Electrical boost mechanism for hydraulic mulcher

Abstract

An electrical boost system for mulching equipment which is hydraulically driven. The electrical boost system has an electric motor with a mechanical output adjustable over time, wherein the electric motor provides an additional mechanical output to the mulching equipment; and a battery system in cooperation with the electric motor that provides electric energy storage, the battery system powering the electric motor. The electrical boost system is adapted to detect when a condition among at least one of i) speed of rotation, ii) a load, and iii) a temperature of at least one component of the mulching equipment has departed from a range of conditions or crossed a threshold, and based on said detecting, to control the electric motor to provide the additional mechanical output. Different boost profiles are possible. Power transmission can be a direct drive or a belt-and-pulley configuration for coupling the electric motor to the hydraulically driven shaft.

Description

File No. P7290PC00ELECTRICAL BOOST MECHANISMFOR HYDRAULIC MULCHERCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to, or benefit of, provisional application US 63 / 715,993, filed November 4, 2024, entitled ELECTRICAL BOOST MECHANISM FOR HYDRAULIC MULCHER, the specification of which is hereby incorporated herein by reference in its entirety.BACKGROUND(a) Field

[0002] The subject matter disclosed generally relates to heavy-duty hydraulic mulchers. More specifically, it relates to an electrical boost mechanism therefor.(b) Related Prior Art

[0003] Equipment such as mulchers can be using to mulch tree residue into mulch. Such equipment uses rotative parts of equipment, with blades and teeth, to make mulch out of the vegetal matter.

[0004] Out in the forest or in remote areas, mulching equipment may experience loss of power due to the intensive nature of the work performed. Such an issue is hereby addressed.SUMMARY

[0005] According to an embodiment, there is provided a

[0006] 1. An electrical boost system for a hydraulically driven mulching equipment, the electrical boost system comprising:- an electric motor with a mechanical output which is adjustable over time, the electric motor adapted to provide an additional mechanical output to the mulching equipment which is hydraulically driven; and- a battery system in cooperation with the electric motor providing electric energy storage, the battery system adapted to power the electric motor, wherein the electrical boost system is adapted to detect when a sensed condition among at least one of i) speed of rotation, ii) a load, and iii) a temperature of at least one component of the mulching equipment has departed from a range of conditions or crossed a threshold, and based on said detecting, to control the electric motor to provide the additional mechanical output.

[0007] According to an embodiment, there is further provided a regenerative braking mechanism to perform energy recovery from the hydraulic power of the mulching equipment, the regenerative braking mechanism being adapted to generate and store electric energy into the battery system.File No. P7290PC00

[0008] According to an embodiment, the regenerative braking mechanism is integrated in the electric motor.

[0009] According to an embodiment, the regenerative braking system comprises an alternator.

[0010] According to an embodiment, there is further provided a control system adapted to adjust the additional mechanical output provided by the electric motor among a plurality of configurations, wherein the configurations comprise a) a boost mode in which the electrical boost system provides the additional mechanical output and b) a brake mode in which the electrical boost system operates against movement of a component of the mulching equipment.

[0011] According to an embodiment, the control system is adapted to set operation of the electrical boost system among a plurality of configurations, wherein the configurations differ from one another based on a maximum mechanical power output provided by the electric motor.

[0012] According to an embodiment, the control system is adapted to set operation of the electrical boost system among a plurality of configurations, wherein the configurations differ from one another based on a maximum duration of a power boost provided by the electric motor.

[0013] According to an embodiment, the control system is adapted to set operation of the electrical boost system among a plurality of configurations, wherein the configurations differ from one another based recharge parameters.

[0014] According to an embodiment, the battery system comprises a battery having a discharge rate with a C-rating between 1 C and 2C.

[0015] According to an embodiment, the battery system is adapted to adjust dynamically a battery discharge rate thereof.

[0016] According to an embodiment, there is further provided a thermal management system adapted to mitigate heat by managing a flow of cooling fluid into the mulching equipment.

[0017] According to an embodiment, the electric motor is coupled to a hydraulically driven shaft of the mulching equipment in a belt-and-pulley configuration, in which a belt and pulley are used for power transmission from the electric motor to the shaft being hydraulically driven, the belt and pulley providing the coupling between the mechanical output of the electric motor and the shaft.

