value , the motor is in the idle speed or shutdown state , then starts to work after the value returns to a figure lower than the set value . Reman all electric conversion has been carried out extensively on Terex brand 100 ton class diesel trucks ( 91 t ), converting them to a HAT-R100E models with 680 kW drive motor traction and 1,280 kW brake plus CATL 793 kW / h battery . HATL ’ s next focus will be retrofit of larger trucks to electric in the 220 ton class and above . The first HAT-R100E vehicle has operated reliably for 13131.3 consecutive hours .
Technical features of HATL battery trucks
The power battery system adopts the LFP core and CTP structure form , which is safe and reliable with high energy density . Adopting a modularised design concept , a power supply branch is set up as a power unit , and each power unit is independent of each other , so that the number of power units can be increased or reduced according to the actual working conditions on site , and the amount of power carried by the whole vehicle can be adjusted . Each power unit adopts an independent mechanical structure , which is convenient for overall assembly and disassembly , improves disassembly and assembly efficiency , and enhances the maintainability of the battery system . At present , the discharging capacity of the supporting power battery system exceeds 5 million kWh , and the system runs stably and reliably .
As stated , HATL will soon launch a higher voltage platform power battery system to match mining dump trucks with load capacity above 220 tons . This battery system does not require high power DC / DC to lift the voltage , which results in higher system efficiency , reduced cost and improved reliability . In addition , for underground specific working condition scenarios , HATL will launch a charging and switching integrated power battery system program , which can meet the various replenishment needs of underground pure electric equipment .
The electric drive system adopts 1,000V highvoltage platform , direct-drive motor , independent water-cooled main and auxiliary converter program , and the battery bus is directly connected to the steering and lifting control module , which effectively reduces the weight and volume of the system , improves the efficiency of electric braking , reduces the weight of the cables , and then improves the operating efficiency of the whole vehicle .
Adopting input design with wide voltage fluctuation range , it adapts to the dynamic power regulation strategy of the power battery system and optimises the energy utilisation rate . Adopting distributed programmable domain control technology to replace the traditional centralised low-voltage power distribution architecture , the power distribution structure is optimised and the low-voltage wiring harness is reduced ; the intelligent chip protection improves the vehicle safety , stronger controllability , higher reliability and longer life .
In addition , it can directly drive high-power components without relay transition ; all output channels can be programmed to set the control logic and protection current , and real-time monitoring of the load status , current and other parameters of all output channels ; it is equipped with output over-current protection , short-circuit protection , over-temperature protection and other functions .
The vehicle control system architecture developed by HATL is highly standardised , reliable and stable , and has abundant control ports for vehicle parameters ; it can collect and remotely transmit vehicle operation bus data , and together with the self-developed cloudbased intelligent fault diagnosis system , it monitors and assists in analysing the causes of faults , and improves the efficiency of fault resolution . Through the accumulation of data and the application of large models , HATL will gradually realise the vehicle failure warning function .
Hydraulic improvements include oil pump frequency conversion drive , high and low speed automatic switching , online and remote monitoring of pressure , temperature and other parameters , plus new electronically controlled pressurisation and unloading ; streamlining of cumbersome pipelines , reducing maintenance difficulties and costs . On the basis of optimising the hydraulic brake , a new electric brake is added , and the hydraulic system of the whole vehicle runs safer , quieter , more energy-saving and friendlier .
The hydraulic system is newly equipped with emergency quick-insertion interface , and emergency power device adapted to high-cold and high-altitude , so that the oil pipe can be inserted quickly without borrowing vehicle power to unload materials and apply emergency steering and braking , so that there is no need to worry about emergency rescue .
Series of photos showing conversion of Terex brand rigid trucks and the final versions
The hydraulic system adopts electro-hydraulic proportional and load-sensitive control , with high pressure , large flow rate , long service life , high efficiency and energy-saving , and no need for cooling . Adopting HATL ' s self-developed patented line-controlled hydraulic technology , it is compatible with manned and unmanned driving and has liquid-controlled and linecontrolled dual-circuit braking functions , which improve the reliability of the system .
Combined with the original fuel vehicle frame equipment layout , HATL analyses the trend of frame load distribution . For the new mechanical structure parts , in the design , the materials selected are the same or similar to the frame materials , the analysis and calculation of the new structural parts are carried out under the actual operating conditions of the vehicle , and the structural lightweight and modularised integrated design is carried out under the premise of guaranteeing the structural strength and taking into consideration of the convenience of maintenance ; in the construction , the reasonable welding process is adopted to ensure that there is no damage to the original frame in the process of transformation , and the service life of the transformed vehicle is improved effectively ; in the industrial design of the whole vehicle , the principle of ‘ original vehicle-oriented ' is followed , and the original vehicle industrial load distribution is retained after the transformation .
Fujian Hongda Contemporary Amperex Technology Co Ltd Guangzhou Branch 6th Floor , Diamond Business Building No 23 Gongyi Road , Huadu District Guangzhou , China
Contact : Olivia Liang , Technical Manager Email : liangst @ hdatl . com
OCTOBER 2024 | International Mining 9