Drive System for Dump Truck
20250326301 ยท 2025-10-23
Inventors
- Satoru KANEKO (Tokyo, JP)
- Masatoshi Yoshimura (Tokyo, JP)
- Kosuke MATSUO (Tokyo, JP)
- Seiji ISHIDA (Ibaraki, JP)
- Toshihiko WATANABE (Ibaraki, JP)
- Tokuma IKEGAMI (Ibaraki, JP)
Cpc classification
B60L50/13
PERFORMING OPERATIONS; TRANSPORTING
H02P21/06
ELECTRICITY
H02P9/10
ELECTRICITY
H02P25/22
ELECTRICITY
H02P29/028
ELECTRICITY
F02D29/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B60L7/06
PERFORMING OPERATIONS; TRANSPORTING
International classification
B60L50/13
PERFORMING OPERATIONS; TRANSPORTING
Abstract
It is an object of the present invention to provide a drive system for dump trucks that is capable of reducing the capacity of a converter that excites a two-winding induced generator and of performing output control according to the converter capacity. To achieve the object, the drive system includes an induced generator having a primary winding including a main winding and a sub-winding, a rectifier for converting an AC voltage generated across the main winding into a DC voltage, a propulsive machinery side load connected to the rectifier, a converter connected to the sub-winding for exciting a secondary winding of the induced generator and converting an AC voltage generated across the sub-winding into a DC voltage, an accessory side load connected to the converter, and a controller for controlling the converter, in which the controller controls a DC voltage of the accessory side load according to electric power required by the accessory side load and controls a DC voltage of the propulsive machinery side load according to electric power required by the propulsive machinery side load and a converter capacity that represents a current capacity of the converter.
Claims
1. A drive system for a dump truck, comprising: an induced generator having a primary winding including a main winding and a sub-winding; a rectifier for converting an AC voltage generated across the main winding into a DC voltage; a propulsive machinery side load connected to the rectifier; a converter connected to the sub-winding for exciting a secondary winding of the induced generator and converting an AC voltage generated across the sub-winding into a DC voltage; an accessory side load connected to the converter; and a controller configured to control the converter, wherein the controller is configured to control a DC voltage of the accessory side load according to electric power required by the accessory side load and control a DC voltage of the propulsive machinery side load according to electric power required by the propulsive machinery side load and a converter capacity that represents a current capacity of the converter.
2. The drive system for a dump truck according to claim 1, wherein the controller is configured to calculate a q-axis current command value of the induced generator on a basis of a difference between a DC voltage value and a DC voltage command value of the accessory side load, calculate a d-axis current command value of the induced generator on a basis of the electric power required by the propulsive machinery side load, the DC voltage thereof, and the converter capacity, and output a control signal according to the d-axis current command value and the q-axis current command value to the converter.
3. The drive system for a dump truck according to claim 2, wherein the controller is configured to calculate, in a case where the converter capacity is changed, the d-axis current command value based on the electric power required by the propulsive machinery side load, the DC voltage of the propulsive machinery side load, and the changed converter capacity.
4. The drive system for a dump truck according to claim 1, wherein the converter includes a plurality of converters, the controller has a plurality of sensors for sensing direct currents outputted from the respective converters, and the controller is configured to calculate, in a case where direct currents are outputted from the respective converters, a sum of capacities of the converters as the converter capacity, and calculate, in a case where no direct current is outputted from a certain one of the converters, a sum capacity of the converter excluding the certain converter from the converters as the converter capacity.
5. The drive system for a dump truck according to claim 1, wherein the DC voltage of the propulsive machinery side load is higher than the DC voltage of the accessory side load.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
[0016]
MODES FOR CARRYING OUT THE INVENTION
[0017] Embodiments of the present invention will be described hereinbelow with reference to the drawings. In the drawings, equivalent components are denoted by identical reference characters, and their duplicate description will be omitted below.
