Analysis and Application of Energy-Saving Approaches for Mining Dump Trucks Based on the Reuse of Braking Energy

The operating characteristics of the continuous climbing time, the long downhill retarding distance, and the wide load variation range make the fuel consumption of mining dump trucks high, and the energy consumption cost can reach 1/3 of the total operating cost. The electric retarding technology with the resistance cabinet is the only way to dissipate the braking energy of large mining dump trucks. However, it cannot realize the recovery and reuse of braking energy. High instantaneous braking power, short braking time, less energy recovery, and short life of the energy storage components make the lithium battery an auxiliary energy storage hybrid technology unable to effectively adjust the engine load rate to achieve the expected energy saving and cost reduction effect. Therefore, a typical operating condition model is established based on the operational characteristics of open-pit mines. Combined with the three topology structures of motor light overload, cooling fan electrification, and reverse drag engine, four technical solutions are proposed to improve the energy utilization rate of mining dump trucks. “Energy-saving coefficient of feedback braking energy” is the evaluation index, taking a mine dump truck with a load of 150 tons as the scheme’s application object and comparing each scheme’s energy-saving effects. The results show that on the premise of ensuring the vehicle’s dynamic performance, maximizing the use of braking energy can reduce engine energy consumption by 2–11%.