CONFIDENTIAL

Energy Flow of AC Drive Dump Truck

Diesel Fuel
Diesel ↓
Engine
Physical Power
(Mechanical Joint)
Physical Power
↓
Alternator High Voltage 3-Phase AC

(Electric Wire)

High Voltage 3-Phase AC

↓ 6 Diodes convert AC into DC
Rectifier High Voltage DC (with Ripple)
AC-Drive System

(Electric Bus Bar)

Control Cabinet

High Voltage DC (with Ripple)

↓ Capacitor makes DC smoother
Capacitor High Voltage DC (Smooth)

(Electric Bus Bar)

High Voltage DC (Smooth)
Inverter ↓ 6 IGBTs convert DC into AC
(IGBT) ↓ with controlled frequency
High Voltage 3-Phase AC

(Electric Wire)
High Voltage 3-Phase AC
↓
Wheel Motor Physical Power

(Mechanical Joint)
Physical Power
Reduction ↓ Reduction Ratio 35.2 : 1
Gear Physical Power

(Mechanical Joint)

Tire
1/7
 CONFIDENTIAL
OVERVIEW of AC Drive System for EH4000ACII

AFR (Auxiliary Alternator Field Regulator)

D311 C311 TRS 311
AC AC DC DC IGBT as DC
→
Fuse Rectifier Capacitor →
To (A)
Chopper
(F301,302) (Smoothing) x2

MFR (Main Alternator Field Regulator)

STK 301 C301 STK 302
AC DC DC IGBT as DC
→
Breaker Rectifier Capacitor →
To (B)
Chopper
AUXILIARY ALTERNATOR

(CB302) (Smoothing)

From Excitation AC AC Alternator

→
Contactor →
(A) 　→ Current Blower
(CTT301)
Auxiliary Inverter (INV 301)
→ Motor
→ DC DC AC Blower
Rectifier Capacitor Inverter
(Smoothing) Coolant
AC → Pump
→
Breaker
Auxiliary Inverter (INV 302)
(CB301)
DC DC AC Grid
→
Rectifier Capacitor Inverter → Blower
(Smoothing) x5

Auxiliary Inverter (INV 303)

AC DC DC AC Motor for
→
Breaker →
Rectifier Capacitor Inverter → Gear Oil
(CB305) (Smoothing) Pump

Main Inverter Unit (R)

Capa DC → IGBT as AC → Wheel

MAIN ALTERNATOR

-citor ← Inverter ← Motor (R)

→
(Charging,
Smoothing DC IGBT as DC x6
) Chopper → Grid
x2 x2 → Box (R)
From Excitation AC Rectifier DC x3
(B) 　→ Current → → Main Inverter Unit (L)
Unit

Capa DC → IGBT as AC → Wheel

-citor ← Inverter ← Motor (L)
(Charging,
→ IGBT as DC x6
Smoothing DC
) Chopper → Grid
x2 x2 → Box (L)
x2
Eng. 2/7
 CONFIDENTIAL
Components Layout for EH4000ACII

( Rear Axle )

Reduc Motor Reduc

WHEEL for WHEEL
Rear Rear -tion -tion Rear Rear
Tire Tire Gear MOTOR Gear Oil MOTOR Gear Tire Tire
Pump
(R) (R) (L) (L)

↓ ↑AC ↑ ↓ ↑AC
Wheel
→ Motor
Blower

Gear Pump
Main Pump x2

Auxiliary
Alternator ALTER-
Alter
NATOR
-nator → Main
Blower Alternator AC →
Cooling Duct

Cooling Duct

Engine
GRID BOX
ECM
Grid Grid
Resistor Blow ← CAN-Line
(R1) -er ↑ ↑ CONTROL CABINET
Grid Grid
Resistor Blow ← CB Fuse AFR CS DSC
(R2) -er ←
C T T Rectifier
MFR
Grid Grid ←
↓DC
CCU

DLU

Resistor Blow ↓
IDU
INV

INV

INV

(R3) -er Main Main

Inverter Inverter
Grid Grid
Unit (R) Unit (L)
Resistor Blow ← Pump CAN-Line
(L1) -er DC↓ ↑ ↓AC DC↓ ↑ ↓AC
CAB
Grid Grid
Resistor Blow ←
(L2) -er

Front
Direction

3/7
 EH4000ACII CONTROL CABINET LAYOUT CONFIDENTIAL

from Auxiliary Alternator to Auxiliary Alternator ↑ ↓ ↑ to Alternator Blower

← from Main Alternator

↓ AC 230V
AFR (Auxiliary Alternator

24V
DC

High-Voltage AC
↓ ↓ ↓ ↓ ↓ ↓ Field Regulator) DSC (Drive System Controller)
(AVR303)
Breaker (CB303) Opt.

Breaker (CB304) Opt.

Fuse (F311)

Fuse (F301)

Fuse (F302)

Fuse (F303)

Fuse (F304)

Fuse (F305)
Breaker (CB301)

Breaker (CB302)

Breaker (CB305)

Power Unit )
CS (Control
DC24V

DC/DC
→

(TRS 311)
Capacitor
Rectifier

IGBT x2
DC

DC

DC

VDC 06

VDC 07
VIO 13

VIO 14

VIO 15
(D311)
AC
→ to Main Alternator

x2
→

DC/DC
↓ ↓ (Smoothing) (Chopper) (AVR302)

↓ ↓ ↓ ↓ AC
Rectifier Unit

CTT302

CTT303

CTT304

CTT305
Contactor
DC (CTT301)

