Construction machine and method for manufacturing a construction machine

Description

[0001] The invention relates to a construction machine, in particular a civil engineering machine, comprising an undercarriage with a chassis, a superstructure rotatably mounted on the undercarriage about a vertical axis, at least one internal combustion engine arranged in the superstructure, and a distribution gearbox arranged in the superstructure and comprising a first drive shaft to which the internal combustion engine is connected in order to transmit and distribute a torque of the internal combustion engine to machine components, according to the preamble of claim 1.

[0002] The invention further relates to a method for manufacturing a construction machine with a hybrid drive arrangement, wherein the construction machine is formed with an undercarriage with a chassis, a superstructure rotatably mounted on the undercarriage about a vertical axis, at least one internal combustion engine arranged in the superstructure, and a distribution gearbox arranged in the superstructure and having a first drive shaft to which the internal combustion engine is connected in order to transmit and distribute a torque of the internal combustion engine to machine components, according to the preamble of claim 12.

[0003] Due to their high energy demands and required mobility, construction machinery is still generally equipped with an internal combustion engine, particularly a diesel engine. However, such an internal combustion engine is no longer permitted, or only permitted to a limited extent, in certain areas and on certain construction sites due to existing environmental regulations, especially regarding exhaust fumes and / or noise emissions.

[0004] It is known to equip construction machinery with a hybrid drive system, which, in addition to an internal combustion engine, also includes at least one electric motor. Such an electric motor is typically mounted in an existing superstructure in a space adjacent to the transfer case, to which the internal combustion engine is also connected. The transfer case can thus accept torque from the electric motor as an alternative to, and / or supplement to, the torque of the internal combustion engine. The electric motor is usually powered via an electrical cable from an external power source.

[0005] However, simply installing at least one electric motor is not sufficient to create a hybrid drive system. Rather, the superstructure of the construction machine must also incorporate the necessary power and control components for operating the electric motor. Currently, it is common practice to integrate these power and control components for operating the at least one electric motor into the existing electronic switching and control units, or to distribute these components across the superstructure in any remaining available space and connect them to the electric motor and other existing electrical power and control units via appropriate cables running through the superstructure. Alternatively, such construction machines may have a completely unique distribution of the various components to create space for the additional power and control components.

[0006] This results in a very considerable effort in the development and production of such a construction machine with a hybrid drive arrangement and leads to a considerable workload in the case of necessary maintenance, repair and / or retrofitting work.

[0007] Publication JP 2015 183483 A discloses a hybrid construction machine which exhibits the features from the preamble of claim 1.

[0008] The invention is based on the Task The basis is to specify a construction machine and a method for manufacturing a construction machine, with which a construction machine with a hybrid drive system can be created in a particularly economical way.

[0009] According to the invention, the problem is solved on the one hand by a construction machine having the features of claim 1 and on the other hand by a method having the features of claim 12. Preferred embodiments of the invention are specified in the dependent claims.

[0010] The construction machine according to the invention is characterized in that power and control components for operating the at least one electric motor are arranged on a modular frame, forming an additional module, and that the additional module can be detachably attached to a rear of the superstructure when the construction machine is designed with the hybrid drive arrangement.

[0011] A fundamental aspect of the invention is to design a construction machine with an internal combustion engine in such a way that the machine can still be efficiently manufactured as a combustion engine machine, but can also be produced with an electric motor and thus a hybrid drive system if desired by the customer. This is achieved by arranging a distribution gearbox in the upper structure of the construction machine, which has a first drive shaft for the internal combustion engine and a second drive shaft for connecting at least one electric motor. The distribution gearbox with the at least two drive shafts is preferably installed independently of whether an electric motor is desired for a hybrid drive system or not. This simplifies manufacturing and reduces inventory, as only one distribution gearbox is required for two different types of construction machines.

[0012] Another aspect of the invention is that the power and control components necessary for operating the at least one electric motor for a hybrid drive arrangement are no longer installed in the superstructure itself, but are combined in an additional module. The additional module has its own module frame, which supports the power and control components. The additional module is designed to be attached to the rear of the superstructure.

