TECHNICAL FIELD

[0001] The present invention relates to an underground mining vehicle for providing electrical supply to heavy mining equipment.

BACKGROUND

[0002] Heavy mining equipment consumes a high level of electrical power. Usually, a high level of electrical power is provided to the equipment through one or more power cables connecting the equipment to the power grid, or through one or more cables connecting the equipment to a generator, or a combination of both. However, underground mining complicates the situation.

[0003] Pulling power cables to connect equipment operating underground to the power grid requires a very long connection. It is not unusual for an underground mining tunnel to run several kilometres to tens of kilometres. Thus, pulling a power cable to provide electrical power to underground equipment is very costly and time consuming. Further, the condition of the tunnel is not ideal, i.e. with rough surfaces, sharp edges etc. Accordingly, the power cable needs to be monitored, maintained and repaired quite frequently. Any repair work or maintenance work conducted to the power cable is costly and will most probably disrupt the operation of the equipment connected to the power cable. Any disruption to equipment in the mining area is very costly too. It is not unusual to incur a cost exceeding thousands of dollars an hour for any disruption to essential mining equipment such as a drill. The situation is even more challenging when the mining equipment needs to be moved after a fixed interval, for example, a mining drill moves progressively as a tunnel is being created. Movement of mining equipment requires disconnection and reconnection of power cables. Since the power cables are usually providing high voltage and carrying high current, such disconnection and reconnection requires specialised handling, which is both time consuming and of high cost.

[0004] Using a generator underground is not ideal as generators, usually run on diesel or petrol, produce fumes or gases which would create a hazardous environment underground.

[0005] The present invention provides an alternative to known methods to provide electrical supply to underground mining equipment. SUMMARY

[0006] According to a first aspect of the present invention, there is provided a vehicle for providing electrical power to a mining equipment, including: an power output for connection with the mining equipment; a battery pack within a battery compartment, wherein the battery compartment is an enclosure protected by a foam fire suppression system; a DC-AC converter for changing a direct current from the battery pack to an alternating current; and a transformer for transforming an output voltage of the DC-AC converter to provide a desired voltage at the power output.

[0007] In one form, the battery compartment is air-conditioned. In one form, the foam fire suppression system is activated manually or activated automatically through a heat/fire detection sensor or both. In one form, the DC-AC converter is protected by the foam fire suppression system. In one form, the desired voltage is between 240V to 1.5kV, and the corresponding current is up to 200A. In one form, the battery compartment has a rating of at least IPX4 in relation to liquid ingress protection. In one form, the battery compartment has a rating of at least IP5X in relation to solid particle protection. In one form, the power rating of the DC-AC converter is between 5kW to 500kW. In one form, the battery pack includes a combi nation of series and parallel battery units with energy charge of between 200Ah to 1600Ah. In one form, the vehicle is with a diesel powered engine, or with an electrical engine powered by the battery compartment or powered by a different battery from the battery compartment. In one form, the power output is positioned at the rear of the vehicle in a form of cable hose. In one form, the DC-AC converter is an inverter. In one form, the DC-AC converter and the transformer are in a form of a variable voltage variable frequency drive. In one form, the battery compartment includes a blast vent.

[0008] According to a second aspect of the present invention, there is provided a system for providing electrical power to a mining equipment, including: a vehicle carrying a battery pack within a battery compartment, an DC-AC converter, a transformer and an power output, wherein the battery pack provides a direct current, the DC-AC converter changes the direct current to an alternating current, the transformer transforms an output voltage of the DC-AC converter to provide a desired voltage at the power output; and wherein the battery compartment is an enclosure protected by a foam fire suppression system; and a charging station for charging the vehicle; wherein during an operation to provide electrical power, the vehicle moves to the mining equipment, and a cable is used to connect the power output to the mining equipment; and after the operation, the vehicle moves to the charging station for charging the battery pack. In one form, the battery compartment includes a blast vent.

[0009] According to a third aspect of the present invention, there is provided a battery compartment on a vehicle to protect a battery pack within the compartment, the battery for providing electrical power to a mining equipment, the compartment is configured to include or have ratings of: at least IPX4 in relation to liquid ingress protection; at least IP5X in relation to solid particle protection; a foam fire suppression system; and an air conditioning system. In one form, the battery compartment includes a blast vent.