[0018] According to an embodiment, the electric motor is coupled to a hydraulically driven shaft of the mulching equipment in a direct drive configuration, the electric motor is directly coupled to the shaft being hydraulically driven.File No. P7290PC00

[0019] According to an embodiment, the electric motor is adapted to provide a mechanical power output comprised between about 20hp (14,710 W) and about 40hp (29,420 W).

[0020] According to an embodiment, the electric motor is adapted to provide a signal to a control system, wherein the signal is indicative of at least one of a speed and a load monitored by sensors on the electric motor.

[0021] According to an embodiment, there is further provided a control system adapted to set the electrical boost system to operate according to a plurality of profiles, each of the profiles having a maximum mechanical output and a maximum boost duration respectively associated therewith.

[0022] According to an embodiment, there is further provided a sensor receiving indication of or determining an operating condition of the mulching equipment, wherein the control system selects one of the profiles accordingly.

[0023] According to an embodiment, there is further provided a sensor for sensing at least one of an environmental temperature and an environmental humidity, wherein the control system is adapted to select one of the profiles accordingly.

[0024] According to an embodiment, there is further provided another electric motor, wherein the additional mechanical output is provided by both said electric motor said other electric motor.

[0025] According to another aspect of the disclosure, there is provided a mulching system comprising a hydraulically driven mulching equipment, which is powered by a hydraulic drive, and the electrical boost system of any one of claims 1 to 19 to provide an additional mechanical output in addition to the hydraulic drive.BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Further features and advantages of the present disclosure will become apparent from the following detailed description, taken in combination with the appended drawings, in which:

[0027] Fig. 1 is a schematic diagram illustrating an electric boost system for a mulcher, according to an embodiment of the invention;

[0028] Fig. 2 is a front right oblique perspective view of a mulching equipment comprising an electrical boost mechanism in accordance with an embodiment;

[0029] Fig. 3 is a rear oblique perspective view of the mulching equipment comprising an electrical boost mechanism of Fig. 2 with the cap of the housing of the hydraulic rotary actuator removed;File No. P7290PC00

[0030] Fig. 4 is a closeup view of the mulching equipment comprising an electrical boost mechanism of Fig. 2 with the cap of the housing of the hydraulic rotary actuator removed;

[0031] Fig. 5 is front left oblique perspective view of the mulching equipment comprising an electrical boost mechanism of Fig. 2 with a cap covering the electric motor removed;

[0032] Fig. 6 is a front right oblique perspective view of a mulching equipment comprising an electrical boost mechanism with the caps of the housing of the hydraulic rotary actuator and of the electric motor removed in accordance with another embodiment;

[0033] Fig. 7 is a rear oblique perspective view of the mulching equipment comprising an electrical boost mechanism of Fig. 6 with the caps of the housing of the hydraulic rotary actuator and the electric motor removed;

[0034] Fig. 8 is a closeup view of the mulching equipment comprising an electrical boost mechanism of Fig. 2 with the cap of the housing of the electrical motor removed; and

[0035] Fig. 9 is front left oblique perspective view of the mulching equipment comprising an electrical boost mechanism of Fig. 2 with the caps of the housing of the hydraulic rotary actuator and of the electric motor removed.

[0036] It will be noted that throughout the appended drawings, like features are identified by like reference numerals.DETAILED DESCRIPTION

[0037] There is disclosed an electrical boost system to be integrated into a mulcher or mulching equipment or the like. The electrical boost system is particularly advantageous for use with a hydraulic- driven heavy-duty mulcher, comprising a hydraulic system to perform the “heavy-duty”, i.e. , high power, mechanical work. The electrical boost system will assist the hydraulic system by maintaining rotor speed during sudden load increases, providing additional power, temporarily, when the rotor RPM (rotations per minute) decreases (indicating a need for additional power to maintain the rotational movement of the mulcher at the required RPM). Advantageously, according to an embodiment of the disclosure, the electric boost system will recharge using surplus energy during low-load operations and / or in idle mode, recharging the battery storing the electric energy.

