Patent Description:
Diesel electric mining machines typically include generators for producing electrical energy. One or more generators may be powered by one or more engines, which produce air pollution emissions. In some examples, the generators can also function as motors and can increase the speed of one or more engines. Rotating components of an engine can store energy during an off-peak phase of a mining operation and discharge the energy during a peak phase in order to reduce overall energy requirements.

In one example not according to the invention, a mining machine includes an engine and an energy storage device having a flywheel or another form of kinetic energy storage system ("KESS"). The KESS can be used with switched reluctance ("SR") technology to store energy in a kinetic form for later use. One or more KESSs may be implemented in a high power, mining traction application, and may be used on surface machines and/or underground machines incorporating SR technology. When the traction system has a net energy surplus, the flywheel stores kinetic energy proportional to the rotational moment of inertia of the flywheel. In one embodiment, this is represented by an increase in voltage on a capacitive DC bus and occurs when braking or torque opposite to a direction of rotation is applied to a motor or element of the traction system. During periods of peak energy demand, the flywheel is discharged and may provide primary energy to a mining machine, while the engine assists by providing additional energy when necessary. The combination of the flywheel and engine may reduce engine emissions, reduce fuel consumption, and reduce overall cost. The energy storage device includes a housing, a rotor shaft extending through the housing, each end of the rotor shaft supported for rotation by a bearing. The energy storage device further includes a stator extending around a portion of the rotor shaft. A flywheel is coupled to the rotor shaft between the bearings such that the flywheel is offset from the stator along an axis of the rotor shaft.

In one example not according to the invention, 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 configured to be driven by the associated traction element in a first mode, and each of the motors is configured to drive the associated traction element in a second mode. The energy storage system includes 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. In the first mode, rotation of the plurality of 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 plurality of motors.

In another example not according to the invention, a mobile haulage vehicle includes 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. The drive system includes a bi-directional electrical bus, a plurality of traction elements supporting the chassis, a plurality of motors, 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. Each motor is coupled to an associated one of the plurality of traction elements and in electrical communication with the bus. Each motor is configured to be driven by the associated traction element in a first mode, and each motor is configured to drive the associated traction element in a second mode. The energy storage system includes 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 defines a shaft axis and is supported for rotation relative to the housing. The stator extends around the rotor and around the shaft axis. 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. 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.

In yet another example not according to the invention, a drive system for a haulage vehicle includes a bi-directional electrical bus, a plurality of wheels. a plurality of motors, a plurality of power converters, a switched reluctance motor in electrical communication with the plurality of motors via the bus, 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. Each motor is coupled to an associated one of the plurality of wheels and is in electrical communication with the bus. Each motor is configured to be driven by the associated wheel in a first mode, and each motor is configured to drive the associated wheel in a second mode. Each power converter provides electrical communication between the bus and one of the motors. The switched reluctance motor is coupled to at least one hydraulic pump for driving at least one auxiliary actuator. The energy storage system includes 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 extends around the rotor and around the shaft axis.

The present invention is defined by the claims and provides advantages over the prior art. Such advantages include, but are not limited to, capturing and releasing energy at high power levels and extending the operating life of mining machines.

Before any embodiments are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, aspects may be implemented in software (e.g., stored on non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and/or an application specific integrated circuits ("ASICs"). As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components may be utilized to implement the invention. For example, "controllers" described in the specification can include one or more processing units, one or more computer-readable medium modules, one or more input/output interfaces, and various connections (e.g., a system bus) connecting the components.

<FIG> illustrate a mining machine <NUM> according to one embodiment. In the illustrated embodiment, the mining machine <NUM> is a load-haul-dump ("LHD") machine. The machine <NUM> can be an underground mining machine (e.g., a continuous miner, a haulage system, a longwall shearer, a loader, etc.) or a surface mining machine (e.g., a wheel loader, a hybrid shovel, a dragline miner, etc.). In the illustrated embodiment, the mining machine <NUM> further includes a chassis <NUM>, boom <NUM> having a first end <NUM> coupled to the chassis <NUM> and a second end <NUM> coupled to an attachment <NUM> (e.g., a bucket). In the illustrated embodiment, the chassis <NUM> also includes an operator cab <NUM>. The mining machine <NUM> further includes traction elements, such as wheels <NUM>, rotatably coupled to the chassis <NUM> and supporting the chassis <NUM> for movement over the ground. As shown in <FIG>, a kinetic energy storage system ("KESS") or energy storage device <NUM> is supported on the chassis <NUM>. In the illustrated embodiment, the energy storage device <NUM> is positioned proximate an end of the chassis <NUM> opposite the attachment <NUM>.