First Embodiment
[0018] First, a dump truck for mines that incorporates drive systems according the embodiments of the present invention will be described below. The dump truck for mines repeats a cycle representing a series of work events that include loading itself with soil at a loading site, traveling from the loading site to a dumping site, dumping the soil at the dumping site, and traveling from the dumping site to the loading site.
[0019]
[0020] An electrical type drive system for driving the drive wheels 5L and 5R will be described below.
[0021]
[0022] The main generator 2 and the sub-generator 14 convert rotary energy of the engine 1 into electric energy (AC electric power). The rectifier 8 rectifies AC electric power supplied from the main generator 2 into DC electric power and supplies the DC electric power to the travelling inverter 9. The travelling inverter 9 converts the DC electric power supplied from the rectifier 8 into AC electric power and supplies the AC electric power to the travelling motor 3.
[0023] The sub-generator 14 is used as a power supply of an accessory system for driving accessories such as a cooling device. The sub-rectifier 11 rectifies AC electric power supplied from the sub-generator 14 into DC electric power and supplies the DC electric power to the accessory inverter 12. The accessory inverter 12 converts the DC electric power supplied from the sub-rectifier 11 into AC electric power and supplies the AC electric power to the accessory motor 13. The accessory motor 13 drives a cooling device (not illustrated) such as a blower, for example. In
[0024] In a system that incorporates a secondary battery for an electric vehicle or the like, regenerative electric power generated when the travelling motor 3 is braked is retrieved in the secondary battery (to charge the secondary battery), and is discharged at the time instantaneously large power is required as for acceleration. On the other hand, dump trucks, with which the present invention is concerned, tend to avoid carrying heavy objects that leads to a reduction in the carrying efficiency, and often have a system free of a secondary battery. Such a system includes the discharging resistor 15 that consumes regenerative electric power generated by the travelling motor 3 when it is braked, making it possible to obtain electric braking forces from the travelling motor 3 while lowering an overvoltage on a DC bus on the travelling motor side (propulsive machinery side).
[0025] The drive system 100X described above is basically a diesel electric type drive system in which the rotary drive power of the engine is used to generate electric power from the generators, unlike mechanical type dump trucks in which the rotary power of the engine is used to directly drive the tires through a torque converter and a transmission. The drive system 100X includes the main generator 2 that generates electric power used to propel the dump truck and the sub-generator 14 that generates electric power used to drive the accessories. Although these generators are not limited to any particular types, if field-winding generators in which a field winding is provided on a rotor, for example, are used as the generators, then converters required to convert the generated electric power into DC electric power may be inexpensive rectifiers, as illustrated in
[0026] One conceivable means for solving the problems is to use, in place of the main generator 2 and the sub-generator 14, a two-winding induced generator in which the winding of the main generator 2 and the winding of the sub-generator 14 are integrally combined with each other (two-winding type) and the generator is of the induction type free of brushes.
[0027]
[0028] The rectifier 8 has its AC side connected to the main winding of the two-winding induced generator 20 and its DC side connected through a propulsive machinery side DC bus 16 to the travelling inverter 9 and the discharging resistor 15. The rectifier 8 rectifies AC electric power generated across the main winding into DC electric power and supplies the DC electric power to the propulsive machinery side DC bus 16. The travelling inverter 9 that is connected to the travelling motor 3 converts the DC electric power from the propulsive machinery side DC bus 16 into AC electric power and supplies the AC electric power to the travelling motor 3. The discharging resistor 15 is energized when the travelling motor 3 operates in a regenerative mode (when the travelling motor 3 is retarded), consuming electric power (regenerative electric power) generated by the travelling motor 3 in the regenerative mode. The excitation converter 21 has its AC side connected to the sub-winding of the two-winding induced generator 20 and its DC side connected through an accessory side DC bus 17 to the accessory inverter 12. The excitation converter 21 converts AC electric power generated across the sub-winding into DC electric power and supplies the DC electric power to the accessory side DC bus 17. The accessory inverter 12 that is connected to the accessory motor 13 converts the DC electric power from the accessory side DC bus 17 into AC electric power and supplies the AC electric power to the accessory motor 13. Since each of the travelling inverter 9 and the accessory inverter 12 is a voltage type inverter, they are required to control the voltages from the DC buses on respective input sides thereof into voltages capable of stably supplying electric power to the propulsive machinery side and the accessory side. To meet the requirement, it is necessary for the excitation converter 21 to stably control the voltages across the main winding and the sub-winding.
