Battery Pack Layout Around Electric Motor in Power Machines
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Solution Overview
Problem
The challenge in power machines, such as excavators, is the limited space available for mounting battery packs, electric motors, and other components, particularly when transitioning from internal combustion engines to electric power sources, which complicates the integration of hydraulic systems and electric actuators.
Innovation Solution
The implementation of a battery pack support structure on the upper frame portion of power machines, configured to mount multiple battery packs in a staggered or wrap-around configuration around the electric motor, optimizing space usage and facilitating the integration of electric motor-powered hydraulic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple battery packs are mounted in a conventional configuration, then the power source capacity is sufficient, but the available space for mounting is exceeded
Solution Approach 1:
The patent applies vertical stacking of battery packs at different heights, transitioning from a single-plane horizontal arrangement to a multi-level three-dimensional configuration. This dimensional change allows multiple battery packs to be mounted within the limited horizontal footprint of the upper frame portion, effectively increasing power source capacity without exceeding the available mounting area.
Solution Approach 2:
The patent arranges battery packs in a nested or wrap-around configuration where packs are positioned at different vertical levels and angular positions around the electric motor. This nesting approach allows compact packaging of multiple battery packs by utilizing both vertical and radial space, maximizing the use of available volume within the constrained mounting area.
2Area of stationary object
If battery packs are mounted in a compact configuration, then space utilization is improved, but cooling effectiveness may be compromised
Solution Approach 1:
The patent segments the battery pack arrangement into multiple discrete vertical levels and angular positions around the electric motor. This segmentation creates distinct cooling zones and airflow paths for each battery pack, allowing effective heat dissipation even in a compact multi-level configuration. Each battery pack can be independently cooled, preventing thermal interference between adjacent packs.
Data Source
AI summary
Disclosed power machines have a frame with an upper frame portion which swivels relative to a lower frame portion. An electric motor powers a hydraulic system to power hydraulic actuators on the machine. A battery pack support structure mounted on the upper frame portion is configured to mount at least first, second and third battery packs at multiple vertical levels and in a staggered or wrap-around configuration around the electric motor.