[0038] Advantages of the electric boost system includes a decrease in fuel consumption and a decrease in hydraulic strain undergone, increasing life cycle of the mulcher. Accordingly, integration of the electric boost system enhance overall productivity and energy efficiency.File No. P7290PC00

[0039] According to an embodiment of the disclosure, and in relation with Fig. 1 , the electrical boost system 10 comprises:

[0040] a) An electric motor 20, which provides additional power output to the hydraulic system. In an embodiment, it is capable of providing a maximum power between about 20hp (14,710 W) and about 40hp (29,420 W), or preferably between about 25hp (18,387 W) and about 35hp (25,742 W), more preferably up to about 30hp boost (22,065 W) to assist hydraulic operation. According to an embodiment, it can be an electric motor system comprising more than one (two or more) electric motors cooperating to provide such capabilities.

[0041] b) A battery, or a battery system 30. The battery system 30 provides sufficient energy storage to be able to output the required power during the required period of operation. A modular battery design can be implemented for sizing the battery system according to specific needs or for later upgrades (swappable batteries of different capacities). Various types of batteries can be envisaged, such as lithium- ion, solid-state batteries, or supercapacitors.

[0042] c) A dynamo / generator 40. If present, it is used to recharge the battery using excess available energy during low load operations or idle times. While not providing the additional power output to the hydraulic system, it provides a significant benefit in terms of energy consumption of the system during operation, especially in the context of operation with a battery system 30 instead of a device directly plugged into the electric grid.

[0043] d) A control system 50. It can measure the rotation speed of the mulcher or, in any case, detect a RPM drop (i.e., diminishing rotational speed of the mulcher, equivalently: negative rate of variation of the speed of rotation when no such variation is expected) and send a signal or instruction to activate the electrical boost system or augment the power thererof until the mulcher’s speed of rotation, or rate of variation thereof, has reached a target or threshold. The control system 50 may be also adapted to control the outputted power of the electric engine (additional power output) based on other sensed conditions such as load and temperature. The control system 50 may be adapted to trigger operation of the electric boot system based on parameters associated with any one or all of these sensed conditions, i.e., if the sensed conditions are detected as departing from normal conditions (outside of a range, above / under [crossed] a threshold, or simply within set conditions or any triggering conditions). If any or a combination of said sensed conditions has departed from a range of conditions or crossed a threshold, the electric motor can be triggered or controlled to provide the additional mechanical output according to any power profile, control configuration (boost, brake) and transmission configuration as described further below. Appropriate sensors are required to measure the sensed conditions needed to trigger said control of additional mechanical output.File No. P7290PC00

[0044] e) A power management system 60, to manage energy distribution between the hydraulic and electric systems (such as from the battery system 30). Implementing a battery management system can optimize the charging system to ensure high efficiency and increase battery life.

[0045] f) Housing 70 and integration components are provided to ensure compactness, robustness, and minimal additional weight. All components should fit in the housing for an acceptable size and also an acceptable weight or mass (e.g., lighter materials, with lower mass density can be selected) for proper handling of the mulcher combined with the electrical boost system 10. In other words, the addition of batteries, motor, and control electronics must not excessively increase the total weight or occupy excessive space.

[0046] g) A thermal management system 80 is used for heat management, e.g., passive and active heat dissipation in both the battery system 30 and motor system(s) 20.

[0047] According to an embodiment of the disclosure, the electric motor 20 should be controlled to provide more or less power in a manner which ensures that the power output is increased or decreased in a way which corresponds to the measured rate of variation of the speed of rotation of the mulcher, such that the electric boost assistance is provided in a smooth manner (no sudden power increases) which make the mulcher more secure to operate.

[0048] According to an embodiment of the disclosure, the recharge efficiency can be in the order of about 80% of energy being recovered for storage into the battery.

[0049] In terms of challenges and constraints, the system needs to withstand harsh working conditions (dust, heat, vibration), so in addition to the cost and maintenance considerations, as well as proper weight and size, the system design disclosed herein can be interpreted as allowing meeting such technical requirements. The boost system 10 should also operate efficiently to prevent rapid battery drain before energy recovery can be engaged.