<FIG> illustrates the primary components of the drive system or drive train <NUM> of the mining machine <NUM>. The drive train <NUM> may include an engine <NUM>, a generator <NUM>, a power converter <NUM>, motors <NUM>, and the energy storage device <NUM>. In some embodiments, the machine <NUM> may include multiple power converters, multiple motors, and/or multiple energy storage devices. The engine <NUM> provides power, in the form of mechanical energy, to the generator <NUM>. In some embodiments, the engine <NUM> is a diesel engine. In some embodiments, the engine <NUM> provides an average power output of <NUM> horsepower ("Hp") and a peak power output of <NUM> Hp. As discussed in further detail below, the energy storage device <NUM> can be used as a power averaging device, discharging stored energy during periods of peak power demand. The energy storage device <NUM> may supplement power supplied by the engine <NUM> in order to reduce the need to operate the engine <NUM> at peak power output.

The generator <NUM> converts mechanical energy received from the engine <NUM> into electrical energy. In some embodiments, the generator <NUM> is a switched reluctance ("SR") motor/generator. In other embodiments, the generator <NUM> is another type of direct current ("DC") motor/generator. In other embodiments, the generator <NUM> is an alternating current ("AC") motor/generator. In some embodiments, the generator <NUM> can also be used as a motor that increases the revolutions per minute ("RPM") of the engine <NUM> (e.g., as an energy storage mechanism used separately or in combination with the energy storage device <NUM> described below).

<FIG> schematically illustrates the components of a drive train for the mining machine <NUM>. In the illustrated embodiment, the generator <NUM> transmits power to a converter <NUM> that converts a received energy into a second energy via a bus <NUM> (e.g., a DC bus). The bus <NUM> is in communication with additional converters <NUM>, each of which transmits the second energy output to a traction motor <NUM>. The converters <NUM> can be configured to transmit energy through the bus <NUM> or to receive power from the bus <NUM>. The traction motors <NUM> convert electrical energy into rotational energy or torque to drive the wheels <NUM> (FIG. 2A) or other components of the mining machine <NUM>. In some embodiments, the motors <NUM> include a motor for each wheel <NUM> of the machine <NUM>. Each traction motor <NUM> is associated with a braking grid <NUM> that converts kinetic energy from the traction motor <NUM> into thermal energy when brakes are applied to slow down the machine <NUM>. In the illustrated embodiment of mining machine <NUM>, the motors <NUM> include a left-front ("LF") motor 130a, a right-front motor ("RF") 130b, a left-rear ("LR") motor 130c, and a right-rear ("RR") motor 130d. The motors <NUM> are used to propel (forward and reverse), brake (forward and reverse), and control tire slip.

In some embodiments, one or more of the motors <NUM> are switched-reluctance ("SR") motors. In such an embodiment, the SR motor may provide full torque at stall (i.e., when the output rotational speed is zero) while consuming a small percentage of the power output of the engine <NUM>, which saves fuel consumption and reduces emissions. It should be understood that in other embodiments, the mining machine <NUM> can include fewer or additional motors.

Referring to <FIG>, the generator <NUM> is also in communication with one or more components of the mining machine <NUM>. These components may operate other aspects of the machine <NUM> (e.g., actuating a loading bucket or driving a cutter head). For example, in some embodiments, the generator <NUM> converts electrical energy to mechanical energy that drives one or more hydraulic components <NUM> (e.g., pumps and/or valves). The hydraulic components <NUM> supply hydraulic energy to the hydraulic systems such as actuators <NUM>. The hydraulic systems can perform hoisting, steering, rotating, and/or other auxiliary functions of the mining machine <NUM>. The hydraulic components <NUM> may also operate parasitic components <NUM>, such as a cooling fan.

