An electric drive system for an electrically powered loader

Abstract

This utility model discloses an electric drive system for an electric loader, relating to the field of new energy three-electric systems. The electric drive system for an electric loader includes a working motor, a two-speed gearbox, a shift motor, a shift fork, a drive motor, a first working pump, and a second working pump. The two-speed gearbox is fixedly connected to the working motor, and the input shaft of the two-speed gearbox is equipped with a second-speed input gear and a first-speed input gear. This utility model achieves multi-condition adaptation through the different gear characteristics of the two-speed gearbox: the first gear utilizes torque-increasing characteristics, combined with dual-motor coupling, to provide the loader with sufficient, stable, and efficient power during loading, while also reducing costs and saving energy; the second gear enables efficient motor operation and energy recovery by the drive motor, facilitating energy-efficient and long-range transfers. Simultaneously, the integration of the motor and gearbox reduces the space occupied by the power system, facilitating maintenance and improving the overall vehicle layout flexibility.

Description

Technical Field

[0001] This utility model belongs to the field of new energy three-electric technology, specifically, it relates to an electric drive system for an electric loader. Background Technology

[0002] In the field of electric loaders, with the promotion and application of new energy technologies, the performance optimization of electric drive systems has become a key focus of the industry. The operating scenarios of electric loaders cover low-speed, high-torque conditions for loading materials and high-speed driving conditions for site transfer, which puts forward higher requirements for the multi-condition adaptability, power efficiency and integration of electric drive systems.

[0003] The electric drive systems of electric loaders currently on the market still have the following defects in actual use. First, traditional single-speed gearboxes or single motor solutions cannot meet the high torque requirements of heavy-duty loading and high-speed efficiency during field transfer. The high-power motors configured to meet peak torque are not only bulky and expensive, but also waste energy due to long-term inefficiency in low-speed conditions.

[0004] Secondly, during high-speed transfers, the single-speed system cannot match the motor speed to the efficient range, and it also lacks an energy recovery mechanism, resulting in insufficient range.

[0005] Thirdly, the distributed layout of the motor, gearbox, and working pump occupies a large amount of vehicle space. The design of the working pump being suspended on the motor end cover is prone to vibration failure due to excessive suspension. The complex hydraulic pipelines and maintenance interfaces also result in poor system reliability and maintenance convenience. In view of this, this utility model is proposed. Utility Model Content

[0006] The technical problem to be solved by this utility model is to overcome the shortcomings of the prior art and provide an electric drive system for an electric loader that can overcome or at least partially solve the above problems.

[0007] To solve the above-mentioned technical problems, the basic concept of the technical solution adopted by this utility model is as follows:

[0008] An electric drive system for an electric loader includes a working motor, a two-speed gearbox, a shift motor, a shift fork, a drive motor, a first working pump, and a second working pump. The two-speed gearbox is fixedly connected to the working motor. The input shaft of the two-speed gearbox is equipped with a second-speed input gear and a first-speed input gear. The output shaft of the two-speed gearbox is equipped with an output gear, an output gear, and an output gear. The shift motor and shift fork are used for gear switching in the two-speed gearbox. The drive motor is located at the output end of the two-speed gearbox and meshes with the third output gear. The first and second working pumps are respectively connected to a power take-off port (PTO) on the two-speed gearbox, with PTO corresponding to output gear 1 and output gear 2, respectively.

[0009] Preferably, after the working motor is engaged with the two-speed gearbox, it is connected to working pump one and working pump two through power take-off port one and power take-off port two to provide hydraulic system power for the whole vehicle.

[0010] Furthermore, the first gear of the two-speed gearbox is driven by a first gear input gear and an output gear set, and the second gear is driven by a second gear input gear and an output gear set.

[0011] Furthermore, the drive motor and the output shaft of the two-speed gearbox are driven by a three-meshing output gear.

[0012] Furthermore, the first power take-off port is connected to the first output gear and is used to drive the first drive pump, and the second power take-off port is connected to the second output gear and is used to drive the second work pump.

[0013] Furthermore, the input shaft of the two-speed gearbox is connected to the output end of the working motor, and the output shaft is connected to the drive motor.

[0014] By adopting the above technical solution, this utility model has the following beneficial effects compared with the prior art:

[0015] This utility model features a two-speed gearbox with a torque-boosting characteristic in the first gear, which allows the motor to meet heavy-load requirements without needing to be configured with excessive power, reducing motor cost and energy consumption. Furthermore, the dual-motor coupling compensates for the insufficient peak torque of a single motor, improving the stability of power output. Additionally, the direct connection of the working pump to the gearbox avoids suspension issues, ensuring system reliability and enabling the loader to be powerful, stable, efficient, and reliable during loading.