[0050] According to an embodiment of the disclosure, the electrical boost system 10 does not communicate with or cooperate with the hydraulic system of the mulching equipment, it can function while being separate, by monitoring the mulching equipment.

[0051] According to an embodiment of the disclosure, the electrical boost system 10 advantageously provides both the “boost”, that is the electrical power assistance (e.g., when the mulcher’s rotor RPM drops) and the brake, that is the regenerative brake that stores energy when there is excess power in the overall system.File No. P7290PC00

[0052] According to an embodiment of the disclosure, the electrical boost system 10 switches between boost and brake modes depending on operational needs, according for example to the underlying system (mulcher or other similar power device) speed of rotation, or rate of variation thereof, as measured. According to an embodiment of the disclosure, the electrical boost system 10 may provide continuous power assistance without any control system intervention that would otherwise control power output assistance based on performance needs.

[0053] According to an embodiment of the disclosure, the power management system 60 can be used as an energy redistribution mechanism, controlling the redistribution of energy between different subsystems of the mulcher (e.g., hydraulic, electric, auxiliary systems).

[0054] According to an embodiment of the disclosure, the system may be controlled to switch between different operational modes (e.g., Boost, Brake, Eco Mode, Power-Saving Mode, which are similar to others, but with capped power output or recharge only capabilities, for example).

[0055] According to an embodiment of the disclosure, measurement data from the underlying apparatus (mulcher) and operation data of the electrical boost system 10 are recorded and used by predictive algorithms to anticipate the need for boost or brake based on real-time or historical data. A plug-and-play software framework may provide for adding new sensors, algorithms, or machine learning models to the control system.

[0056] According to an embodiment of the disclosure, the electric motor 20 and / or the battery system 30 can be modular and scalable, for example removable, replaceable, swappable or augmentable to ensure that they can be replaced, scaled or upgraded.

[0057] According to an embodiment of the disclosure, a plurality of electric motors in the electric motor system and / or a plurality of batteries in the battery system 30 can be used to provided redundancy in the system for greater reliability. Multiple motors or batteries ensure uninterrupted operation in case of failure of one component, which can be very advantageous in remote environments where replacement parts are not readily available.

[0058] The thermal and power management systems can adjust performance based on heat dissipation and energy needs.

[0059] Power sources are switched or combined in a controlled, reactive manner based on load requirements (as measured in real time), for a seamless hydraulic-electric integration based on additional power output being sized and varied in a way which is smooth and which compensates the power that is lacking, and no more, to avoid sudden power outbursts which could be dangerous.File No. P7290PC00

[0060] According to an embodiment of the disclosure, the boost or brake mechanism is triggered by specific conditions like terrain, load, or temperature.

[0061] In view of recorded data, there may be software-defined power profiles according to which there may be predefined or customizable power profiles for different types of terrain, brush density, or operating conditions.

[0062] According to an embodiment of the disclosure, there are customized energy profiles for different mulching conditions, adjusting the boost or brake power vs time output profile based on mulching conditions (e.g., brush density, terrain slope, or soil conditions).

[0063] According to an embodiment of the disclosure, the electrical boost system 10 may be capable of sharing energy with other connected machines or devices (e.g., charging another mulcher or equipment).

[0064] According to an embodiment of the disclosure, the electrical boost system 10 ensures that the operation of the hydraulic system of the mulcher or similar equipment is decoupled from the operation of the electric systems, ensuring they can function independently ortogether. According to an embodiment of the disclosure, the electrical boost system 10 ensures a dynamic load balancing between hydraulic and electric systems, optimizing energy usage and preventing overload on one system, which is provided by the power management system 60.

[0065] According to an embodiment of the disclosure, the electrical boost system 10 comprises wireless control and monitoring of the boost or brake mechanism via wireless technologies (e.g., Wi-Fi, Bluetooth).

[0066] According to an embodiment of the disclosure, the electrical boost system 10 is able to adjust power output based on environmental conditions like temperature or humidity.

[0067] According to an embodiment of the disclosure, the electrical boost system 10 comprises automatic diagnostic and maintenance alerts, for example a diagnostic system that monitors the condition of the motor, battery, and hydraulic components and provides alerts for maintenance.