In one embodiment, the energy storage device <NUM> may be charged by capturing braking energy from the traction system and/or by receiving power from the engine <NUM> and generator <NUM> during times of low power demand. The energy storage device <NUM> receives and stores electrical energy from the generator <NUM> via the bus <NUM>. The energy storage device <NUM> also outputs stored electrical energy to other components of the mining machine <NUM> (e.g., the converters <NUM>, the motors <NUM>, a hydraulic system, etc.). In operation, each energy storage device <NUM> is configured to store electrical energy when there is available (i.e., excess) power from the engine <NUM> and output stored energy when energy demand is greater than the engine <NUM> can provide. In some embodiments, the energy storage device <NUM> includes a SR motor/generator (e.g., variable speed SR motor/generator).

In one embodiment, the primary energy source for the energy storage device <NUM> is the traction system. When the components (e.g. , the wheels <NUM> and motors <NUM>) of the traction system are braking or slowing down, the energy of the slowing wheels is transmitted to the energy storage device <NUM> and stored as rotational energy in an inertial mass (i.e., flywheel <NUM>).

<FIG> illustrates various potential power transmission paths through the drive train <NUM>. For example, the generator <NUM> and engine <NUM> can provide power to the hydraulic pumps <NUM>, and the generator <NUM> can also receive energy from the bus <NUM> (e.g., when the traction system is braking). Also, each motor <NUM> can receive energy from the bus <NUM> and supply energy to the bus <NUM>. Similarly, the energy storage device <NUM> can receive energy from the bus <NUM> and supply energy to the bus <NUM>. In some embodiments, each motor <NUM> may include a mechanical brake (not shown). When a controller detects that the mechanical brake of the motor <NUM> is engaged, the speed of the motor <NUM> is retarded or reduced to inhibit propulsion of the machine. Braking mechanisms (e.g., braking grid resistors <NUM>) may receive energy from the bus <NUM> and dissipate the energy as heat.

<FIG> illustrates a power flow path through the drive train <NUM> when the energy storage system <NUM> is charged. Power supplied by the generator <NUM> is provided to the bus <NUM>, which transmits power to the energy storage device <NUM>. In some embodiments, the energy storage device <NUM> is charged during start-up of the machine <NUM>. The energy storage device <NUM> may be charged during times of low load on the generator <NUM> (i.e., the generator <NUM> receives surplus energy from the engine <NUM> than is required to operate the traction motors <NUM> or the other components of the machine <NUM>).

<FIG> illustrates a power flow path through the drive train <NUM> when the traction motors <NUM> are driven to propel the machine <NUM>. The energy storage device <NUM> can discharge and transmit power to the bus <NUM>, which transmits the power to the motors <NUM> to drive the wheels <NUM>. In some embodiments, the energy storage device <NUM> acts as the primary or master power source for the motors <NUM> and provides all of the energy required to drive the motors <NUM>. If the energy storage device <NUM> cannot supply all of the energy required by the motors <NUM>, the generator <NUM> and engine <NUM> supply additional power to the bus <NUM> that can be consumed by the motors <NUM>. In this arrangement the energy storage device <NUM> is the primary power supply for the motors <NUM> and the generator <NUM> provides auxiliary or backup power.

In one embodiment, the energy storage device <NUM> is a more responsive power source than the generator <NUM>. The drive train <NUM> relies on the most responsive power source first, allowing the traction system to accelerate and decelerate faster than a conventional drive system. Furthermore, using the energy storage system <NUM> as the primary energy source reduces the need to operate the engine <NUM> at its full output. Rather, using the energy storage device <NUM> as the primary power source to the traction system allows the engine <NUM> to operate at a steadier output, thereby reducing fuel consumption, engine output requirements, and engine wear <NUM>.

In another mode of operation, shown in <FIG>, the drive train <NUM> may operate the traction motors <NUM> without using the energy storage device <NUM>. That is, the energy supplied to the motors <NUM> via the bus <NUM> is supplied solely by the generator <NUM>. This mode may be implemented when the energy storage device <NUM> is not charged, is malfunctioning, or is not present.

<FIG> illustrate power flow paths when the machine <NUM> is braking and the motors <NUM> act as generators supplying electrical energy to the bus <NUM>. During light braking (<FIG>), the energy supplied by the motors <NUM> can be supplied to the generator <NUM>. The generator <NUM> can use the received energy to speed up the drive line between the generator <NUM> and the hydraulic pumps <NUM> (e.g., to speed up the engine <NUM> to a set speed at which fuel injectors are programmed to cease delivering fuel to the engine <NUM>). In some situations, this mode of operation reduces engine fuel consumption (e.g., to operate at zero fuel or near-zero fuel levels).