[0013] Overall, this significantly reduces the effort required to manufacture a construction machine with a hybrid drive system. The machine can be assembled in much the same way as a construction machine with a conventional combustion engine drive system.

[0014] Furthermore, it is not necessary to redesign a construction machine with a classic drive arrangement, which would usually lead to new individual part variants.

[0015] If a customer requests a hybrid construction machine with a hybrid drive system, the main difference compared to manufacturing a conventional construction machine is the installation of an additional electric motor in the superstructure. Since the transfer case is already designed to accommodate an electric motor, this is easily accomplished. Furthermore, the installation and integration of the power and control components required for operating the electric motor are significantly simplified, as these are combined in an additional module that can be manufactured and prepared separately. This additional module can be relatively easily attached to the rear of the superstructure during the production of the hybrid construction machine. Pre-wired connections and plugs can preferably be provided for the necessary cable connections.

[0016] According to a further development of the invention, it is particularly preferred that the upper structure includes a receiving space for at least one electric motor to form the hybrid drive arrangement. If the construction machine is manufactured simply as a conventional construction machine with an internal combustion engine, the receiving space generally remains unused. The construction machine according to the invention is thus designed so that, during the manufacture of a new machine, it can be easily configured either as a conventional construction machine with only one internal combustion engine or as a hybrid construction machine with a hybrid drive arrangement without major modifications to the manufacturing process.

[0017] In principle, according to the invention, a suitably prepared construction machine with an internal combustion engine can also be retrofitted at a later date with relatively limited effort by installing at least one electric motor and attaching a corresponding additional module.

[0018] The power and control components of the add-on module can comprise various components necessary for supplying and operating an electric motor on a construction machine. These can include, in particular, DC and AC inverter units, as well as components for current and voltage adaptation, specifically to adjust an externally supplied current and voltage to the requirements of the electric motor. The necessary power electronics and cooling devices for the components are also preferably arranged on the add-on module.

[0019] According to one embodiment of the invention, it is particularly advantageous that the additional module has a connection for a power line for supplying electrical current from an external power source to operate the at least one electric motor. The external power source can be a direct current source or an alternating current or three-phase current source. Depending on the conditions in different countries, the power and control components are designed to convert and transform the supplied electrical energy in a manner suitable for operating the electric motor.

[0020] Another preferred embodiment of the invention consists in the auxiliary module being designed in a box-like form with a height and width adapted to the height and width of the superstructure. The auxiliary module can thus be mounted almost flush with the rear of the superstructure. The auxiliary module can therefore be integrated into the overall design of the construction machine, so that it is not perceived as disruptive. Furthermore, a box-like design also allows for simplified manufacturing and maintenance of the auxiliary module. Additionally, it is possible to replace the entire auxiliary module if the electronic components are changed, thus enabling adjustments and improved performance programs for the operation of the electric motor on the construction machine.

[0021] According to a further embodiment of the invention, it is particularly advantageous that the add-on module includes a cooling device for cooling the power and control components. Components for transforming electrical energy, as well as electronic control units, can generate a considerable amount of heat, which is hardly economical to dissipate when installed in the superstructure itself. By arranging a cooling device directly in the add-on module itself, efficient cooling of the power and control components, and thus efficient operation, can be achieved.

[0022] It is particularly advantageous for the cooling system to have at least one fan, which is positioned at an opening of the add-on module to the outside. This allows for efficient cooling of the components within the add-on module's housing, while heat can be easily dissipated to the environment.

[0023] According to a further development of the invention, particularly efficient cooling can be achieved by designing the cooling device with at least one coolant circuit, wherein coolant is circulated between at least one component of the power and control components and a heat exchanger by means of at least one pump. Preferably, the at least one fan can be arranged in the area of ​​the at least one heat exchanger in order to ensure efficient heat dissipation from the cooling circuit to the outside.