[0029] Here, the main winding of the two-winding induced generator 20 is connected to the travelling inverter 9 through only the rectifier 8 without being connected to a battery and a large-capacity capacitor, or is not connected to an electric power system. Therefore, the main winding of the two-winding induced generator 20 does not need to output a constant voltage. The voltages across the main winding and the sub-winding of the two-winding induced generator 20 are generally proportional to each other. Consequently, the excitation converter 21 that is connected to the sub-winding can change both of the voltages across the auxiliary winding and the main winding by exciting the auxiliary winding. By thus exciting the sub-winding of the two-winding induced generator 20 with the excitation converter 21, it is possible to make the generator including its propulsive machinery and accessory sides brushless. With the drive system 100 according to the present embodiment, as the capacity of the travelling inverter 9 is larger than the capacity of the accessory inverter 12, a better cost advantage can be achieved by connecting the converter that is more expensive than the rectifier to the accessory inverter 12 that is of smaller electric power requirements rather than to the travelling inverter 9.
[0030]
[0031]
[0032] The voltage deviation computing section 31 calculates a difference (voltage deviation) between an accessory side DC voltage command value preset in the controller 30 and the accessory side DC voltage, and outputs the difference to the voltage controlling section 32. The voltage controlling section 32 calculates an accessory side current command (q-axis current command value) based on the difference (voltage deviation) between the accessory side DC voltage command value and the accessory side DC voltage, and outputs the calculated accessory current command to the current command determining section 33 and the current controlling section 34. Specific contents of the computation performed by the voltage controlling section 32 are irrelevant to the present invention in particular, and may be carried out by, for example, a proportional plus integral process that is normally often used in the art. Here, the accessory side current command outputted from the voltage controlling section 32 is a current command corresponding to the q-axis with respect to the two-winding induced generator 20 because it is necessary to compensate for fluctuations of the voltage on the accessory side DC bus 17 that occur depending on the magnitude of the accessory side load with the effective electric power of the sub-winding because the excitation converter 21 connected to the sub-winding is connected directly to the accessory side load.
[0033] The current command determining section 33 calculates an accessory side current command (d-axis current command value) with respect to the two-winding induced generator 20 on the basis of the converter capacity (current capacity), the propulsive machinery side DC voltage, propulsive machinery side required electric power, and the accessory side current command (q-axis current command value), and outputs the calculated accessory current command to the current controlling section 34. Here, the accessory side current command outputted from the current command determining section 33 is a current command corresponding to the d-axis because the excitation converter 21 connected to the sub-winding adjusts magnetic fluxes for controlling the voltage across the winding.
[0034] The current controlling section 34 calculates an input voltage of the excitation converter 21 on the basis of the accessory side current commands (the d-axis current command value and the q-axis current command value), and outputs a control signal according to the calculated input voltage to the excitation converter 21. Specific contents of the computation performed by the current controlling section 34 are irrelevant to the present invention in particular, and may be carried out by, for example, a proportional plus integral process that is normally often used in the art.
[0035]
[0036] The target DC voltage determining section 33a determines a target value for the propulsive machinery side DC voltage (target DC voltage) according to the electric power required by the propulsive machinery side load 9, and outputs the determined target DC voltage to the target field current determining section 33b and the generator current computing section 33c. The target DC voltage may not necessarily be equal to a DC voltage according to the electric power required by the propulsive machinery side load 9, and is established in a range that can be output by the travelling inverter 9. If the propulsive machinery side DC voltage becomes a very low voltage, then an excessive current flows through the travelling inverter 9, possibly resulting in a large loss. Therefore, the target DC voltage is adjusted to make the propulsive machinery side DC voltage as high as possible. Here, taking the characteristics of the two-winding induced generator 20 and the travelling motor 3 into account in advance, the target DC voltage determining section 33a determines a target DC voltage according to the electric power required by the travelling motor 3. Processes of determining a target DC voltage may include a process of generating a table of data representing calculated results and searching the table for a target DC voltage and a process of determining a target DC voltage by solving actual characteristic equations.