During heavy braking, shown in <FIG>, the motors <NUM> may generate more energy than the energy generated during light braking. Therefore, the energy generated by the motors <NUM> and supplied to the bus <NUM> may be transmitted to both the generator <NUM> and to charging the energy storage device <NUM>. In another mode (<FIG>), the motors <NUM> may perform heavy braking without charging the energy storage device <NUM> (e.g., the energy storage device <NUM> is full, malfunctioning, or not present). Although some of the power supplied to the bus <NUM> from the motors <NUM> is transmitted to the generator <NUM>, additional or excess energy can be supplied to one or more of the braking grids <NUM> to dissipate the energy as heat.

Other modes of operation can be used with the energy storage device <NUM>. For example, in some embodiments, the generator <NUM> can be used as the primary power source of the traction system and the energy storage device <NUM> can provide backup power. A controller can be incorporated and programmed to control the energy storage device <NUM> based on the operating speed of the traction system.

Referring now to <FIG>, the energy storage device <NUM> includes a housing <NUM> having feet <NUM> mounted on the chassis <NUM> (<FIG>). The housing <NUM> also includes a junction box <NUM> in communication with the generator <NUM> (<FIG>). As shown in <FIG> and <FIG>, the energy storage device <NUM> further includes a shaft <NUM>, a flywheel <NUM> coupled to the shaft <NUM>, and a motor stator <NUM> including coils <NUM>. The shaft <NUM> extends through the housing <NUM> and includes a first end <NUM> and a second end <NUM>. A shaft axis <NUM> extends between the first end <NUM> and the second end <NUM>. Each end <NUM>, <NUM> of the shaft <NUM> is supported for rotation relative to the housing <NUM> by bearings <NUM> (see also <FIG> and <FIG>). In the illustrated embodiment, the bearings <NUM> are double ball bearings. A lamination stack <NUM> forms a rotor and is secured to the outer surface of the shaft <NUM> proximate the first end <NUM>. In the illustrated embodiment, the flywheel <NUM> is axially spaced apart from the rotor <NUM>.

Referring to <FIG> and <FIG>, the motor stator <NUM> is secured within the housing <NUM> and extends around the lamination stack <NUM>. The flywheel <NUM> is positioned within the housing <NUM>. The flywheel <NUM> is secured to the shaft <NUM> proximate the second end <NUM>, such that the flywheel <NUM> is spaced apart from the stator <NUM> along the axis <NUM>. In the illustrated embodiment, the flywheel <NUM> is positioned between the bearings <NUM>. That is, the second end <NUM> of the shaft <NUM> extends beyond the flywheel <NUM> and is supported for rotation by a bearing 205b. The rotation of the flywheel <NUM> and the operation of the machine induces a gyroscopic load on the bearings, and this load is related to the distance between the bearings and the gyroscopic load. Increasing the distance between the flywheel and the bearings reduces the resultant load on the bearings.

In conventional energy storage systems, larger energy storage capacity requires larger masses for the flywheel/storage component. Increasing the mass of the flywheel <NUM> increases the gyroscopic loads on the bearings. The configuration of the flywheel <NUM> with respect to the bearings <NUM> reduces the gyroscopic loads applied to the bearings <NUM> during operation. This allows a larger inertial mass, which in turn increases the energy storage capacity of the device <NUM>. Increasing the energy storage capacity reduces the demand for engine power. In some embodiments, the increased storage capacity reduces the required engine output power by <NUM>%.

The flywheel <NUM> stores kinetic energy in the form of rotational energy. The energy storage device <NUM> is configured to receive electrical energy and output rotational energy, as well as to receive rotational energy and output electrical energy. In some embodiments, the flywheel <NUM> is capable of rotating at speeds between approximately <NUM> revolutions per minute (rpm) and approximately <NUM>,<NUM> rpm. In some embodiments, the maximum rotational speed of the flywheel <NUM> is between approximately <NUM>,<NUM> rpm and approximately <NUM>,<NUM> rpm. In some embodiments, the maximum rotational speed of the flywheel <NUM> is between approximately <NUM>,<NUM> rpm and approximately <NUM>,<NUM> rpm. In some embodiments, the maximum rotational speed of the flywheel is approximately <NUM>,<NUM> rpm. Also, in some embodiments, the maximum energy storage and discharge capacity of the energy storage device <NUM> is between approximately <NUM> megajoule and approximately <NUM> megajoules. In some embodiments, the maximum energy storage and discharge capacity of the energy storage device <NUM> is between approximately <NUM> megajoules and approximately <NUM> megajoules. In some embodiments, the maximum energy storage and discharge capacity of the energy storage device <NUM> is approximately <NUM> megajoules.

