System and method for all electrical operation of a mining haul truck

Abstract

A mining haul truck driven by electrical wheel motors is operated with all electrical power sources; that is, without a diesel engine. While travelling on the loading site, the mining haul truck is powered by an on-board energy storage system, which may include a bank of ultracapacitors. The mining haul truck then moves to the bottom of a trolley ramp and is coupled to trolley lines. While travelling uphill, the mining haul truck is powered by the trolley lines, and the on-board energy storage system is charged by the trolley lines. When the mining haul truck reaches the top of the trolley ramp, the mining haul truck is uncoupled from the trolley lines. While travelling on the unloading site, the mining haul truck is powered by the on-board energy storage system. The on-board energy storage system may also be charged by retard energy generated by the wheel motors during braking.

1 .- 20 . (canceled) 
     
     
         21 . An on-board energy storage system that travels with a mining haul truck, the on-board energy storage system comprising:
 an electrical energy storage unit, and   an energy management controller configured to manage the electrical energy storage unit,   wherein the energy management controller is configured to receive electrical data that characterize operation of a drive system configured to power electrical wheel motors of the mining haul truck.   
     
     
         22 . The system of  claim 21 ,
 wherein the electrical data include direct current (DC) link voltage data, current data and temperature data.   
     
     
         23 . The system of  claim 21 ,
 wherein the on-board energy storage system is configured to integrate with a trolley power system.   
     
     
         24 . The system of  claim 23 ,
 wherein, in response to control signals or control commands from the energy management controller, the electrical energy storage unit is configured to   transmit electrical energy to the electrical wheel motors,   receive electrical energy from the trolley power system, or   receive retard electrical energy from the electrical wheel motors.   
     
     
         25 . The system of  claim 21 ,
 wherein the on-board energy storage system comprises a bank of ultracapacitors, or a bank of batteries, or combinations of ultracapacitor banks and battery banks.   
     
     
         26 . The system of  claim 25 ,
 wherein the bank of ultracapacitors and the bank of batteries comprise traction grade ultracapacitors and traction grade batteries.   
     
     
         27 . The system of  claim 21 ,
 wherein the on-board energy storage system is mounted on the mining haul truck or attached to the mining haul truck or mounted on a trailer attached to the mining haul truck.   
     
     
         28 . The system of  claim 21 ,
 wherein the on-board energy storage system is configured to recover and store retard energy from the electrical wheel motors generated during braking of the mining haul truck.   
     
     
         29 . The system of  claim 21 ,
 wherein the energy management controller comprises
 a processor, a memory, and a data storage device, 
 an electrical storage unit interface for interfacing with the electrical storage unit, and 
 a drive system interface configured to receive the electrical data. 
   
     
     
         30 . The system of  claim 21 ,
 wherein the management controller comprises a communications network interface for communicating with a remote access network, and   wherein the management controller is accessible via the remote access network.   
     
     
         31 . The system of  claim 21 ,
 wherein the on-board energy storage system is configured to be retrofitted into an existing mining haul truck that has a diesel engine and a generator, wherein the diesel engine is retained for operation under fault conditions or for charging while the mining haul truck is idling.   
     
     
         32 . A method for supplying electrical power to electrical wheel motors on an all electrically powered mining haul truck, the method comprising:
 receiving, by an electrical energy storage unit, control signals or control commands from an energy management controller, and   in response to the control signals or control commands, by the electrical energy storage unit,
 transmitting electrical energy to the electrical wheel motors, or 
 receiving electrical energy from a trolley power system, or 
 receiving retard electrical energy from the electrical wheel motors. 
   
     
     
         33 . The method of  claim 32 , comprising:
 receiving, by the energy management controller, electrical data that characterize operation of a drive system configured to power the electrical wheel motors of the mining haul truck.   
     
     
         34 . The method of  claim 33 ,
 wherein the electrical data include DC link voltage data, current data and temperature data.   
     
     
         35 . The method of  claim 32 ,
 wherein the electrical energy storage unit comprises a bank of ultracapacitors, or a bank of batteries, or combinations of ultracapacitor banks and battery banks.   
     
     
         36 . The method of  claim 33 , comprising:
 recovering and storing retard energy from the electrical wheel motors generated during braking of the mining haul truck.   
     
     
         37 . The method of  claim 32 , comprising:
 supplying electrical energy to the electrical wheel motors from the trolley power system while the mining haul truck is travelling on an uphill grade; and   charging the electrical energy storage unit with electrical energy from the trolley power system while the mining haul truck is travelling on the uphill grade.   
     
     
         38 . The method of  claim 32 , further comprising:
 supplying electrical energy to the electrical wheel motors from the trolley power system while the mining haul truck is travelling on a downhill grade; and   charging the electrical energy storage system with electrical power from the trolley power system while the mining haul truck is travelling on the downhill grade.   
     
     
         39 . A method for determining a storage capacity of an electrical energy storage unit on a mining haul truck, the method comprising:
 determining a haul profile, the haul profile including multiple profile legs, wherein each profile leg comprises travel distance, slope of ground, travel path and payload status of the mining haul truck, and   determining speed and acceleration for the mining haul truck for the haul profile, and   calculating the storage capacity of the electrical energy storage unit based on the haul profile, speed, and acceleration.   
     
     
         40 . The method of  claim 39 , further comprising:
 determining a weight of the mining haul track in an empty state and in a loaded state, wherein calculating of the storage capacity is further based on the weight of the mining haul truck.