[0024] Another preferred embodiment of the invention consists in the superstructure having a support frame, wherein a first connecting device is arranged and configured at the rear of the superstructure to interact with a suitable second connecting device for attaching counterweight elements to the rear and / or the auxiliary module. Typically, the rear of the superstructure is equipped with a connecting device that allows counterweight elements to be detachably attached for tip-proof operation. According to one aspect of the invention, the auxiliary module is equipped with a corresponding connecting device so that it can be attached to the existing connecting device for attaching counterweight elements. This simplifies the attachment of the auxiliary module. Furthermore, the auxiliary module can also function as a counterweight element.

[0025] A particular advantage is that a second connection device for attaching the add-on module to the superstructure is provided on one front side, and that a further connection device is arranged on the rear side of the add-on module on the module frame, which is designed for attaching counterweight elements to the add-on module. Thus, even when an add-on module is attached to the superstructure, additional counterweight elements can be attached to the rear of the add-on module on the module frame if required. For this purpose, the add-on module has a corresponding further connection device on its rear side for attaching counterweight elements, which can preferably be identical or similar to the first connection device for attaching counterweight elements to the superstructure. In this arrangement, the add-on module is therefore positioned between the superstructure on the one hand and further counterweight elements on the other.

[0026] In principle, the construction machine can be designed in any suitable way, particularly as a civil engineering machine. It is especially preferred that a mast, a boom, or a jib arm is arranged on the superstructure, particularly at its front. In this arrangement, an additional module generally serves as a counterweight, thus increasing the stability and rollover resistance of the construction machine.

[0027] A particularly advantageous embodiment of the invention is one in which the construction machine is configured as a drilling rig, a milling device, a grab device, a vibrator, a pile driver, a grab excavator, or a cable excavator. In particular, when configured as a drilling rig, a drilling drive can be slidably arranged along a mast to drive a drill string with a drilling tool in a rotating manner and drive it into the ground. Similarly, a diaphragm wall cutter, a diaphragm wall grab, a vibrator, or a pile driver can be arranged on a mast or boom arm for carrying out a civil engineering project. In the case of a grab excavator, a grab can be attached to a boom arm. The same applies to a cable excavator, which can also be used as a mobile carrier for civil engineering projects, for example, for lifting and lowering drop weights for soil compaction.A pile driver may have a vibratory vibrator or diesel or hydraulic hammer and may be designed in particular for driving or pulling planks or piles.

[0028] The method according to the invention is characterized in that at least one electric motor is arranged, which is connected to a second drive shaft of the distribution gearbox to form the hybrid drive arrangement, that line and control components for operating the electric motor are arranged on a module frame, whereby an additional module is formed, and that the additional module is detachably attached to a rear of the superstructure to form the hybrid drive arrangement.

[0029] The inventive method can be used, in particular, to manufacture a construction machine according to the invention, as specified in the claims and / or described above. The advantages described in each case result from this.

[0030] A preferred embodiment of the invention consists in arranging at least one electric motor in a receiving compartment within the superstructure. The electric motor can be connected in parallel to the internal combustion engine on the second drive shaft of the transfer case. This readily enables alternating operation using either a conventional internal combustion engine or the at least one electric motor.

[0031] Another advantageous embodiment of the method according to the invention consists in the fact that the additional module is attached to a first connecting device at the rear of the superstructure with a second connecting device which is arranged at the front of the additional module. This allows for simple attachment and detachment by means of a coupling-like connecting device.

[0032] A particular advantage is that the first connecting device is also designed for attaching counterweight elements, with a further first connecting device, also designed for attaching counterweight elements, being arranged on the rear side of the additional module. The existing connecting device for attaching counterweight elements can thus be used to attach the additional module. This further reduces manufacturing effort.

[0033] The invention is further explained below with reference to preferred embodiments, which are shown schematically in the drawings. The drawings show: Fig. 1 a side view of a construction machine according to the invention; Fig. 2 a detailed view of the rear of the upper structure of the construction machine. Fig. 1on an enlarged scale; Fig. 3 a perspective view of a section of the superstructure relating to the construction and arrangement of an additional module; Fig. 4 another perspective view of a superstructure with an attached additional module and counterweight elements; Fig. 5 a perspective view of the construction of an additional module; and Fig. 6 another schematic representation of the construction of an additional module.

