Energy management for an 8000HP hybrid hydraulic mining shovel

The concept of hybrid architecture is penetrating the heavy industry machines including Hydraulic Mining Shovels (HMS). Achieving increased machine efficiency, productivity, and performance, reduced emissions, and prolonged lifetime are the main goals in developing hybrid shovel structures. This paper presents the energy management concept for an HMS, which uses high power density energy storage system to supplement the existing diesel-powered generators. A 2.25 MW ultracapacitor system is applied to improve the sluggish dynamic response of the diesel engine during sudden load changes and to limit the engine power requirements by maintaining an optimal engine speed. In addition to the engine dynamic improvement, the ultracapacitor system supports the engine during peak power demand allowing for a smaller engine size for the machine, which results in higher fuel savings and less exhaust emissions. Detailed control schemes for the converters and system are described and modeling and experimental results are also provided to verify the analyses.