Chinese
English
Russian
I、 Power fluctuation characteristics of loader excavation conditions and the significance of power reserve
The power demand for loader excavation operations fluctuates greatly. Empty vehicle operation and light material transportation belong to low-power continuous working conditions; When the bucket is used to cut into dense material piles or excavate large blocks of material, it will generate short-term peak power demand, and the peak duration is usually only a few hundred milliseconds to a few seconds. Continuous power determines the ability of the equipment to operate for a long time, while peak power determines the ability to excavate hard material piles.
If the reserved power of the whole machine is insufficient, when the instantaneous load exceeds the maximum output allowed by the system, the VCU will actively limit the power output to protect the motor and battery from overload damage. The intuitive manifestation is that the power suddenly weakens when shoveling, and the material cannot be fed into the pile. If the power reserve is excessive, the hardware specifications of the motor and battery are selected too large, the equipment weight increases, the procurement cost rises, the working point of the light load operation motor deviates from the high-efficiency range, and the unit operation power consumption increases. So the larger the power reserve, the better. It is necessary to match the real load cycle curve of the loader and find a reasonable reserve interval.
Fuel loaders rely on the engine flywheel to store energy and can output excess torque in a short period of time; Electric loaders rely on battery discharge to provide peak power, and the battery discharge rate capability and motor peak torque capability jointly determine the peak power that the entire machine can release. The power reservation strategy requires the coordination of battery discharge characteristics, motor overload capacity, and electronic control power protection threshold, and cannot amplify a single component specification. Many devices have impressive motor parameters, but their battery discharge capacity is insufficient, and they cannot provide sufficient current during heavy loads. The peak power still cannot be released, which is due to the lack of overall planning for the power reserve scheme.
II、 Design Ideas for Power Reserve Strategy of Jining Xinghang Aircraft
During the product development phase, Jining Xinghang collected a large amount of measured load data from the material yard, constructed a typical shovel loading load spectrum, and calculated the continuous power and peak power duration of different materials such as loose sand, clay, and construction waste during the shovel loading process, which served as the basis for power reserve design. The scheme distinguishes between two sets of indicators: continuous rated power reserve and instantaneous peak power reserve. Continuous power reserve ensures long-term continuous operation, and the working temperature of the motor and battery is maintained within a safe range, without causing rapid temperature rise due to long-term full load operation. Instantaneous peak power reserve is specifically designed to cope with short-term impact loads when the bucket cuts into the material pile, allowing for the release of power exceeding the rated limit in a short period of time to complete the excavation of the hard material pile. The peak power is set with a time threshold, and automatically drops back to the rated power after exceeding the time limit to prevent long-term overload damage to the three electrical components.
As the core of power scheduling, the vehicle VCU monitors the available discharge power of the battery, motor temperature, and hydraulic system pressure in real time, and dynamically adjusts the peak power margin that can be released. When the battery is fully charged and the temperature is in the optimal range, release the full peak reserved power; When the battery level is low, the temperature is too high or too low, the system automatically lowers the peak power limit, reserves a safety margin, prioritizes the protection of the battery and motor, and avoids hardware damage. Power reserve is not a fixed and unchanging value, but a dynamically adaptive adjustment based on the real-time status of the three electrical components.
At the same time, match the power reserve at the structural and transmission levels. The strength of transmission components is checked according to peak torque to ensure that when the electronic control releases peak power, the transmission shaft, hinge pin shaft, and wheel edge structure have sufficient strength reserve, and there will be no power increase, and the mechanical structure will not be able to withstand impact damage. If only electric drive power is reserved, the transmission structure strength is insufficient, and heavy excavation is prone to mechanical component damage, the power reservation strategy has shortcomings. Jining Xinghang achieves synchronous matching of electric drive power reserve and mechanical structural strength reserve.
III、 Multi condition calibration, balancing heavy-duty performance, energy consumption, and component lifespan
After completing the framework design of the power reservation strategy, carry out multi scenario real vehicle calibration. Test in different material yards, observe the dynamic response during heavy-duty excavation, and adjust the peak power release curve. The calibration focuses on balancing three dimensions: first, the explosive force of heavy-duty excavation to ensure that the dense material pile can be smoothly cut in; Secondly, the energy efficiency of light load operations ensures that daily loose material operations do not result in high energy consumption due to excessive hardware reserves; The third is the service life of the three electrical components, controlling the peak impact frequency and reducing the fatigue loss of the battery and motor.
The built-in power mode selection of the electronic control allows the operator to switch according to the material type. Ordinary bulk material operation, using standard mode, moderate peak power reserve, and prioritizing energy conservation; Heavy load operation of ore and compacted clay, switch to heavy load mode, unlock greater instantaneous power reserve, and improve excavation capability. Mode switching will not exceed the hardware safety red line, and the three electric protection logic will continue to be effective under all operating conditions.
IV、 The actual value and usage awareness of power reservation strategy for users
The most intuitive value of a reasonable power reserve strategy is to face dense and hard material piles, with sufficient power during excavation, without sudden power drops, increasing the amount of material loaded per shovel, and accelerating the operation cycle. At the same time, there is no need to blindly purchase larger models and control equipment procurement investment. Dynamic power reserve can automatically adjust the power upper limit when the battery state changes, avoiding the risk of overload during heavy load operations after battery aging.
Users need to establish a correct understanding that peak power reserve is a short-term burst capability and does not support long-term continuous full power operations. Continuously overloading tasks will cause the system to automatically reduce power, which is a normal protection mechanism. After the battery of the device decays, the maximum discharge capacity decreases, and the peak power margin that the whole machine can release will correspondingly decrease, which is a normal characteristic and not a device failure. Daily operation and maintenance require regular monitoring of the health status of BMS batteries, understanding changes in battery discharge capacity, and arranging overload operations reasonably.
Conclusion
The reserved power of the entire electric loader is not simply about increasing the hardware parameters of the motor and battery, but rather a systematic design based on the actual load spectrum of the shovel, integrating the battery, motor, electronic control, and transmission structure. Jining Xinghang electric loader distinguishes between continuous power reserve and instantaneous peak power reserve, relying on VCU dynamic power scheduling and adaptively adjusting power margin according to the real-time status of the three electric systems. While ensuring the explosive power of heavy load excavation of hard material piles, it also considers the energy consumption of conventional operations, protects the safety of core components, and helps users cope with changing material excavation conditions without blindly increasing equipment procurement costs.