BRIEF DESCRIPTION OF DRAWINGS

[0010] Embodiments of the present invention will be discussed with reference to the accompanying drawings wherein:

[001 1] Figure 1 depicts one embodiment of the present invention;

[0012] Figure 2 shows another view of the embodiment of Figure 1 ;

[0013] Figure 3 shows an alternative from the embodiment of Figures 1 and 2;

[0014] Figure 4a and 4b depict an operation of one embodiment of the present invention in a mine.

[0015] Figure 5 depicts an exemplary control panel; and

[0016] Figure 6 depicts an exemplary enclosure to protect a rechargeable energy storage unit. DESCRIPTION OF EMBODIMENTS

[0017] The invention is in relation to a mobile power supply vehicle for providing power supply to heavy mining equipment that relies on electricity for their operation. The invention is not limited to specially made trucks, utes, or vans with mounted power supply system, and include a power supply "box" or "container" which can be made to be mounted on any truck, ute, or van.

[0018] The power supply system of the present invention runs on a rechargeable energy storage. It can run on one or more battery bank, a number of battery packs connected in series or parallel etc. The battery bank or battery packs can be based on various technologies such as Lithium ion, NiCd, lead-acid etc. The present invention is also expected to work with future battery technologies as long as the battery works as rechargeable energy storage. There can be more than one rechargeable energy storage units on a vehicle. If there are more than one rechargeable energy storages, each rechargeable energy storage can be of different technology and types. The battery i s with energy charge rating of between 200 Ah to 1600Ah. Higher energy charge may be possible with advancement in battery technology.

[0019] The main function of the mobile power supply vehicle is to supply electrical power to heavy mining equipment which runs on very high voltage > 415 V through use of a rechargeable energy storage. Heavy mining equipment includes, but not limited to, jumbo drills and simba drills. In the case of jumbo drills and simba drills, power is usually supplied at lkV. Of course, the mobile power supply vehicle can provide output of lower voltages, for example at 240V. The mobile power supply vehicle can have controllable voltage output, or multiple outputs each with a different output voltage. For example, the mobile power supply vehicle can have two outputs, one provides 1000V to a mining drill, and another one provides 240V for an illuminating device.

[0020] The mobile power supply vehicle can be driven to an intended destination (especially, but not limited to, an underground destination without power supply) to deliver electricity to heavy mining equipment that requires electricity. The vehicle can be equipped with various mining safety equipment (more to be discussed later with reference to Figure 1), such as proximity sensors/alarms etc. The engine of the vehicle can run on diesel, petrol, or even electricity. The electricity can be from the same rechargeable energy storage used to power the mining equipment, or can be a separate battery. In other words, when the engine is an electrical engine, it can draw power from the main battery bank used to power the heavy mining equipment, or from a battery different from the main battery bank. Accordingly, the vehicle is not limited to be powered by a diesel engine (to drive it). It could also be powered electrically using an electric motor powered by batteries which replaces the diesel engine, thus creating a totally green, diesel particulate matter free vehicle to be used underground.

[0021 ] The rechargeable energy storage of the mobile power-supply vehicle can be charged at a charging station. There may be numerous mobile power supply vehicles and charging stations in a mine. A charging station is linked to the power grid, and a charging station provides electricity to charge the rechargeable energy storage. Charging involves connecting a cable from the charging station to the vehicle. The charging point can be the same output for providing electricity. Fast or ultra-fast charging techniques can be applied depending on the type of rechargeable energy storage chosen.

[0022] The immediate output of the rechargeable energy storage is usually DC. Since most of the mining equipment requires AC supply, the vehicle is equipped with a DC-AC converter. The DC-AC converter can takes the form of an inverter. Alternatively the DC-AC converter can be a variable voltage variable frequency (VVVF) drive running in DC-AC topology.

[0023] The immediate output voltage of the rechargeable energy storage may not match the required voltage of a mining equipment (1000V for a drill, for example). Thus a transformer may be required.

