Systems and methods for operating excavation machines

Abstract

An excavation machine is provided. The excavation machine includes an excavation device and an excavation device drive system that powers the excavation device to move cutting tools, wherein the excavation device drive system includes an electric motor and a motor controller, wherein the motor controller is programmed to control the speed of the excavation device drive system. The motor controller sets the speed of the excavation device drive system at a predetermined excavation speed based on a predetermined target power, the predetermined target power being associated with a target torque generated by the electric motor. The speed of the excavation device drive system is set at a predetermined first excavation speed when a power transmitted to the electric motor is below the predetermined target power and at a predetermined second excavation speed to maintain the power transmitted to the electric motor at the predetermined target power.

What is claimed is: 
     
         1 . An excavation machine comprising:
 an excavation device having a plurality of cutting tools mounted thereon; and   an excavation device drive system that powers the excavation device to move at least one of the plurality of cutting tools through a cutter travel path, wherein the excavation device drive system comprises an electric motor and a motor controller, the electric motor being powered by a power supply,   wherein the motor controller is programmed to control a speed of the excavation device drive system via a control algorithm, wherein, the control algorithm, when executed by the motor controller, causes the motor controller to set the speed of the excavation device drive system at a predetermined excavation speed based on a predetermined target power, the predetermined target power being associated with a target torque generated by the electric motor, and   wherein the speed of the excavation device drive system is set at a predetermined first excavation speed when a power transmitted to the electric motor is below the predetermined target power, and wherein the speed of the excavation device drive system is set at a predetermined second excavation speed to maintain the power transmitted to the electric motor at the predetermined target power, the predetermined second excavation speed being less than the predetermined first excavation speed and being associated with an increase in the target torque generated by the electric motor, the speed of the excavation device drive system being set at the predetermined second excavation speed when a first force required to propel at least one of the plurality of cutting tools exceeds a second force that the excavation device drive system can generate with the excavation device drive system operating at the predetermined first excavation speed at the predetermined target power.   
     
     
         2 . The excavation machine of  claim 1 , wherein the power supply includes at least one of an energy storage device, an energized power line, and an engine. 
     
     
         3 . The excavation machine of  claim 1 , wherein the power supply includes an internal combustion engine that powers a generator, wherein the generator provides power to the electric motor powering the excavation device drive system and the motor controller is configured to manage the power transmitted to the electric motor to operate the internal combustion engine at an optimum operating condition, the optimum operating condition including varying values of the speed and the torque generated by the electric motor powering the excavation device drive system, wherein the varying values of the speed and the target torque vary independently to provide the first force required to propel at least one of the plurality of cutting tools. 
     
     
         4 . The excavation machine of  claim 3 , wherein the motor controller automatically adjusts the predetermined target power applied to the excavation device drive system as a function of an engine power data stream generated by an engine controller. 
     
     
         5 . The excavation machine of  claim 1 , further comprising an advancement system for moving the excavation device, wherein the motor controller is further programmed to automatically control the advancement system via a second control algorithm, wherein, the second control algorithm, when executed by the motor controller, causes the motor controller to control the advancement system as a function of at least one of the speed and the torque generated by the electric motor. 
     
     
         6 . The excavation machine of  claim 5 , wherein the motor controller will reduce an advancement system speed or reduce the first force propelling at least one of the plurality of cutting tools when at least one of the speed is equal to or less than 0.7 times the predetermined first excavation speed and the torque is equal to more than 1.4 times the target torque. 
     
     
         7 . An excavation machine comprising:
 a diesel engine having an engine control unit (ECU) that controls and monitors a fuel system and an air intake system that provides diesel fuel and combustion air to the diesel engine, wherein the ECU calculates an engine load parameter at least partially based on a fuel amount and a flow of air;   an active cutting system;   a power transmission device that transfers power from the diesel engine to the active cutting system at a variable operating speed, wherein the variable operating speed is based on an operating parameter that affects a variable torque and a speed characteristic of the power transmission device; and   an advancement system that propels the active cutting system during excavation; and   a control system that controls the advancement system based on the variable operating speed of the power transmission device, and wherein the control system controls the operating parameter of the power transmission device based on the engine load parameter.   
     