[0068] According to an embodiment of the disclosure, the electrical boost system 10 has a mulcher-mounted battery system configuration, in which the battery (system) is mounted directly on the mulcher. This configuration optimizes power delivery by keeping the battery close to the motor and hydraulic components, ensuring minimal power loss during transmission. According to another embodiment of the disclosure, the electrical boost system 10 has a carrier-mounted battery system configuration, in which the battery is mounted inside or on the carrier vehicle, not in the mulcher. ThisFile No. P7290PC00 setup provides flexibility for larger battery capacity and easier access for maintenance, making it ideal for high-powered systems requiring frequent recharging or swapping. According to another embodiment of the disclosure, the electrical boost system 10 has a swappable battery configuration, between mulcher and carrier. The swappable battery system can be easily detached from the mulcher and reconnected to the carrier, or vice versa. This design allows for fast battery replacements in the field, ensuring minimal downtime during operations. According to another embodiment of the disclosure, the electrical boost system 10 has a dual-battery system configuration (mulcher and carrier). Two batteries are used simultaneously, one mounted on the mulcher and another on the carrier. The system can intelligently switch between batteries depending on power demand or charge status, optimizing energy usage.

[0069] According to an embodiment of the disclosure, there is a customizable battery placement, which is customizable depending on operational needs. The battery can be positioned either on the mulcher for lightweight operations or on the carrier for extended use, giving users flexibility to adjust the system based on workload or terrain.

[0070] According to an embodiment of the disclosure, there is a wireless battery charging between carrier and mulcher, that allows the carrier’s battery to charge the mulcher’s battery without physical connections. This reduces wear on electrical contacts and enables easier movement of the carrier and mulcher.

[0071] According to an embodiment of the disclosure, the electrical boost system 10 provides for power transmission with alternator. More specifically, an alternator in the system to generate electrical energy while the rotor operates. The alternator can convert mechanical energy into electrical energy to charge the battery while the mulcher is running, providing a continuous boost when needed. This patent could focus on the control mechanism that allows power to be switched between boosting and charging functions. The system could also include dual-function alternators that serve both as a generator and a motor, allowing them to switch between charging and boosting modes depending on the load and rotor speed. The system could also include power transmission without alternator (direct drive or integrated motor), in which the electric motor is integrated directly into the rotor without the need for an alternator. This would cover systems where the motor provides both mechanical assistance and electrical generation in a compact unit. The system 10 could include capacitive storage systems where excess energy is temporarily stored in capacitors and then released to provide a boost when needed, without relying on an alternator to recharge the battery.

[0072] According to an embodiment of the disclosure, the electrical boost system 10 comprises direct connection of motor shaft to rotor, in which the motor shaft is directly coupled to the rotor to provide instant mechanical assistance. This configuration avoids transmission losses and simplifies the system.File No. P7290PC00The direct coupling could also include protection for a clutch mechanism that engages or disengages the motor when the boost is needed, allowing for smooth transitions between hydraulic and electric power. Alternatively, a belt and pulley power transmission would comprise a belt and pulley system for transferring power from the electric motor to the rotor. This allows for flexibility in positioning the motor and provides a cost-effective, reliable transmission of power. This would comprise a method by which the belt tension is automatically adjusted to engage or disengage the motor boost based on rotor speed or hydraulic system load.

[0073] According to an embodiment of the disclosure, the electric boost is activated only when the mulcher is actively working. This could involve sensors that detect when the hydraulic load increases (e.g., when encountering dense materials), and the system automatically activates the electric boost to maintain or increase rotor RPM. There can be a timing mechanism that engages the boost just before the hydraulic system experiences a drop in RPM, ensuring seamless power delivery.

[0074] According to an embodiment of the disclosure, the system triggers the electric boost specifically to increase the rotor's RPM when it drops below a certain threshold. This could involve using real-time RPM sensors to monitor the rotor's speed and dynamically engage the electric boost as needed. There can be a method of sensing RPM using sensors for measuring RPM, comparing it to a preset threshold, and automatically engaging the motor to raise the RPM to optimal levels.