[0024] For example, if an inverter is used as the DC- AC converter, the output of the inverter can be input to a transformer so that the output of the transformer matches the required voltage. If a VVVF drive is used instead, depending on the settings and types of VVVF drive, a separate transformer may not be required as the function of a transformer may be incorporated in some VVVF drive. [0025] During a typical operati on, the rechargeable energy storage of the mobile power supply vehi cle is charged at a charging station. Once charged, the mobile power supply vehicle moves to a destination to provide electrical supply to power a heavy mining equipment. When the heavy mining equipment finishes its operation or when the rechargeable energy storage runs low, the mobile power supply vehicle returns to the charging station for charging the rechargeable energy storage of the mobile power supply vehicle.

[0026] The invention is particular useful as connecting, disconnecting and reconnecting electricity cables to heavy mining equipment takes a long time (may be hours to a day). Further, heavy mining equipment moves frequently from a position to another position (for example, a drill moves progressively to make tunnels). The invention allows the mobile power supply vehicle to follow the heavy mining equipment while continue to provide the required operational power to the heavy mining equipment. The invention can also replace a diesel-powered generator for proving electricity, thus reducing gas emission from a diesel-powered generator.

[0027] Due to the hostile environment in underground mining, the rechargeable energy storage is protected in an enclosure, such as a cabinet etc. The enclosure can be set to achieve certain ratings in terms of liquid ingress protection and solid particle protection depending on the rules and regulations of a particular mine. For example, some mines requires IP56 (IPX6 in relation to liquid ingress protection; IP5X in relation to solid particle protection), thus for those mines the cabinet or enclosure of the rechargeable energy storage is designed to achieve 1P56.

[0028] The cabinet or enclosure is protected with foam fire suppression mechanism. The foam fire suppression system can be activated manually or activated automatically through a heat/fire detection sensor or both. The health and the charge level of the rechargeable energy storage can be monitored and presented to the driver of the vehicle (through a panel near the driver seat), or presented to an outside operator (through a control panel outsi de of the driver compartment).

[0029] The cabinet or enclosure can be provided with air conditioning. The air conditioning is provided through a ducted system delivering chilled/cold air to the cabinet or enclosure. The mobile power supply vehicle further includes certain mining equipment, such as ventilation fans and dewatering pump systems, powered by the battery on the mobile power-supply vehicle.

[0030] Figure 1 depicts one embodiment of the present invention. In this embodiment, the invention takes a form of a truck 1 with enclosures 3 and 3' for storing rechargeable energy storage units, an inverter 5 and a transformer 7. Truck 1 also includes a control panel 9, a reel of cable 1 1 , a foam fire protection system (not shown) within enclosure 3, foam tank 13 for storing foam for the foam fire protection system. [0031] In this embodiment, there are two enclosures 3 and 3' for storing rechargeable energy storage. The number of enclosure can be one or more depending on the design of the truck.

[0032] In this embodiment, the rechargeable energy storage units within enclosures 3 and 3' provide DC power. Inverter 5 coverts the DC from the rechargeable energy storage units into AC. Transformer 7 transforms the AC output of inverter 5 to a desired voltage. The desired voltage can be changed using control panel 9. The desired voltage is then provided through the cable of the reel of cable 1 1.

[0033] The enclosures 3 and 3', while shown as boxes, can take a form of a cabinet. The aim of the enclosures 3 and 3' is to protect the rechargeable energy storage within the enclosures 3 and 3'. The enclosures 3 and 3' can include, but not necessarily, one or more blast vent. The enclosures 3 and 3' is at least IPX4 in relation to liquid ingress protection, and at least IP5X in relation to solid particle protection. In some cases, to adhere to mine regulations, the enclosures 3 and 3' is at least IP56.

[0034] The functions provided by inverter 5 and transformer 7 can be replaced by a combination of a VVVF drive and a transformer, or can be replaced by a VVVF drive on DC-AC mode (i.e. VVVF with voltage transformation capability). In short, any configuration that can convert DC to AC then transform the AC to a desired voltage can be used.