[0034] According to Fig. 1 Figure 10 shows a construction machine with a crawler undercarriage 12. A box-shaped superstructure 14 with an operator's cabin is rotatably mounted on the superstructure 12 about a vertical axis. A mast 20 can be movably arranged on one front side of the superstructure 14 via a generally known linkage mechanism 19.

[0035] In the illustrated embodiment, the mast 20 is designed as a telescopic mast. A working device 22 is movably mounted on one front side of the mast 20 for carrying out a construction process. Here, the working device 22 is designed as a so-called vibrator, with which sheet piles can be vibrated or driven into the ground or pulled out again.

[0036] According to the invention, an additional module 40 for a hybrid drive arrangement is attached to a rear of the superstructure 14, which is opposite the front with the mast 20. In this example, counterweight elements 26 are attached to the rear of the additional module 40, which faces away from the superstructure 14.

[0037] As can be seen from the enlarged detail view after Fig. 2As can be seen, the additional module 40 is provided with a cladding 43, which is preferably adapted to the superstructure 14 and its cladding with regard to its dimensions and design.

[0038] A possible detachable attachment of the additional module 40 with a module frame 42 to a superstructure 14 is shown in the Figures 3 and 4This is illustrated. The superstructure 14, only partially depicted, is shown without cladding or internal components, with a scaffold-like support frame 16. A first connecting device 18, only schematically indicated, is arranged at the rear of the superstructure 14. This device can interact with a corresponding second connecting device 48 on the front of the auxiliary module 40 to connect and fasten the auxiliary module 40. A further connecting device 47 can be arranged on the module frame 42 of the auxiliary module 40, facing away from the superstructure 14. This second connecting device 47 is preferably designed in accordance with the first connecting device 18 on the superstructure 14 and serves to connect and hold counterweight elements 26, as illustrated in Fig. 4 is shown.

[0039] Thus, ballast weights 26 can either be attached directly to the superstructure 14 by means of the first connecting device 18 or, in the case of a design of the construction machine 10 with a hybrid drive arrangement, to the rear of the additional module 40 by means of the further connecting device 47.

[0040] The additional module 40 preferably has a protruding connection 50 for connecting a power cable from an external power source. This connection 50 allows electrical power to be supplied to the additional module 40 during electrical operation of the construction machine 10.

[0041] A possible configuration of an additional module 40 according to the invention for a hybrid drive is shown schematically in connection with the Figures 5 and 6explained. The additional module 40 with the module frame 42 is shown essentially without cladding. It is particularly noticeable that a further connecting device 47 for attaching counterweight elements 26 to the module frame 42 is arranged on the rear side of the additional module 40.

[0042] Furthermore, several power and control components 30 are arranged on the module frame 42. These can include an AC PDU (AC Power Distribution Unit), which is connected in particular to the terminal 50 for supplying electrical current from an external power source. One or more OBCs (On-Board Chargers) and an inverter, as well as an HV PDU (High Voltage Power Distribution Unit), can also be arranged as part of the power and control components 30. A line can be routed via the inverter to the electric motor (not shown) in the superstructure 14.

[0043] For cooling the power and control components 30, a cooling device 60 with a schematically indicated cooling circuit 64 can be arranged on the additional module 40. A fan 62 can be mounted on a plate-shaped heat exchanger 68 in a side area of ​​the additional module 40. Heat can be dissipated to the outside via an opening 46 in the housing 43 of the additional module 40 by means of the fan 62. A fluid flow of cooling fluid is created by the pump 66 from the individual power and control components 30 to the heat exchanger 68. This ensures effective cooling and thus efficient operation of the power and control components 30 in the additional module 40.

