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1

Lightweight LHD BEV loader with an individual drive for each wheel

Korski Wojciech, Horak Wojciech, Bołoz Łukasz, Niestrój Roman, Kozłowski Artur

Management Systems in Production Engineering

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2023

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nr 3 (31)

281--289

EN

The paper is devoted to the construction and design solutions of the power supply and drive systems of a prototype, lightweight LHD (Load-Haul-Dump) loader with an innovative "in-wheel drive" transmission system. The loader is a Battery Electric Vehicle (BEV) with replaceable energy storage. It is intended for use in underground mines with no explosion hazard, especially in metal ore mines. The developed model contains four independent, electric drive systems installed in the road wheels. The paper presents the results of simulation tests, which enabled estimating the required driving power and electricity demand in various regimes and working conditions of the loader. The results of the calculations were used to determine the parameters of the drive system components and the battery capacity. Challenges and problems faced by constructors of BEV LHD loaders with an in-wheel drive have been pointed out.

2

Assessment of the stability of bev lhd loader

Bołoz Łukasz, Kozłowski Artur, Horak Wojciech

Management Systems in Production Engineering

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2022

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nr 4 (30)

377--387

EN

The article concerns the computational model for analysing the stability of the BEV LHD loader. Works were carried out to develop an innovative, light battery-powered loader, which was the subject of an R&D project implemented in cooperation with Bumech S. A. Compared to the existing solutions of loaders with similar load capacity, this one is distinguished by the use of an individual electric drive in each wheel and a replaceable battery. A physical and mathematical model was developed taking into account the specificity of the BEV LHD loader. In the model, the masses of the battery, individual drives, the platform and excavated material are taken into account separately. The developed model allows determining the loader wheel pressure on the floor, depending on the location of its components’ centres of gravity, the turning angle of the machine, the amount of excavated material in the bucket and the position of the bucket. The input parameters also include the longitudinal and transverse excavation slope angles. In addition, the model enables determining the inner and outer turning radius of the loader. To verify the theoretical model, dynamic simulation tests were carried out. The results of simulation analyses confirmed the correctness of the developed theoretical model. The model was used to prepare a calculation sheet for analysing the stability on the basis of the adopted parameters. In the article, selected results of the conducted stability analyses have been presented, along with the proposed parameters ensuring the loader’s stability. The developed theoretical model enables a quick assessment of the loader’s stability, which, due to a number of innovative solutions, differs from existing designs. The structure of the loader at the design stage is subject to numerous modifications, which affect the distribution of the centres of gravity of individual components. The developed model of the loader is a useful, parameterized tool that allows assessing the stability and the values of the turning radii of the machine.

3

Samojezdne maszyny górnicze zasilane bateryjnie

Kozłowski Artur, Bołoz Łukasz, Czajkowski Andrzej, Ostapów Lesław

Przegląd Górniczy

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2021

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T. 77, nr 10-12

44--53

PL

W przedmiotowym artykule przedstawiono dwie samojezdne elektryczne maszyny górnicze zasilane bateryjnie, przeznaczone do pracy w warunkach polskiej kopalni rud miedzi. Obecnie w górnictwie światowym obserwuje się rosnące zainteresowanie maszynami elektrycznymi zasilanymi bateryjnie, które zastępują rozwiązania napędzane silnikami spalinowymi. W wyniku współpracy firmy Mine Master, Sieci Badawczej Łukasiewicz – Instytutu Technik Innowacyjnych EMAG oraz AGH w Krakowie zrealizowano szereg prac, które pozwoliły w rezultacie na wyprodukowanie dwóch zupełnie nowych maszyn. W celu opracowania wymagań i założeń do projektowanych układów napędowych z zasilaniem bateryjnym przeprowadzono badania dołowe istniejących maszyn spalinowych. Wykorzystując wyniki tych badań, opracowano układy zasilania oraz algorytmy sterowania, które zostały zweryfikowane w środowisku wirtualnym. Następnie opracowano i wykonano laboratoryjne stanowisko badawcze, na którym przeprowadzono walidację układów zasilania i algorytmów sterowania. Podczas badań sprawdzono wszystkie możliwe sytuacje, w których bateria jest rozładowywana w wyniku jazdy lub pracy oraz ładowana z sieci kopalnianej lub energią odzyskaną podczas hamowania. Na stanowisku badawczym zasymulowano również niepożądane sytuacje, jak wahania napięcia zasilana czy ograniczenie mocy ładowania. Uzyskano pozytywne wyniki testów. Finalnie układy zasilania wraz z algorytmami sterowania zostały zaimplementowane i sprawdzone w wyprodukowanych maszynach bateryjnych, podczas prób ruchowych.