     
         8 . The excavation machine of  claim 7 , wherein the power transmission device is an electric-mechanical transmission having a generator physically coupled to the diesel engine, a motor physically coupled to the active cutting system, and power electronics electrically coupling the generator with the motor. 
     
     
         9 . The excavation machine of  claim 8 , wherein the control system controls a target power of the power electronics based on a predefined target of the engine load parameter, the target power being increased when the engine load parameter is below the predefined target and the target power being decreased when the engine load parameter is above the predefined target. 
     
     
         10 . The excavation machine of  claim 7 , wherein the power transmission device is a torque converter type transmission having an adjustable operating parameter. 
     
     
         11 . The excavation machine of  claim 10 , wherein the control system controls at least one of a pitch of a stator and a bypass clutch as the operating parameter of the power transmission device. 
     
     
         12 . A mechanical arrangement for an excavation machine, the mechanical arrangement comprising:
 a cutting tool;   a head shaft coupled to the cutting tool and defining a longitudinal axis;   a gearbox coupled to the head shaft such that the head shaft supports the gearbox; and   a motor coupled to the gearbox, wherein the motor is offset from the longitudinal axis of the head shaft, and wherein the motor is configured to drive rotation of the head shaft and the cutting tool via the gearbox.   
     
     
         13 . The mechanical arrangement of  claim 12 , wherein the motor is an electric motor. 
     
     
         14 . The mechanical arrangement of  claim 12 , wherein the motor is a hydraulic motor. 
     
     
         15 . The mechanical arrangement of  claim 12 , wherein the cutting tool is a chain of a chain trencher. 
     
     
         16 . The mechanical arrangement of  claim 12 , wherein the cutting tool is a drum of a surface miner. 
     
     
         17 . The mechanical arrangement of  claim 12 , wherein the motor is coupled to the gearbox using a flexible coupling. 
     
     
         18 . The mechanical arrangement of  claim 12 , wherein the motor is mounted to a frame of the excavation machine via at least one isolator. 
     
     
         19 . A mechanical arrangement for an excavation machine, the mechanical arrangement comprising:
 a cutting tool;   a head shaft coupled to the cutting tool;   at least one gearbox coupled to the head shaft such that the head shaft supports the gearbox; and   a plurality of motors, wherein the plurality of motors are configured to drive rotation of the head shaft and the cutting tool, and wherein at least one of the plurality of motors is coupled to the at least one gearbox.   
     
     
         20 . The mechanical arrangement of  claim 19 , wherein the at least one gearbox comprises a single gearbox, and wherein the plurality of motors comprises a first motor and a second motor, each of the first motor and the second motor being coupled to the single gearbox. 
     
     
         21 . The mechanical arrangement of  claim 19 , wherein the at least one gearbox comprises a first gearbox and a second gearbox, the first and second gearboxes being located on opposite sides of the cutting tool, and wherein the plurality of motors comprises a first motor coupled to the first gearbox and a second motor coupled to the second gearbox. 
     
     
         22 . The mechanical arrangement of  claim 19 , wherein at least one of the plurality of motors is an electric motor. 
     
     
         23 . The mechanical arrangement of  claim 19 , wherein at least one of the plurality of motors is a hydraulic motor. 
     
     
         24 . The mechanical arrangement of  claim 19 , wherein the cutting tool is a chain of a chain trencher. 
     
     
         25 . The mechanical arrangement of  claim 19 , wherein the cutting tool is a drum of a surface miner. 
     
     
         26 . The mechanical arrangement of  claim 19 , wherein at least one of the plurality of motors is coupled to the at least one gearbox using a flexible coupling. 
     
     
         27 . The mechanical arrangement of  claim 19 , wherein at least one of the plurality of motors is mounted to a frame of the excavation machine via at least one isolator. 
     
     
         28 . The mechanical arrangement of  claim 19 , wherein at least one of the plurality of motors is offset from a longitudinal axis of the head shaft.