[0016] Two gearboxes enable the motor to operate efficiently, reducing energy consumption during transfers. The energy recovery of the drive motor also improves the vehicle's range. The working pump continuously adapts to ensure smooth switching between operating conditions, making the transfer process energy-saving, efficient, and with a long range.

[0017] The integration of the gearbox and motor allows the power system to occupy less space, leaving more room for the placement of other components of the loader, which improves the flexibility of the whole vehicle and makes it easier to maintain. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of this utility model.

[0019] In the diagram: 1. Working motor; 2. Two-speed gearbox; 3. Shift motor; 4. Shift fork; 5. Second-speed input gear; 6. Input shaft; 7. Output gear one; 8. Output shaft; 9. Output gear two; 10. Complete vehicle; 11. Output gear three; 12. Power take-off port one; 13. Working pump one; 14. Power take-off port two; 15. Working pump two; 16. First-speed input gear; 17. Drive motor. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate this utility model, but are not intended to limit the scope of this utility model.

[0021] Example:

[0022] Reference Figure 1 An electric drive system for an electric loader includes a working motor 1, a two-speed gearbox 2, a shift motor 3, a shift fork 4, a drive motor 17, a first working pump 13, and a second working pump 15. The two-speed gearbox 2 is fixedly connected to the working motor 1. The input shaft 6 of the two-speed gearbox 2 is equipped with a second-speed input gear 5 and a first-speed input gear 16. The output shaft 8 of the two-speed gearbox 2 is equipped with an output gear 7, an output gear 9, and an output gear 11. The shift motor 3 and the shift fork 4 are used for gear switching in the two-speed gearbox 2. The drive motor 17 is located at the output end of the two-speed gearbox 2 and meshes with the third output gear 11. The first working pump 13 and the second working pump 15 are respectively connected to a first power take-off port 12 and a second power take-off port 14 on the two-speed gearbox 2. The first power take-off port 12 corresponds to the first output gear 7, and the second power take-off port 14 corresponds to the second output gear 9.

[0023] The electric drive system of this electric loader uses a two-speed gearbox 2 as its core integrated hub. The working motor 1, as one of the main power sources, is connected to the input shaft 6 of the two-speed gearbox 2 through its output end, providing initial power to the gearbox. The shift motor 3, in conjunction with the shift fork 4, switches the meshing state of the second-speed input gear 5, the first-speed input gear 16, and the output shaft 8 gear based on the gear meshing principle, realizing gear shifting of the gearbox. The drive motor 17 is located at the output end of the gearbox and meshes with the output shaft 8 through the third output gear 11 to supplement or assist in the output power. The first working pump 13 and the second working pump 15 are connected to the first output gear 7 and the second output gear 9 through the first power take-off port 12 and the second power take-off port 14, respectively, to convert the power of the gearbox into hydraulic energy to meet the needs of the loader's working device.

[0024] After the working motor 1 is engaged with the two-speed gearbox 2, it is connected to the working pump 13 and the working pump 25 through the power take-off port 12 and the power take-off port 24 to provide hydraulic system power to the whole vehicle 10.

[0025] When the working motor 1 is running, its output power is transmitted to the two-speed gearbox 2 via the input shaft 6. After the gearbox completes gear matching (first gear or second gear), the output shaft 8 drives the output gear 7 and output gear 9 to rotate. Since the power take-off port 12 and power take-off port 14 are respectively connected to the two output gears, the power can be directly transmitted to the working pump 13 and working pump 25, driving the pump body to generate high-pressure oil. This direct power take-off method of motor, gearbox and working pump, compared with the traditional motor driving the working pump alone, shortens the power transmission path, reduces intermediate component losses, and allows the hydraulic system to respond more quickly. At the same time, it reduces the complexity of pipeline connection caused by the dispersed arrangement of components, improves the compactness of the overall vehicle 10 layout, and provides a stable high-pressure oil source for the hydraulic actuators of the loader (such as bucket and boom), ensuring the smooth operation of the entire vehicle 10.

[0026] The first gear of the two-speed gearbox 2 is driven by the first gear input gear 16 and the output gear set, and the second gear is driven by the second gear input gear 5 and the output gear set.

