Authors: A.B. Vinogradov, A.N. Sibirtsev, V.L. Chistoserdov, N.E. Gnezdov, A.A. Korotkov, K.K. Ermakov

Title of the article: Enhanced functionality and import substitution in traction electrical equipment for mining dump trucks

Year: 2025, Issue: 4, Pages: 3-11

Branch of knowledge: 2.4.2. Electrotechnical complexes and systems (engineering)

Index UDK: 622.684

DOI: 10.26730/1816-4528-2025-4-3-11

Abstract: The article introduces a new development by the Electrical Drive Research and Technical Center "Vector" in the field of control systems for mining dump trucks with a payload capacity of 90–240 tons. Compared to similar systems available on the Russian market, it stands out due to its high reliability, high-quality and energy-efficient control across all driving modes both with and without a speed sensor on the traction motor shaft, enhanced maintainability, independence from imported key power components, and advanced monitoring, diagnostic, and service functions based on modern information technologies. The paper provides a detailed analysis of new design solutions and control algorithms that operate without sensors on the shafts of the mining truck’s traction motors. The new rational design and layout of control systems cabinet elements for the entire range of 90-ton dump trucks have minimized parasitic parameters, significantly reduced production costs, and improved reliability, maintainability, and manufacturability. The truck control system characteristics presented in this study have been validated through bench, factory (at the OJSC "BELAZ"), and operational tests as part of a 90-ton mining dump truck. The article includes test results of the electric transmission in real operating conditions, its new functional capabilities, unique design features of its control system, and the organization of on-site service support. The implementation and mass production of the developed control system will ensure uninterrupted operation of mining industry equipment with minimal dependence on imported components, while also reducing equipment costs and enhancing reliability without compromising control quality.

Key words: dump truck traction electrical drive import substitution control system sensorless control vector control

Receiving date: 06.03.2025

Approval date: 30.06.2025

Publication date: 28.08.2025

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