[0075] Referring to Fig. 2 to Fig. 5 (direct drive configuration), a first embodiment of a mulching equipment 90 comprises a hydraulic system including a hydraulic rotary actuator 92, also known as a hydraulic motor, driving a shaft 94, and an electric motor 20 that is mounted at one end of the shaft 94 driven by the hydraulic rotary actuator 92. In the embodiment, being at one end of the driven shaft 94 and the hydraulic rotary actuator 92 at the other end of the driven shaft 94, the electric motor 20 is adapted to provide mechanical output to the shaft 94 on demand. Furthermore, since coupled together through the driven shaft 94, the electric motor 20 rotates at the same speed as the hydraulic rotary actuator 92, being thereby able to monitor speed and / or speed variation of the driven shaft 94 and hydraulic rotary actuator 92 under variable loads.

[0076] Referring to Fig. 6 to Fig. 9 (belt and pulley configuration), a second embodiment of a mulching equipment 90’ comprises the same components of the hydraulic rotary actuator 92, the driven shaft 94 and the electric motor 20, with one distinctive characteristic of this embodiment residing in the nature of the coupling between the electric motor 20 and the shaft 94. With this embodiment, the coupling of the electric motor 20 to the shaft 94 driven by the hydraulic rotary actuator 92 involves a belt 96 and pulleys 98a, 98b used for power transmission.File No. P7290PC00

[0077] Regardless thereof, both embodiments are adapted to provide continuous coupling therebetween, allowing continuous monitoring of the speed and speed variation of the hydraulic rotary actuator 92 by e.g., the electric motor 20, eventually used for the control of additional power provided by the electric motor.

[0078] Furthermore, other components for mitigating vibrations transmitted to the electric motor 20 may take place, include the belt and pulley embodiments slightly damping speed changes transmitted to the electric motor 20 or solutions for coupling the electric motor 20 the shaft 94 on demand, involving other sensors for monitoring e.g., speed of shaft 94 and / or the hydraulic rotary actuator 92.

[0079] It is worth mentioning that according to embodiments battery system 30, control system 50, power management system 60 may be located remote from the electric motor 20, these components being electrically coupled to one another for power transmission and / or signal transmission in-between components.

[0080] According to an embodiment of the disclosure, different voltage configurations may be used depending on the power demands and size constraints of the system. For instance: a high-voltage (e.g., 96V or higher) battery configuration for applications requiring more sustained or powerful boosts; a lower-voltage (e.g., 24V or 48V) configuration for applications where space is limited or when the system needs to provide short bursts of power. There can be implemented an automatic selection of different voltage configurations, where the system switches between different voltage levels depending on the load on the hydraulic system.

[0081] As mentioned above, according to an embodiment of the disclosure, there can be a modular battery system, which can be implemented by having swappable voltage packs. The modular battery system may allow for the swapping of battery packs with varying voltages and capacities based on the application’s power requirements. For example, you could patent the mechanism where a 51 ,2V, 10OAh battery is used for heavy-duty applications, while a 48V, 50Ah battery can be swapped in for lighter tasks, optimizing weight, cost, and efficiency. The modular design could also cover the ability to mix and match battery packs in parallel or series to dynamically adjust voltage and capacity based on real-time needs. A hybrid battery pack configuration may even be envisaged, where different battery chemistries (e.g., NCM, LFP) or different voltage packs (e.g., 48V, 24V, or 12V) are combined in series or parallel to provide a customizable power solution. This system could involve using low-voltage batteries in parallel for safety and energy storage, while high-voltage batteries provide quick bursts of power for the electric boost. These multiple chemistries or voltage systems can be integrated together. High-capacity (e.g., 200Ah or more) battery systems designed for extended operation could be used. In heavy-duty applications, a large battery pack could provide both power for continuous electric boosts and extendedFile No. P7290PC00 operational time. Multiple high-capacity battery packs could be integrated together, possibly with a secondary lower-voltage system to handle monitoring, safety, or auxiliary functions (e.g., sensors or system diagnostics).

