Analysis of energy consumption during the braking process of electrically driven mining dump trucks (Case Study: Komatsu 860E)

Abstract

In open-pit mines, freight transportation accounts for a large portion of the mine's operating costs. Electric-powered quarry dump trucks, such as the Komatsu 860E, are widely used in such conditions. This article analyzes the energy consumption during deceleration (braking) and its recovery based on the real-life duty cycle of the Komatsu 860E quarry dump truck. As a result of the research, a mathematical model was developed and how much energy is lost or recovered through the engine and electric drive system during deceleration was estimated. Based on the test data, the changes in deceleration, speed, power, and time are analyzed. The results of the study show that, in the presence of an energy recovery system, 30–50% of the kinetic energy generated during the deceleration phase can be converted into electrical energy. This serves to optimize energy efficiency, energy conservation, and operational energy in quarry transport. Based on data obtained from the electronic control unit, the developed model takes into account not only the total energy consumption but also the amount of energy that can be recovered during braking, which was simulated accordingly. The study analyzes how the use of recoverable energy can reduce transportation costs and improve energy efficiency. Furthermore, enhancing the regenerative braking system and optimizing routes can further increase overall efficiency. This approach is evaluated as an economically and environmentally beneficial solution.