[0037] The target field current determining section 33b determines a target field current (Idtgt) according to the target DC voltage and outputs the determined target field current to the generator current computing section 33c. Processes of determining a target field current may include a process of generating a table of data representing calculated results and searching the table for a target field current and a process of determining a target field current by solving actual characteristic equations.
[0038] The generator current computing section 33c calculates the magnitude (I1) of the current of the two-winding induced generator 20 on the basis of the q-axis current command value (Iqref) and the target field current (Idtgt). The magnitude (I1) of the current of the two-winding induced generator 20 is calculated according to the following equation (1):
[0039] Here, in a case where the actual propulsive machinery side DC voltage and the target DC voltage deviate largely from each other, the generator current computing section 33c makes appropriate adjustments to increase or reduce the target field current (Idtgt) to bring the propulsive machinery side DC voltage closely to the target DC voltage value.
[0040] In a case where the magnitude (I1) of the current of the two-winding induced generator 20 exceeds the converter capacity (current capacity), the current limiting section 33d limits the target field current (Idtgt) in order to make the magnitude (I1) of the current of the two-winding induced generator 20 equal to or smaller than the converter capacity (current capacity) according to the equation (1), and determines the limited target field current (Idtgt) as the d-axis current command value (Idref). By thus determining the q-axis current command value (Iqref) based on the target DC voltage in a range not exceeding the capacity of the excitation converter 21, it is possible to control the DC voltage of the propulsive machinery side load 9 in the range not exceeding the capacity of the excitation converter 21 that is connected to the sub-winding of the two-winding induced generator 20.
Conclusion
[0041] According to the present embodiment, the drive system 100 for the dump truck includes the induced generator 20 having the primary winding including the main winding and the sub-winding, the rectifier 8 for converting the AC voltage generated across the main winding into the DC voltage, the propulsive machinery side load 9 connected to the rectifier 8, the converter 21 connected to the sub-winding for exciting the secondary winding of the induced generator 20 and converting the AC voltage generated across the sub-winding into the DC voltage, the accessory side load 12 connected to the converter 21, and the controller 30 for controlling the converter 21, in which the controller 30 controls the DC voltage of the accessory side load 12 according to the electric power required by the accessory side load 12 and controls the DC voltage of the propulsive machinery side load 9 according to the electric power required by the propulsive machinery side load 9 and the converter capacity that represents the current capacity of the converter 21.
[0042] According to the present embodiment arranged as described above, it is possible to reduce the capacity of the converter 21 by connecting the converter 21 that excites the secondary winding of the induced generator 20 to the sub-winding. It is also possible to output the electric power required by the accessory side load 12 by controlling the DC voltage of the accessory side load 12 on the basis of the electric power required by the accessory side load 12. Furthermore, it is possible to control the DC voltage of the propulsive machinery side load 9 within the range not exceeding the converter capacity by controlling the DC voltage of the propulsive machinery side load 9 on the basis of the electric power required by the propulsive machinery side load 9 and the converter capacity that represents the current capacity of the converter 21.
[0043] In addition, the controller 30 according to the present embodiment calculates the q-axis current command value (Iqref) of the induced generator 20 on the basis of the difference between the DC voltage value and the DC voltage command value of the accessory side load 12, calculates the d-axis current command value (Idref) of the induced generator 20 on the basis of the electric power required by the propulsive machinery side load 9, the DC voltage thereof, and the converter capacity, and outputs the control signal according to the d-axis current command value (Idref) and the q-axis current command value (Iqref) to the converter 21. It is thus possible to compensate for fluctuations of the voltage of the accessory side DC bus 17 that occur depending on the magnitude of the accessory side load 12 with the effective electric power of the sub-winding.