[0082] According to an embodiment of the disclosure, the battery’s voltage and capacity are dynamically adjusted based on real-time demand. For example, you could a control system could use multiple 48V batteries and switches between them depending on load requirements. During high-power demands, batteries could be connected in parallel for increased current, while lower power demands could engage only one battery. Alternatively, a battery voltage boost system could be envisaged, where capacitors or additional battery packs temporarily increase the system voltage during peak load conditions (e.g., 48V boosted to 96V for a few seconds).

[0083] Low voltage batteries, such as 48V, 50Ah capacity, could be used for lower- power tasks or short boosts, where the boost duration is brief, and space / weight constraints are a concern.

[0084] Medium voltage batteries like 51.2V 100Ah or 96V 50Ah, or in between voltage-wise or capacity-wise, could be used for applications needing higher bursts of power. These would provide the flexibility of handling both moderate and intense workloads while remaining relatively compact.

[0085] High voltage systems (greater than 96V and more specifically 120V or more) are used for high-demand applications, allowing the motor to generate more power efficiently and support larger mulchers or heavier-duty equipment.

[0086] Batteries with lower discharge rates (also known as C-rating) such as 1C or below can deliver lower currents over a longer period, making them ideal for systems that provide sustained boosts rather than short, high-power bursts. For example: A 48V, 100Ah battery with a 1 C discharge rate delivers 100A continuously. This battery van be integrated into the boost system for continuous low-power assistance, ideal for energy-saving modes or applications where the hydraulic system does not need high- power bursts.

[0087] Medium discharge rate batteries, such as 2C to 5C, can provide moderate power boosts over medium durations. For example: a 48V, 100Ah battery with a 2C discharge rate can provide 200A, delivering 9.6 kW at 48V. Such batteries could be used in the boost system for applications where the rotor occasionally requires higher torque, or in scenarios where the power demand fluctuates but doesn’t require maximum power continuously.

[0088] High discharge capacity batteries, above 5C, can handle high current loads for short bursts, making them ideal for systems that provide immediate high-power boosts to the rotor. For example: a 48V, 50Ah battery with a 10C discharge rate can deliver 500A, providing up to 24 kW at 48V. ThisFile No. P7290PC00 configuration is well-suited for situations where system needs to provide short, high-intensity power bursts, for instance, when the hydraulic rotor encounters heavy resistance. This high discharge capacity could also be part of a hybrid configuration, where supercapacitors are used in conjunction with the battery to handle ultra-short bursts.

[0089] Variable discharge systems use variable discharge rate batteries, where the battery management system (BMS) adjusts the battery discharge rate dynamically based on the rotor’s load and power demand. The BMS could switch between low, medium, and high discharge rates depending on real-time conditions, ensuring optimal performance and battery longevity. This would cover scenarios where multiple discharge profiles are possible within the same system, enabling the electric boost to switch between energy-saving and high-performance modes as needed.

[0090] Multiple battery configurations can exist, for example multiple batteries in parallel or series to achieve various discharge capacities. For instance, several low-capacity, high C-rate batteries could be used in parallel to meet high current requirements, or multiple lower-voltage batteries in series could be used to create flexible voltage and discharge combinations. For example: A system using four 48V 25Ah batteries in parallel could deliver a total of 200A with a 2C discharge rate, providing a scalable and modular solution that adapts to the system’s needs.

[0091] In view of these embodiments, the electrical boost system provides increased power stability and torque, a reduction in downtime due to improved rotor response, a decreased in fuel consumption and extended battery life, a regenerative braking adapted to recover energy, and flexible installations on different designs of mulchers, with multiple configuration options associated therewith.

[0092] Embodiments contemplated therein are for heavy-duty forestry and land clearing equipment, including described hydraulic mulchers, hydraulic brush cutters, and vegetation management attachments on hydraulic vehicles. The modularity of the electrical boost system described herein allows it to be adapted to various carriers and power ranges.

[0093] While preferred embodiments have been described above and illustrated in the accompanying drawings, it will be evident to those skilled in the art that modifications may be made without departing from this disclosure. Such modifications are considered as possible variants comprised in the scope of the disclosure.