[0027] The shift motor 3 drives the shift fork 4, which meshes the first gear input gear 16 with the corresponding gear on the output shaft 8. The power of the working motor 1 is transmitted to the output shaft 8 through the input shaft 6 and the first gear input gear 16. The gear transmission ratio of this gear is designed to be a large speed ratio (such as fewer teeth on the input gear and more teeth on the output gear). Based on the principle of increasing torque and reducing speed by driving a large gear with a small gear, the torque can be greatly amplified, which is suitable for low-speed, high-torque working conditions such as loader shoveling, allowing the loader to output strong driving force when shoveling heavy materials.

[0028] The shift fork 4 switches to second gear, and the input gear 5 meshes with the output shaft 8 gear. Second gear uses a small transmission ratio (small difference in the number of teeth between the input and output gears). The power of the working motor 1 is transmitted through this gear to achieve high-speed, low-torque output, which meets the high-speed driving requirements of the loader during site transfers. This allows the motor to maintain a relatively reasonable speed under high-speed conditions, avoiding inefficient operation such as a small motor pulling a large load or a large motor pulling a small load.

[0029] The drive motor 17 and the output shaft 8 of the two-speed gearbox 2 are driven by the meshing of the output gear 11.

[0030] The drive motor 17 meshes with the output gear 3 11. When the output shaft 8 of the two-speed gearbox 2 rotates, the output gear 3 11 drives the drive motor 17 to operate. When the loader is working, if it is in electric mode, the drive motor 17 can serve as an auxiliary power source, working together with the working motor 1 to output torque. Based on the principle of torque superposition of the two motors, the total driving force of the system is increased. If it is in a coasting or braking condition, the drive motor 17 can switch to the power generation mode, converting mechanical energy into electrical energy for recycling and storage, realizing energy reuse. This power coupling design allows the system to flexibly adapt to different working conditions and optimize power output and energy management.

[0031] Power take-off port 12 is connected to output gear 7 and is used to drive working pump 13; power take-off port 14 is connected to output gear 9 and is used to drive working pump 15.

[0032] Power take-off port 12 and power take-off port 24 serve as the connection interfaces between the gearbox and the working pump. Internally, they are linked with output gear 17 and output gear 29 through transmission structures such as gears or splines. When the output gears rotate, the power take-off ports rotate synchronously and drive working pump 13 and working pump 25. This design replaces the traditional method of suspending the working pump on the motor end cover, avoiding the risk of vibration amplification and component fatigue fracture caused by excessive suspension, ensuring the stability of the working pump operation, and at the same time, allowing the working pump to be placed closer to the power source, shortening the hydraulic pipeline length, reducing pressure loss, and improving the efficiency of the hydraulic system.

[0033] The input shaft 6 of the two-speed gearbox 2 is connected to the output end of the working motor 1, and the output shaft 8 is connected to the drive motor 17.

[0034] The two-speed gearbox 2 has an input shaft 6 that receives the output power from the working motor 1. The output shaft 8 then transmits the power, which has been changed in speed and torque by the gearbox, to the drive motor 17 through the output gear 3 11. On the other hand, it distributes the power to the working pump through the output gear 1 7, the output gear 2 9 and the power take-off port. This one-input-multiple-output power connection mode, based on the meshing of gear transmission, realizes the rational distribution and conversion of power, so that the power of a single working motor 1 can simultaneously meet the multiple needs of the loader's travel drive, the hydraulic drive of the working device and so on, simplifying the system structure and improving the power utilization efficiency.

[0035] In actual use, during the loading operation (low speed and high torque requirement), the working motor 1 starts and the output end drives the input shaft 6 of the two-speed gearbox 2 to rotate. At this time, the system defaults or according to the working condition command, the shift motor 3 drives the shift fork 4 to make the first gear input gear 16 mesh with the corresponding gear on the output shaft 8, and enter the first gear mode. The first gear high transmission ratio gear set is used to convert the power of the working motor 1 to increase torque and reduce speed, so as to provide sufficient torque for the heavy loading.

[0036] During the rotation of the output shaft 8, the output gear 3 11 drives the drive motor 17 to operate. The drive motor 17, as an auxiliary power source, works with the working motor 1 to output torque. The torques of the two are superimposed, and according to the principle of force composition, the total driving force of the system is improved, so that the loader can smoothly scoop up even heavy materials. At the same time, the rotation of the output gear 1 7 and the output gear 2 9 drives the working pump 1 13 and the working pump 2 15 through the power take-off port 1 12 and the power take-off port 2 14, which can quickly generate high-pressure oil to drive the working devices such as the bucket and boom. Because the power transmission path is short and the response is fast, the hydraulic device can quickly cooperate with the mechanical action to improve the shoveling efficiency.