In operation, the energy storage device <NUM> may receive electrical energy from, e.g., the generator <NUM>. The electrical energy in the stator <NUM> induces the rotor shaft <NUM> to rotate about the shaft axis <NUM>, thereby rotating the flywheel <NUM> and storing kinetic energy in the form of rotational energy in the flywheel <NUM>. To discharge or extract the stored energy (i.e., to send electrical energy out of the energy storage device <NUM>), the rotation of flywheel <NUM> is used to rotate the rotor shaft <NUM>. Rotation of the rotor <NUM> in this manner acts as a generator to induce a current in the stator <NUM>, thereby converting rotational energy into electrical energy. The electrical energy can be provided to other components of the mining machine <NUM>, such as the motors <NUM>. In some embodiments, when the energy storage device <NUM> is used in the mining machine <NUM>, one of the converters <NUM> that would normally serve the generator <NUM> becomes the converter for the energy storage device <NUM>.

<FIG> illustrates an energy storage device <NUM> according to another embodiment. A flywheel <NUM> is formed as a cylindrical member, such that the flywheel <NUM> includes a first or web portion <NUM> coupled to the shaft <NUM> and extending radially outwardly from the axis <NUM> of the shaft <NUM>. The web portion <NUM> includes an outer periphery. The flywheel <NUM> further includes a cylindrical portion <NUM> extending from the periphery of web portion <NUM> along the axis <NUM> of the shaft <NUM>. In the illustrated embodiment, the cylindrical portion <NUM> extends around the rotor lamination stack <NUM> and the stator <NUM>, and the cylindrical portion <NUM> extends along the length of the rotor and stator assembly. In other embodiments, the cylindrical portion <NUM> may have a different length compared to the rotor and stator assembly. In some embodiments, the stator <NUM> is secured to an end wall <NUM> of the housing <NUM>. This configuration increases the power density of the energy storage device per unit of mass.

Claim 1:
A mobile mining machine (<NUM>) comprising:
a plurality of traction elements (<NUM>);
a plurality of motors (<NUM>), each motor (<NUM>) being coupled to an associated one of the plurality of traction elements (<NUM>), each motor (<NUM>) configured to be driven by the associated traction element (<NUM>) in a first mode, each motor (<NUM>) configured to drive the associated traction element (<NUM>) in a second mode;
a power source in electrical communication with the plurality of motors (<NUM>); and
an energy storage system (<NUM>, <NUM>, <NUM>) in electrical communication with the plurality of motors (<NUM>) and the power source,
wherein, in the first mode, rotation of the plurality of motors (<NUM>) causes rotation of a flywheel (<NUM>, <NUM>, <NUM>) to store kinetic energy,
wherein, in the second mode, rotation of the rotor (<NUM>, <NUM>) and the flywheel (<NUM>, <NUM>, <NUM>) discharges kinetic energy to drive the plurality of motors (<NUM>),
characterized in that the mobile mining machine further includes a bi-directional electrical bus (<NUM>) providing electrical communication between the motors (<NUM>), the power source, and the energy storage system (<NUM>, <NUM>, <NUM>), and
wherein the energy storage system (<NUM>, <NUM>, <NUM>) includes a switched reluctance motor/generator in electrical communication with the plurality of motors (<NUM>) via the bi-directional electrical bus (<NUM>), the switched reluctance motor/generator including a shaft (<NUM>) defining a shaft axis (<NUM>), a rotor (<NUM>, <NUM>) secured to the shaft (<NUM>), a stator (<NUM>, <NUM>, <NUM>) extending around the rotor (<NUM>, <NUM>) and around the shaft axis (<NUM>), and a flywheel (<NUM>, <NUM>, <NUM>) coupled to the shaft (<NUM>) for rotation therewith;
wherein the switched reluctance motor/generator is coupled to an engine (<NUM>); and
wherein, in the first mode, the switched reluctance motor/generator may receive energy from the plurality of motors (<NUM>), the switched reluctance motor/generator driving the engine (<NUM>) at a constant speed to reduce fuel consumption.