[0035] While there is a control panel 9 in the embodiment of Figure 1 to control the desire voltage, it is possible that truck 1 has a prefixed voltage output. For example, the system of truck 1 can be modified to be without any means to control the output voltage. The voltage output can be pre-set at 1000V @ max 250A to provide electrical power a specified drill.

[0036] Control panel 9 presented in truck 1 provides the function to control the voltage provided through the cable of the reel of cable 1 1. Control panel 9 may include many other functions or indications, for example, but not limited to: an indicator on the health of the rechargeable energy storage units, including, charged status, temperature of rechargeable energy storage units etc, emergency stop button for isolating the rechargeable energy storage units, emergency stop button for stopping the electrical power supply through the cable of the reel of cable 1 1. An alternate embodiment of control panel 9 is described with reference to Figure 5. An extra control pane with similar or the same functions or indications can be positioned within the driver compartment. The control panel may also include a starter panel which includes receptacle for a specific drill, such as a 1000V receptacle for a jumbo drill, and may also include circuit breakers for auxiliary equipment.

[0037] The reel of cable 1 1 can removed from truck 1. For example, truck 1 can be modified to just provide a voltage output terminal. A separate cable can be used to connect the voltage output terminal to a mining equipment. [0038] Foam tank 13 can include several containers, and also can be designed to provide foam fire protection system to inverter 5 besides already providing foam fire protection system to enclosures 3. Enclosure 3 is also provided with air conditioning unit (for example, an 8kW ducted chiller system to maintain the temperature to a specified temperature, such as 18 degrees Celsius or 20 degrees Celsius). In one form, the tank carries approximately 300 to 400 litres of foam.

[0039] Truck 1 is equipped with safety features. For the driver compartment, Roll Over Protection Systems (ROPS) and Falling Object Protection Systems (FOPS) are applied to reduce the risk of the destruction of the driver compartment in the case of a rollover accident and reduce possible injuries in the case of a falling object. Various techniques can be used, for example, by strengthening the driver compartment with steel cages, bars, hops etc.

[0040] Truck 1 is also equipped with flashing light, such as a green flashing light 15 used in mine. The truck has reversing camera 17 (such as a 180 degree camera), reversing flood lights (such as LED lights), reversing beeper, front LED spotlights and work lights (such as LED around truck 1 ). Truck 1 can also be white in colour with reflective striping along the sides, and with front bull bar and rear steel protection (not shown).

[0041 ] Figure 2 shows another view of truck 1. The arrangement of enclosures 3 and 3', inverter 5 and transformer 7, control panel 9, reel of cable 1 1, foam tank 13 can be rearranged to suit various designs. For example, the reel of cables can be position at the side of truck 1 and not necessarily at the rear of truck 1. Outline 19 may be used as a guideline where the different parts can be rearranged. Note however, outline 19 is merely a guide and is by no means to limit the position of various parts as long as the positions of the parts are deemed safe according to safety regulations of the place where the truck is being operated. For example, the front face of the control panel 9 may be protruding from outline 19. Also. Truck 1 may be modified to include other parts that would protrude from the outline 19. For example, the truck may include a strengthened cage surrounding outline 19. The truck may also include excavation means, robotic arms etc depending on the needs at a mining site or at a place the truck is being operated.

[0042] Figure 3 shows another alternative from the embodiment of Figures 1 and 2. This embodiment exemplifies that the main components i.e. the rechargeable energy storage units within an enclosure, and parts for converting the DC to an AC of desired voltage can be a separate box 21 and can be moved and mounted on a truck. This is particularly useful when the separate box 21 can be configured and shipped to a destination prior to being mounted on top of a vehicle at the destination.

[0043] Figure 4a and 4b depicts an operation of one embodiment of the present invention in a mine. In figure 4a, charging station 51 takes a form of a standing panel with multiple sockets 53a, 53b and 53c. Charging station 51 may take other forms, as long as there is a way to provide a charging current to truck 1. For example, charging station 51 may take a form of a vehicle depot, and charge the rechargeable energy storage units of truck 1 inductively. Charging station 51 may use more than one method to charge the rechargeable energy storage units. Charging station may always use, or can be controlled to use, fast or ultra-fast charging technique.

