rotation of the rotor and the flywheel transmits electrical energy to the motors via the bus, driving the plurality of motors.

12. The mobile haulage vehicle of claim 11, further comprising a plurality of power converters, each power converter providing electrical communication between the bus and one of the energy storage system, the switched reluctance motor, and one of the motors.

13. The mobile haulage vehicle of claim 11, further comprising a plurality of braking mechanisms, each of the braking mechanisms associated with one of the motors, wherein when the speed of the motor is reduced, the motor supplies energy to the energy storage system.

14. The mobile haulage vehicle of claim 11, wherein, in the first mode, when the energy storage system reaches a maximum storage capacity, additional energy created by the rotation of the plurality of motors is transmitted to one of the braking mechanisms and dissipated as heat.

15. The mobile haulage vehicle of claim 11, wherein the drive system further includes an engine coupled to the switched reluctance motor.

16. The mobile haulage vehicle of claim 11, wherein the switched reluctance motor is coupled to at least one hydraulic pump for driving at least one auxiliary actuator.

17. The mobile haulage vehicle of claim 11, wherein, in the first mode, the switched reluctance motor may receive energy from the plurality of motors, the switched reluctance motor driving an engine at a constant speed to reduce fuel consumption.

18. The mobile haulage vehicle of claim 11, wherein the flywheel may rotate between approximately 0 revolutions per minute and approximately 6500 revolutions per minute, and wherein the energy storage system outputs energy of up to approximately 3 megajoules.

19. A drive system for a haulage vehicle, the drive system comprising:

a bi-directional electrical bus;

a plurality of wheels;

a plurality of motors, each motor being coupled to an associated one of the plurality of wheels and in electrical communication with the bus, each motor configured to be driven by the associated wheel in a first mode, each motor configured to drive the associated wheel in a second mode;

a plurality of power converters, each power converter providing electrical communication between the bus and one of the motors;

a switched reluctance motor in electrical communication with the plurality of motors via the bus, the switched reluctance motor coupled to at least one hydraulic pump for driving at least one auxiliary actuator;

an engine coupled to the switched reluctance motor; and

an energy storage system in electrical communication with the plurality of motors and the switched reluctance motor via the bus, the energy storage system including a housing, a shaft defining a shaft axis and supported for rotation relative to the housing, a rotor secured to the shaft, a stator, and a flywheel coupled to the shaft for rotation about the shaft axis, the stator extending around the rotor and around the shaft axis.

20. The drive system of claim 19, wherein in a first mode the rotation of the motors transmits electrical energy to the energy storage system and causes rotation of the flywheel, wherein in a second mode rotation of the rotor and the flywheel discharges energy to drive the plurality of motors.

21. The drive system of claim 19, further comprising a plurality of braking mechanisms, each of the braking mechanisms associated with one of the motors, wherein when the speed of one of the motors is reduced, the one motor supplies energy to the energy storage system.

22. The drive system of claim 19, wherein, in at least one mode of operation, the switched reluctance motor may receive energy from the plurality of motors, the switched reluctance motor driving the engine at a constant speed to reduce fuel consumption.