EN

This article discusses the work which resulted in the development of two battery-powered self-propelled electric mining machines intended for operation in the conditions of a Polish copper ore mine. Currently, the global mining industry is seeing a growing interest in battery-powered electric machines, which are replacing solutions powered by internal combustion engines. The cooperation of Mine Master, Łukasiewicz Research Network - Institute of Innovative Technologies EMAG and AGH University of Science and Technology allowed carrying out a number of works which resulted in the production of two completely new machines. In order to develop the requirements and assumptions for the designed battery-powered propulsion systems, underground tests of the existing combustion machines were carried out. Based on the results of these tests, power supply systems and control algorithms were developed and verified in a virtual environment. Next, a laboratory test stand for validating power supply systems and control algorithms was developed and constructed. The tests were aimed at checking all possible situations in which the battery gets discharged as a result of the machine’s ride or operation, and when it is charged from the mine’s mains or with energy recovered during braking. Simulations of undesirable situations, such as fluctuations in the supply voltage or charging power limitation, were also carried out at the test stand. Positive test results were obtained. Finally, the power supply systems along with control algorithms were implemented and tested in the produced battery-powered machines during operational trials. The power systems and control algorithms are universal enough to be implemented in two different types of machines.

4

Global Trends in the Development of Battery-Powered Underground Mining Machines

Bołoz Łukasz

Multidisciplinary Aspects of Production Engineering

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2021

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Vol. 4, Iss. 1

178--189

EN

The growing requirements and needs of users as well as a strong emphasis on pro-ecological solutions cause an increasing interest in battery-powered electric mining machines. Internal combustion machines consume oxygen, generate noise, fumes and heat, which affects work in underground mines, and minimizing these factors is expensive. Battery solutions allow achieving the same operational parameters of machines with significantly higher safety, comfort and work culture. The problem, however, is their range or working time. The article presents global trends in the development of battery-operated machines for underground mining. Various machines in battery-powered versions have been presented. The applied solutions have been discussed, especially in the field of battery replacement or recharging and braking energy recovery. Manufacturers around the world offer more and more battery-powered machines. Some producers are announcing complete replacement of combustion solutions with electric ones within the next few years. There are also hydrogen machines on the horizon, which will probably be the next step on the road to a zero-emission industry.

5

Badania innowacyjnego układu zasilająco-sterującego spągoładowarki górniczej

Deja Przemysław, Kapuściński Dariusz, Niedworok Andrzej, Polnik Bartosz

Napędy i Sterowanie

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2020

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R. 22, nr 7/8

38--42

PL

W artykule omówione zostały badania laboratoryjne innowacyjnego układu zasilająco-sterującego spągoładowarki górniczej, opracowanego w ramach realizacji projektu o akronimie HYDKOM 75, współfinansowanego przez Narodowe Centrum Badań i Rozwoju. Badania miały na celu zweryfikowanie przyjętych założeń technicznych oraz funkcjonalności opracowanego rozwiązania z uwzględnieniem możliwości zastosowania przedmiotowego układu zasilająco-sterującego w przestrzeniach potencjalnie zagrożonych wybuchem. Innowacyjny układ zasilająco-sterujący spągoładowarki górniczej został opracowany i zbudowany w oparciu o baterię ogniw litowych, zwiększającą mobilność przedmiotowego rozwiązania. Ponadto po rozładowaniu baterii układ zasilająco-sterujący umożliwia pracę spągoładowarki przy zasilaniu przewodowym z sieci kopalnianej, kiedy to następuje proces ładowania baterii ogniw. Dzięki takiemu rozwiązaniu górnicza spągoładowarka może być eksploatowana praktycznie bez przerwy.

EN

The article discusses laboratory tests of an innovative power supply and control system for a roadheading mining machine, developed as part of the project on the acronym HYDKOM 75 co-financed by the National Center for Research and Development. The research was aimed at verifying the adopted technical assumptions and functionality of the developed solution, taking into account the possibility of using the power and control system in potentially explosive atmospheres. The innovative power supply and control system of the roadheading mining machine was developed and built based on the battery of lithium cells, increasing the mobility of the solution in question. In addition, after the battery has been discharged, the power supply and control system allows the charger to operate on the line power from the mine network, when the battery cells are being charged. Thanks to such a solution, the mining machine can be operated practically without interruption.