Detachable Hopper Energy Insert for Longer Paver Operating Time
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Solution Overview
Problem
Conventional road construction machines face limitations in range and operating time due to the use of fossil fuels, leading to interruptions in construction sites and compromised paving quality when using electric power sources, and larger batteries result in reduced working time or increased machine size.
Innovation Solution
A road construction machine equipped with a detachable material hopper insert containing a secondary storage unit for electrical energy or energy medium, which extends operating time and range by allowing seamless energy supply through a combination of primary and secondary storage units, including batteries or fuel tanks, and a control system for managing energy distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a battery is used as an energy source for an electrified road construction machine, then exhaust emissions are reduced, but the range and operating time are significantly reduced
Solution Approach 1:
The energy storage system is segmented into a primary battery and a secondary storage unit (energy container). The secondary storage unit can be detached and replaced independently, allowing the primary battery to be recharged or replaced without interrupting the overall operation. This segmentation resolves the contradiction by separating the energy storage function into replaceable modules, thereby extending operational range while maintaining electric drive benefits.
Solution Approach 2:
The system implements a discard-and-recover mechanism where the secondary storage unit (energy container) can be quickly detached and replaced when depleted. The removed unit can be recovered, recharged externally, and reused. This approach allows continuous operation without long interruption periods, resolving the contradiction between using electric power (low emissions) and maintaining extended operating time.
2Duration of action of moving object
If a larger battery is used to extend the range, then the operating time increases, but the machine size and weight increase significantly
Solution Approach 1:
Instead of using one large battery, the system segments energy storage into a primary battery (integrated into the machine) and a secondary storage unit (detachable energy container). This segmentation allows the machine to carry only the necessary primary battery weight, while extending range through replaceable secondary units, thus avoiding the weight penalty of a single large battery while maintaining extended operating time.
Solution Approach 2:
The energy storage solution moves from a single-dimension approach (one large battery) to a multi-dimensional approach (primary battery + replaceable secondary units). The secondary storage units can be stored separately and attached as needed, effectively extending range without proportionally increasing the machine's permanent weight or size.
3Loss of energy
If the road construction machine is stopped to replace or recharge the battery, then energy can be conserved, but paving quality deteriorates due to interruptions
Solution Approach 1:
The system prepares multiple secondary storage units in advance that can be quickly swapped. When the primary battery needs recharging, a pre-prepared secondary unit is already available for immediate attachment, minimizing interruption time. This preliminary preparation allows energy conservation through strategic planning while maintaining paving quality by reducing stoppage duration to negligible levels.
Solution Approach 2:
The quick-change mechanism for secondary storage units enables the replacement process to be rushed through in minimal time. The standardized interface and rapid attachment/detachment design allow the battery swap to occur so quickly that the interruption to paving operations is negligible, thereby maintaining paving quality while still allowing energy conservation through scheduled recharging of secondary units.
4Duration of action of moving object
If diesel fuel is used as an energy source, then the range and operating time are extended, but exhaust emissions and energy efficiency worsen
Solution Approach 1:
The secondary storage unit acts as an intermediary between the electric drive system and external charging infrastructure. It stores energy that can be quickly transferred to the primary battery, enabling the machine to operate electrically (zero emissions) for extended periods without requiring a large integrated battery or resorting to diesel fuel, thus resolving the contradiction between operating time and emissions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures continuous operation without interruptions, maintains paving quality, and enhances energy efficiency by allowing easy replacement and integration of secondary storage units, thus extending the machine's range and working time.
Implementation Method 1
a secondary storage unit (15) for storing electrical energy or an energy medium
Implementation Method 2
a primary drive (3) for driving the chassis (4)
Data Source
AI summary
A road construction machine includes a chassis for moving the road construction machine, a primary drive for driving the chassis, a primary storage unit for supplying the primary drive with electrical energy or an energy medium, a material hopper and a material hopper insert for receiving paving material. The material hopper insert is detachably mounted on the material hopper. The material hopper insert has at least one secondary storage unit for driving the chassis and/or for supplying the primary drive with electrical energy or the energy medium.