Claims

File No. P7290PC00CLAIMS1 . An electrical boost system for a hydraulically driven mulching equipment, the electrical boost system comprising:- an electric motor with a mechanical output which is adjustable over time, the electric motor adapted to provide an additional mechanical output to the mulching equipment which is hydraulically driven; and- a battery system in cooperation with the electric motor providing electric energy storage, the battery system adapted to power the electric motor, wherein the electrical boost system is adapted to detect when a sensed condition among at least one of i) speed of rotation, ii) a load, and iii) a temperature of at least one component of the mulching equipment has departed from a range of conditions or crossed a threshold, and based on said detecting, to control the electric motor to provide the additional mechanical output.

2. The electrical boost system of claim 1 , further comprising a regenerative braking mechanism to perform energy recovery from the hydraulic power of the mulching equipment, the regenerative braking mechanism being adapted to generate and store electric energy into the battery system.

3. The electrical boost system of claim 2, wherein the regenerative braking mechanism is integrated in the electric motor.

4. The electrical boost system of claim 2, wherein the regenerative braking system comprises an alternator.

5. The electrical boost system of claim 1 , further comprising a control system adapted to adjust the additional mechanical output provided by the electric motor among a plurality of configurations, wherein the configurations comprise a) a boost mode in which the electrical boost system provides the additional mechanical output and b) a brake mode in which the electrical boost system operates against movement of a component of the mulching equipment.

6. The electrical boost system of claim 5, wherein the control system is adapted to set operation of the electrical boost system among a plurality of configurations, wherein the configurations differ from one another based on a maximum mechanical power output provided by the electric motor.File No. P7290PC007. The electrical boost system of claim 5, wherein the control system is adapted to set operation of the electrical boost system among a plurality of configurations, wherein the configurations differ from one another based on a maximum duration of a power boost provided by the electric motor.

8. The electrical boost system of claim 5, wherein the control system is adapted to set operation of the electrical boost system among a plurality of configurations, wherein the configurations differ from one another based recharge parameters.

9. The electrical boost system of claim 1 , wherein the battery system comprises a battery having a discharge rate with a C-rating between 1C and 2C.

10. The electrical boost system of claim 1 , wherein the battery system is adapted to adjust dynamically a battery discharge rate thereof.11 . The electrical boost system of claim 1 , further comprising a thermal management system adapted to mitigate heat by managing a flow of cooling fluid into the mulching equipment.

12. The electrical boost system of claim 1 , wherein the electric motor is coupled to a hydraulically driven shaft of the mulching equipment in a belt-and-pulley configuration, in which a belt and pulley are used for power transmission from the electric motor to the shaft being hydraulically driven, the belt and pulley providing the coupling between the mechanical output of the electric motor and the shaft.

13. The electrical boost system of claim 1 , wherein the electric motor is coupled to a hydraulically driven shaft of the mulching equipment in a direct drive configuration, the electric motor is directly coupled to the shaft being hydraulically driven.

14. The electrical boost system of claim 1 , wherein the electric motor is adapted to provide a mechanical power output comprised between about 20hp (14,710 W) and about 40hp (29,420 W).

15. The electrical boost system of claim 1 , wherein the electric motor is adapted to provide a signal to a control system, wherein the signal is indicative of at least one of a speed and a load monitored by sensors on the electric motor.

16. The electrical boost system of claim 1 , further comprising a control system adapted to set the electrical boost system to operate according to a plurality of profiles, each of the profiles having a maximum mechanical output and a maximum boost duration respectively associated therewith.File No. P7290PC0017. The electrical boost system of claim 16, further comprising a sensor receiving indication of or determining an operating condition of the mulching equipment, wherein the control system selects one of the profiles accordingly.

18. The electrical boost system of claim 16, further comprising a sensor for sensing at least one of an environmental temperature and an environmental humidity, wherein the control system is adapted to select one of the profiles accordingly.

19. The electrical boost system of claim 1 , further comprising another electric motor, wherein the additional mechanical output is provided by both said electric motor said other electric motor.

20. A mulching system comprising a hydraulically driven mulching equipment, which is powered by a hydraulic drive, and the electrical boost system of any one of claims 1 to 19 to provide an additional mechanical output in addition to the hydraulic drive.

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