[0044] According to the present embodiment, the DC voltage of the propulsive machinery side load 9 is higher than the DC voltage of the accessory side load 12. Consequently, in the drive system for the dump truck in which the DC voltage of the propulsive machinery side load 9 is higher than the DC voltage of the accessory side load 12, it is possible to reduce the capacity of the converter 21 that excites the two-winding induced generator and perform output control according to the converter capacity. By performing output control according to the converter capacity, it is possible to reduce energy loss and heat-induced damage.
Second Embodiment
[0045] A second embodiment of the present invention will be described below primarily with respect to its differences from the first embodiment. The drive system 100 according to the first embodiment supplies electric power to the propulsive machinery side load 9 and the accessory side load 12 with only the excitation converter 21 that is connected to the sub-winding of the two-winding induced generator 20. Therefore, a failure of the excitation converter 21 possibly makes it difficult to perform voltage control over the propulsive machinery, disrupting the operation of the machine. The present embodiment allows fallback operation in the event of failure of the excitation converter.
[0046]
[0047] The controller 30 according to the present embodiment measures currents outputted from the converters 21a and 21b with respective sensors 22a and 22b. The controller 30 determines a converter that does not output a current as a failure, and turns off the gate of the converter. At this time, the current limiting section 33d (see
[0048] For example, assuming that the two converters 21a and 21b illustrated in
Conclusion
[0049] The controller 30 according to the present embodiment changes, in a case where the converter capacity is changed, the d-axis current command value (Idref) based on the electric power required by the propulsive machinery side load 9, the DC voltage of the propulsive machinery side load 9, and the changed converter capacity.
[0050] According to the present embodiment arranged as described above, in a case where the converter capacity is changed, it is possible to control the DC voltage of the propulsive machinery side load 9 within a range not exceeding the changed converter capacity.
[0051] Further, the converter 21 according to the present embodiment includes the converters 21a and 21b, and the controller 30 has the sensors 22a and 22b for sensing direct currents outputted from the respective converters 21a and 21b. When direct currents are outputted from the respective converters 21a and 21b, the controller 30 calculates the sum of the capacities of the converters 21a and 21b as a converter capacity. When no direct current is outputted from a certain one of the converters 21a and 21b, the controller 30 calculates the sum capacity of the converter excluding the certain converter from the converters 21a and 21b as a converter capacity. In the case of failure of either one of the converters 21a and 21b, therefore, it is possible to control the DC voltage of the propulsive machinery side load 9 within a range not exceeding the sum capacity of the normal converter.
[0052] Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above embodiments and covers various changes and modifications therein. For example, the above embodiments have been described in detail for an easier understanding of the present invention, and the present invention should not be limited to any arrangements including all the features described above. Some of the features of one of the embodiments may be added to the features of the other embodiment, and some of the features of one of the embodiments may be deleted or replaced with some of the features of the other embodiment.
DESCRIPTION OF REFERENCE CHARACTERS
[0053] 1: Engine [0054] 2: Main generator [0055] 3: Travelling motor [0056] 4L, 4R: Driven wheel [0057] 5L, 5R: Drive wheel [0058] 6: Driver's cabin [0059] 7: Vessel [0060] 8: Rectifier [0061] 9: Travelling inverter (propulsive machinery side load) [0062] 11: Sub-rectifier [0063] 12: Accessory inverter (accessory side load) [0064] 13: Accessory motor [0065] 14: Sub-generator [0066] 15: Discharging resistor [0067] 16: Propulsive machinery side DC bus [0068] 17: Accessory side DC bus [0069] 20: Two-winding induced generator [0070] 21: Excitation converter [0071] 21a, 21b: Converter [0072] 22a, 22b: Sensor [0073] 30, 30X: Controller [0074] 31: Voltage deviation computing section [0075] 32: Voltage controlling section [0076] 33: Current command determining section [0077] 33a: Target DC voltage determining section [0078] 33b: Target field current determining section [0079] 33c: Generator current computing section [0080] 34: Current controlling section [0081] 100, 100X: Drive system