Current

Voltage
Sensor
Sensor
DC

DC
MFR (Main Alternator Field Regulator) → Rectifier DC
AC ↓ AC (STK01) →
DC

DC
→ Rectifier Capacitor IGBT x4 →
AC (STK 301) x2 (C301) (STK 302) DC Connectors
(Smoothing) (Chopper)
→ ←
Auxiliary Inverter ↓ Auxiliary Inverter Auxiliary Inverter
(INV 303) (INV 301) (INV 302) Main Inverter Unit (R) Main Inverter Unit (L)
→ to Gear Oil Motor

DC

DC

→ AC
Capacitor
Rectifier

Inverter

DC

DC
Capacitor

Capacitor

→ IGBT as IGBT as
Rectifier

Rectifier

→
Inverter

Inverter

Inverter Inverter
DC

DC

→ →
AC → DC → x6 AC → DC → x6 AC →
← (TSR11 ← ← (TSR11 ←
Capacitor -TSR16) Capacitor -TSR16)
x2 x2
← → →
to Motor Blower ←

↓ DC (C11A , DC (C11A ,
C11B) IGBT as C11B) IGBT as
AC DC Chopper x2 DC DC Chopper x2 DC
→ (TSR17A , → → (TSR17A , →
Cooling Water Pump (Smoothing TSR17B) (Smoothing TSR17B)
(PUMP 301) & Charging) & Charging)

↓ to Grid Blowers x5 to Grid Boxes (R) x3↓ to Grid Boxes (L) x2↓
High Voltage AC Middle Voltage AC (230V)
High Voltage DC Middle Voltage DC 　 to/from Wheel Motor (R) ↑ ↓ to/from Wheel Motor (L) ↑ ↓
Low Voltage DC (24V) 4/7
 Layout of AC-DRIVE FIXED SIMULATOR CONFIDENTIAL

Trolley Option Components

Motor Motor
High as Load as Load Motor Motor
as Controller
Voltage Engine
Cubicles
WHEEL WHEEL Electric
Hydraulic MOTOR (R) Wheel MOTOR (L) Power
Power
Main
Motor
Alternator Source
Source Blower

Pantograph (R) Alter-

Cooling Duct Cooling Duct nator Auxiliary
Blower Alternator
GRID BOX x2
Grid Grid ALTERNATOR
Blower Blower CB Fuse AFR CS New DSC
Trolley Box
Grid Grid C T T Rectifier
MFR
Resist Resist
-or (R) -or (L) INV INV Main Main
Inverter Inverter DSC Box
Pump Unit (R) Unit (L) (Old Type)
Pantograph (L) Duct

CONTROL CABINET

Power
Switch CCU Sw. Switch Switch
LCD Laptop Supply
Box 4 Touch DLU Box 3 Box 1 Box 2
PC Box for
Panel IDU
Simulator

CONTROL BOOTH

5/7
 CONFIDENTIAL

SERVICE TOOLS (PC Software)

Controller Tool Data

Operator's Cab

CCU
( Central RS232C
Self Extract ← Program Update ← Supply from HCM
Control Unit )

← Parameters
(Hour Meter, Odometer, Satellite, etc)
DLU Maintenance
RS232C
PRO → Work Record → Send to HCM ( as
( Data occasion demands )
Logging
Unit )

RS232C
Self Extract ← Program Update ← Supply from HCM

IDU RS232C
Self Extract ← Program Update ← Supply from HCM
( Information
Display Unit ) RS232C
UpDownloadToolV4 ← Data Files Update ← Supply from HCM

←KE-CAN Line

Control Cabinet

→ High-Trace Data → Send to HCM

( as occasion
DSC → Low-Trace Data → demands )
( Drive
RS232C EH System
Monitor Changeable Parameters
System ⇔ (Serial Number, Tire Size, Speed Limit, etc)
Controller )

CPU1 ～ ⇔ Fixed Parameters

CPU5

RS232C
Self Extract ← CPU Program Update ← Supply from HCM

Engine
ECM ( Engine INSITE
Control
(Cummins Tool)
Module )

←SAE-J1939 Line 6/7

 CONFIDENTIAL

SOFTWARE UPLOAD for EH4000ACII

TOOL FILE NAME

CCU ← (Self Extract) ← EH4000AC2_CCU_xxxx.exe (Program File)

← (Self Extract) ← EH4000AC2_DLU_yyyy.exe (Program File)

DLU
Dump Truck

Maintenance
→ → EH4000-ssss-dddd-tttt.dpf (Data Backup)
PRO

← (Self Extract) ← EH4000AC2_IDUV_zzzz.exe (Program File)

← EH4000AC2_IDUV_zzzz_FIGURE.mot (Data File)

UpDownload
IDU ToolV4 ← EH4000AC2_IDUV_zzzz_FONT.mot (Data File)
←
← EH4000AC2_IDUV_zzzz_SYSTEM.mot (Data File)
(Up loader)
← EH4000AC2_IDUV_zzzz_TEXT.mot (Data File)

CPU1 ← (Self Extract) ← EH4000AC2_DSC_CPU1_aaaa.exe (Program File)

CPU2 ← (Self Extract) ← EH4000AC2_DSC_CPU2_bbbb.exe (Program File)
AC Drive System

CPU3 ← (Self Extract) ← EH4000AC2_DSC_CPU3_cccc.exe (Program File)

CPU4 ← (Self Extract) ← EH4000AC2_DSC_CPU4_dddd.exe (Program File)
CPU5 ← (Self Extract) ← EH4000AC2_DSC_CPU5_eeee.exe (Program File)

DSC → → EH4000AC2_ssss_dddd_ParaOld.csv
(Parameters
EH System Backup)
Monitor
← ← EH4000AC2_ssss_dddd_tttt_ParaUP.csv (Parameters)

7/7