Design and Experimental Validation of Dump Truck Active Safety System Algorithms

Anatoly Vinogradov
Electric drive department
Scientific drive technical center “Vector”
Ivanovo, Russian Federation
vinogr_ab@mail.ru

Alexandr Korotkov
Electric drive department
Scientific drive technical center “Vector”
Ivanovo, Russian Federation
korotkov_alexand@mail.ru

Kirill Ermakov
Electric drive department
Scientific drive technical center “Vector”
Ivanovo, Russian Federation
nice.ermakov19@gmail.ru

Abstract— As a result of experimental tests and operating experience of BELAZ mining dump trucks, it has been established that the active safety system in difficult driving conditions on haul roads is in great demand. Loss of control on a slippery road as a result of driver error can lead to a serious accident and costly mining equipment repairs. The article proposes control algorithms that use additional information from the front wheel sensors. This made it possible to significantly improve the dump truck controllability in driving conditions of poor wheel adhesion, preventing the dump truck from yaw and wheels block, reduce mechanical impacts on the transmission and structural elements of the vehicle. Adapt the dump truck active safety system characteristics to changes in driving conditions. The test results are shown on a BELAZ dump truck with a carrying capacity of 90 tons. They confirm the effectiveness of the developed control system in comparison with that currently used in serial products.

Keywords— road vehicles, control systems, wheels, process control, vehicle safety, advanced driver assistance systems, motor drives.

Introduction

Mining (off-road) dump trucks are used in open-pit mining and work mainly in difficult road and climatic conditions. The maximum load capacity of such dump trucks, today, is 450 tons, and the speed of movement on a horizontal surface exceeds 60 km/h. Under such operating conditions, the dump truck control system must be adaptive, ensure driving stability and controllability.

Modern vehicles are equipped with many different traffic safety systems. These are the anti-lock brake system (ABS), the acceleration slip regulation (ASR), the electronic differential lock system (EDS), as well as electronic stability program (ESP), which was named ESC, DSC, VDC, etc. in dependence to the vehicle manufacturer. The main task of the ABS and ASR systems is to maintain controllability on a slippery road by maintaining slip in the optimal range corresponding to the maximum coefficient of longitudinal grip of the wheels with the road surface [2]. The width of this range is a criterion for the quality of systems operation. The effective operation of ABS allows you to shorten the braking distance, ASR together with EDS - to increase the cross-country ability, and ESP - to prevent truck yaw.

In conditions of driving on dry asphaltic concrete surface, ABS increases the braking distance, but retains controllability and reduces wear on the expensive wheel rubber of a mining truck. A modern ABS system should provide: minimum braking distance, maintaining control, adaptability to external conditions (changes in slip coefficient), smooth braking (jerk-free).

The use of ASR allows you to increase the traction force, maintain driving stability and reduce the load on the transmission. ESP, combining and developing the advantages of ABS and ASR, prevents skidding and side slip, helps to stabilize the car's position during extreme maneuvering on slippery road surfaces.

The development of traffic safety systems for mining dump trucks with electromechanical transmission (EMT) is an important task. Difficult road conditions (mud, wet clay, ice) and dump truck operation modes (descents and ascents uphill) place increased demands on such systems.

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