Claims

1. Construction machine, in particular civil-engineering machine, comprising an undercarriage (12) having a chassis, - an upper structure (14) which is mounted on the undercarriage (12) so as to be rotatable about a vertical axis, - at least one combustion engine, which is arranged in the upper structure (14), - a transfer gear, which is arranged in the upper structure (14) and comprises a first drive shaft, to which the combustion engine is connected, in order to transfer and distribute a torque of the combustion engine to machine components, characterised - in that the transfer gear comprises at least one second drive shaft, which is configured for connecting at least one electric motor for a hybrid drive assembly, - in that power and control components (30) for operating the at least one electric motor are arranged on a module frame (42), wherein an additional module (40) is formed, and - in that the additional module (40) can be attached to a tail of the upper structure (14), when the construction machine is configured with the hybrid drive assembly.

2. Construction machine according to claim 1, characterised in that a receiving space for receiving at least one electric motor for forming the hybrid drive assembly is formed in the upper structure (14).

3. Construction machine according to claim 1 or 2, characterised in that a connection (50) for a power supply line for supplying electrical power from an external power source for operating the at least one electric motor is arranged on the additional module (40).

4. Construction machine according to any one of claims 1 to 3, characterised in that the additional module (40) is configured in a box-like manner having a height and a width which are adapted to a height and width of the upper structure (14).

5. Construction machine according to any of claims 1 to 4, characterised in that the additional module (40) comprises a cooling device (60) for cooling the power and control components (30).

6. Construction machine according to claim 5, characterised in that the cooling device (60) comprises at least one fan (62), which is arranged at an opening (46) of the additional module (40) towards the outside.

7. Construction machine according to claim 5 or 6, characterised in that the cooling device (60) is configured having at least one coolant circuit (64), wherein coolant can be circulated between at least one component of the power and control components (30) and a heat exchanger (68), by means of at least one pump (66).

8. Construction machine according to any one of claims 1 to 7, characterised in that the upper structure (14) comprises a support frame (16), wherein a first connection device (18) is arranged on the tail of the upper structure (14) and is configured for interacting with a matching second connection device (48) for attaching counterweight elements (26) on the tail and / or of the additional module (40).

9. Construction machine according to claim 8, characterised in that a second connection device (48) is formed on a front side of the additional module (40), for attaching to the upper structure (14), and in that a further connection device (47) is arranged on a rear side of the additional module (40) on the module frame (42), which further connection device is configured for attaching of counterweight elements (26) on the additional module (40).

10. Construction machine according to any one of claims 1 to 9, characterised in that a mast (20), a leader or a boom arm is arranged on the upper structure (14), in particular on its front side.

11. Construction machine according to any of claims 1 to 10, characterised in that the construction machine (10) is configured as a drill, a milling device, a gripper device, a vibrator, a pile driver, a grab excavator, or as a cable excavator.

12. Method for producing or retrofitting a construction machine (10), in particular according to any one of claims 1 to 11, with a hybrid drive assembly, wherein the construction machine (10) will be formed or is formed having - an undercarriage (12) having a chassis, - an upper structure (14) which is mounted on the undercarriage (12) so as to be rotatable about a vertical axis, - at least one combustion engine, which is arranged in the upper structure (14), and - a transfer gear, which is arranged in the upper structure (14) and comprises a first drive shaft, to which the combustion engine is connected, in order to transfer and distribute a torque of the combustion engine to machine components, characterised - in that at least one electric motor is arranged, which is connected to a second drive shaft of the transfer gear in order to form the hybrid drive assembly, - in that the power and control components (30) for operating the electric motor are arranged on a module frame (42), wherein an additional module (40) is formed, and - in that the additional module (40) is releasably attached to a tail of the upper structure (14), for forming the hybrid drive assembly.

13. Method according to claim 12, characterised in that at least one electric motor is arranged in a receiving space within the upper structure (14).

14. Method according to claim 12 or 13, characterised in that the additional module (40) is attached to a first connection device (18) on the tail of the upper structure (14) with a second connection device (48), which is arranged on a front side of the additional module (40).

15. Method according to claim 14, characterised in that the first connection device (18) is also configured for attaching ballast weights (26), wherein a further connection device (47) is formed on a rear side of the additional module (40), which is configured for attaching ballast weights (26).