Design and Control Strategy Research of PS Type Hybrid Power Systems for 100 Ton Double Bridge Rigid Mine Trucks

doi:10.3969/j.issn.1004-132X.2025.10.035

Abstract

Abstract:

Aiming at the problems of insufficient power and poor fuel economy in the traditional mechanical or series electric transmission systems of open-pit mine dump trucks， a PS hybrid power system and the deterministic rule power switching control strategy suitable for 100 ton double bridge rigid mining trucks were proposed. The PS type hybrid power mining truck joint simulation models were built by using MATLAB/Simulink and CRUISE software， and vehicle power and economy simulation tests were conducted. The results show that in both pure motor driving mode and diesel engine-motor hybrid mode， the maximum equivalent stress， equivalent elastic deformation， safety factor， etc. of the designed dual planetary gear transmission system are all within the allowable ranges of the materials and may meet the requirements of mechanical transmission structurally. The variation of meshing force between the sun gear， planetary gear， and ring gear shows a sinusoidal waveform in the time domain， which conforms to the variation law of planetary gear transmission. The amplitude changes uniformly in the frequency domain， which may meet the stable operation requirements of the transmission systems. The modified PS type hybrid mining truck has a maximum speed of 63 km/h， a maximum climbing slope of 32%， and a comprehensive fuel consumption of 288 L for uphill and downhill， which has increased by 26%， 60%， and 17.7% respectively compared to the original vehicle model.

Key words: hundred-ton mining truck, power split（PS） type, hybrid power system, dual planetary transmission, control strategy

摘要：

针对露天矿自卸车传统机械式传动系统与串联式电传动系统存在的动力性不足、燃油经济性不佳等问题，提出了一种适用于百吨级双桥刚性矿用自卸车（简称“矿卡”）的功率分流（PS）型混合动力系统及其确定性规则动力切换控制策略。利用MATLAB/Simulink与CRUISE软件搭建PS型混合动力矿卡联合仿真模型，进行了整车动力性与经济性仿真试验。研究结果表明：在纯电驱动模式与柴-电混动模式下，所设计的双行星齿轮排传动系统的最大等效应力、等效弹性形变、安全系数等均在材料的许用范围内，在结构上可满足机械传动要求；太阳轮、行星轮与齿圈之间的啮合力变化在时域上总体呈现正弦波形，符合行星齿轮传动变化规律，在频域上幅值变化均匀，满足传动系统稳定运行要求；改造后的PS型混合动力矿卡的最大车速可达63 km/h、最大爬坡度为32%、上下坡综合油耗为288 L，比原车型分别提高了26%、60%和17.7%。

关键词: 百吨级矿卡, 功率分流型, 混合动力系统, 双行星排传动, 控制策略

CLC Number:

TD57

Huaqing ZHANG, Jiusheng BAO, Lei ZHANG, Deping HU, Xiao WEI, Yan YIN, Haohao XIE, Chenzhong ZHU, Jiao YANG. Design and Control Strategy Research of PS Type Hybrid Power Systems for 100 Ton Double Bridge Rigid Mine Trucks[J]. China Mechanical Engineering, 2025, 36(10): 2453-2462.

张华清, 鲍久圣, 张磊, 胡德平, 魏肖, 阴妍, 颉浩浩, 朱晨钟, 杨姣. 百吨级双桥刚性矿用自卸车功率分流型混动系统设计及控制策略研究[J]. 中国机械工程, 2025, 36(10): 2453-2462.

Figures/Tables 29

Fig.1 Diesel engine-motor transmission system

Fig.2 Design of PS type hybrid power system

Fig.3 Energy flow direction under pure electric driving mode

Fig.4 Energy flow direction under pure diesel-electric hybrid driving mode

Fig.5 Energy flow direction under drive charging mode

Fig.6 Energy flow direction under regenerative braking mode

Fig.7 Energy flow direction under park charging mode

Tab.1 Performance parameters of power components

参数名称	数值
发动机最大扭矩	3300 N·m
发动机额定功率	566 kW
发动机额定转速	2000 r/min
发动机最大扭矩对应转速	1500 r/min
发动机气缸数	8
发动机排量	16.72 L
MG1最大转矩	7000 N·m
MG1最大功率	710 kW
MG1额定电压	1500 V
MG1额定转速	1000 r/min
动力电池电压	1600 V
动力电池容量	390 A·h
动力电池单体电压	3.2 V
动力电池串联数量	500
动力电池最大充放电倍率	1.5

Tab.2 Planetary gear parameters

	太阳轮	行星轮	齿圈
模数/mm	10	10	10
齿数	36	18	72

Fig.8 Dual planetary gear transmission system

Fig.9 Finite element analysis results of pure motor mode transient dynamics

Fig.10 Finite element analysis results of transient dynamics in diesel engine-motor mixed mode

Fig. 11 Rigid flexible coupling model of dual planetary gear transmission system

Fig.12 Angular velocity output diagram of planet carrier Ⅰ and planet carrier Ⅱ

Tab.3 Comparison between theoretical and simulation values of planetary carrier speed

转速理论值/（r·min^-1）

转速仿真值/

（r·min^-1）

Fig.13 The meshing force between solar gear Ⅰ and planetary gear Ⅰ

Fig.14 Analysis of the meshing force between planetary gear Ⅰ and ring Ⅰ

Fig.15 Logical conditions for switching work modes

Tab.4 Target torque value allocation under different modes

工作模式	整车需求转矩与动力源转矩的关系
纯电驱动	T_req=T_MG1（k+1）/k
柴-电混合	T_req=T_E+kT_MG1+T_MG2
行车充电	T_req=（1+k）T_E+kT_MG1 T_MG2=T_E
再生制动	T_MG1=T_brkk/（k+1）
停车充电	T_MG2=T_E

Fig.16 CRUISE vehicle simulation model

Fig.17 Open pit mine cycle working condition

Fig.18 Maximum speed at full load

Fig.19 Maximum climbing slope

Fig.20 Full-load climbing speed follow

Fig.21 Empty downhill speed follow

Fig.22 SOC value of full load climbing battery

Fig.23 Fuel consumption for full load hill climbing

Fig.24 SOC value of no-load downhill battery

Fig.25 No-load downhill fuel consumption

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