[0037] In this process, the torque-boosting characteristics of the two-speed gearbox in the first gear allow the motor to meet heavy-load requirements without needing to be configured with excessive power, reducing motor cost and energy consumption. Furthermore, the dual-motor coupling compensates for the insufficient peak torque of the single motor, improving the stability of power output. In addition, the direct connection of the working pump to the gearbox avoids suspension problems, ensuring system reliability and making the loader powerful, stable, efficient and reliable when loading.

[0038] In the case of relocation (high-speed travel requirement), when the loader needs to relocate after loading, the vehicle control system 10 issues a command, the shift motor 3 drives the shift fork 4 to switch to second gear, the input gear 5 meshes with the output shaft 8 gear. The small transmission ratio of second gear allows the power of the working motor 1 to be converted by the gearbox, and the output shaft 8 achieves high-speed low-torque rotation, which is suitable for the high-speed requirements of relocation, and allows the motor to operate in the high-efficiency speed range, avoiding the problems of low-speed high-load heat generation and inefficiency of the motor;

[0039] Output shaft 8 drives output gear 11 to rotate drive motor 17. If the transfer is at a constant speed, drive motor 17 can assist working motor 1 in outputting power to maintain high-speed travel. If coasting or braking occurs, drive motor 17 switches to power generation mode to convert mechanical energy into electrical energy for storage and energy recovery. At the same time, output gear 7 and output gear 9 still drive the working pump to provide basic pressure holding and standby power for the hydraulic system, ensuring that the working device can respond quickly after the transfer.

[0040] In this process, the two-speed gearbox in second gear allows the motor to operate efficiently, reducing energy consumption during transfer. The energy recovery of the drive motor 17 also improves the range of the entire vehicle 10. The working pump continuously adapts to ensure smooth switching of working conditions, making the transfer process energy-saving, efficient, and with a long range.

[0041] In summary, due to the integrated design of the system, the disassembly and assembly of a large number of pipelines and supports are reduced during maintenance compared to the traditional decentralized layout. For example, when inspecting the working pump, the operation can be performed directly on the connection between the power take-off port and the pump without disassembling unnecessary parts such as the motor end cover. Furthermore, the integration of the gearbox and the motor makes the power system occupy less space, leaving more room for the layout of other components of the loader. This improves the overall flexibility of the vehicle and facilitates its maintenance.

[0042] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model.

Claims

1. An electric drive system for an electric loader, characterized in that, Includes a working motor (1), a two-speed gearbox (2), a shift motor (3), a shift fork (4), a drive motor (17), a working pump one (13), and a working pump two (15). The two-speed gearbox (2) is fixedly connected to the working motor (1). The input shaft (6) of the two-speed gearbox (2) is provided with a second-speed input gear (5) and a first-speed input gear (16). The output shaft (8) of the two-speed gearbox (2) is provided with an output gear one (7), an output gear two (9) and an output gear three (11). The shift motor (3) and shift fork (4) are used for shifting gears in the two-speed gearbox (2); The drive motor (17) is located on the output end of the two-speed gearbox (2) and is meshed with the output gear three (11); The first working pump (13) and the second working pump (15) are respectively connected to the first power take-off port (12) and the second power take-off port (14) on the two-speed gearbox (2). The first power take-off port (12) corresponds to the first output gear (7), and the second power take-off port (14) corresponds to the second output gear (9).

2. The electric drive system for an electric loader according to claim 1, characterized in that, After the working motor (1) is engaged with the two-speed gearbox (2), it is connected to the working pump (13) and the working pump (15) through the power take-off port one (12) and the power take-off port two (14) to provide hydraulic system power to the whole vehicle (10).

3. The electric drive system for an electric loader according to claim 1, characterized in that, The two-speed gearbox (2) is driven by a first gear input gear (16) and an output gear set in first gear, and by a second gear input gear (5) and an output gear set in second gear.

4. The electric drive system for an electric loader according to claim 1, characterized in that, The drive motor (17) and the output shaft (8) of the two-speed gearbox (2) are driven by the meshing of the output gear three (11).

5. The electric drive system for an electric loader according to claim 1, characterized in that, The first power take-off port (12) is connected to the first output gear (7) and is used to drive the first driving pump (13). The second power take-off port (14) is connected to the second output gear (9) and is used to drive the second working pump (15).

6. The electric drive system for an electric loader according to claim 1, characterized in that, The input shaft (6) of the two-speed gearbox (2) is connected to the output end of the working motor (1), and the output shaft (8) is connected to the drive motor (17).

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