[0044] In the particular embodiment shown in Figures 4a and 4b, truck 1 is with reel of cable 1 1. A cable 55 is pulled from reel of cable 1 1 then connected to socket 53a. The charging of the rechargeable energy storage units can be started automatically or controlled to start manually. Charging station 51 or truck 1 or both may include indicator to indicate when the rechargeable energy storage units are fully charged. It is also possible for the charged level to be shown on a screen of the charging station 51 or on truck 1, or both, such as charged 80%, 85% etc.

[0045] Once charged, truck 1 is ready to be deployed to provide electrical power supply. In Figure 4b, it is shown that a charged truck 1 is deployed to provide electrical power supply to a mining drill 57. Cable 55 from reel of cable 1 1 is connected to a power input of mining drill 57. As the drill moves progressively in the direction indicated by arrow 59, truck 1 can move at the same time. Potentially, there would be no down time for the mining drill 57. In other words, truck 1 provides electrical power to the mining drill 57 continuously as the mining drill 57 moves, by moving together with the mining drill 57, to avoid any downtime of the mining drill 57.

[0046] Note that while the example depicted in Figures 4a and 4b shows that truck 1 charges its rechargeable energy storage units and provide electrical power supply through a same cable, truck 1 can have separate charging/discharging terminals. The discharging terminal can be at the front of truck 1 , so that truck 1 moves forward rather then moves backwards to follow the movement of the mining drill 57. Of course, it is also possible, while not the most efficient way, to have truck 1 with a sufficiently long cable 55 from the rear of truck 1, so that the cable is connected to mining drill 57 with the truck being able to move forward with mining drill 57 despite having the cable 55 from the rear.

[0047] Figure 5 depicts an exemplary control panel 71 which can be assessed from external of the driver compartment of truck 1. In this embodiment, the control panel 71 includes a voltage indicator 73, a charged status indicator 75, an emergency stop button 77, a screen 79, controls buttons 81, and control knobs 83. When multiple rechargeable energy storage units are presented in a truck, controls buttons 81 and/or control knobs 83 can be used to select and present the voltage of a particular rechargeable energy storage unit through voltage indicator 73 and the charged status of the particular rechargeable energy storage unit through charged status indicator 75. Controls buttons 81 and/or control knobs 83 can also be used to change what is shown on screen 79, for example, temperature of a particular rechargeable energy storage unit. Of course, modification to control panel 71 can be made when there is only one rechargeable energy storage unit on truck 1. Further, modification can be made to adhere to rules and regulations of a location where the truck is being deployed.

[0048] Figure 6 depicts an exemplary enclosure 101 to protect a rechargeable energy storage unit 103. In this example, the enclosure 101 can be mounted on a truck through any known mechanism positioned near the base. Alternatively, enclosure 101 can be made to be part of a truck. Two safety systems are implemented in this example. The first safety system is to provide air conditioning to the space within enclosure 101. In one form, the temperature is maintained to be < 20 degree Celsius to cool off the rechargeable energy storage unit 103. The air conditioning is implemented through a ducted system with cooling air coming through 105 and exiting through an aperture or opening. Ducted system is used in this example to move the coolant a distance from the enclosure to reduce any potential risk of the coolant affecting the rechargeable energy storage unit 103. For example, leaking coolant may explode when it interacts with the rechargeable energy storage unit 103. Having a ducted system effectively mitigates this issue. The second safety system is to provide a fire extinguishing system and fire prevention system through a foam fire protection system. There will be one or more foam dispensing outlets spraying over the one or more rechargeable energy storage units when there is a fire or when the temperature of the battery is detected to exceed a determined threshold (for example, exceeding 80 degree Celsius). In Figure 6, seven dispensing outlets 1 1 la, 1 1 lb, 1 1 lc, 1 1 Id, t i l e, 1 1 I f, 1 1 lg are presented. The enclosure may have strengthened wall using known methods (steel beams, cage etc) and may include a blast vent or explosion vent.

[0049] Throughout the specification and the claims that follow, unless the context requires otherwise, the words "comprise" and "include" and variations such as "comprising" and "including" will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.

[0050] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge.

[0051 ] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention as set forth and defined by the following claims.