Dual Engine Harvester Power Coupling for Load Stability
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Solution Overview
Problem
Work machines with internal combustion engines face challenges in responding to sudden loads, leading to engine speed drops and potential stalling, and struggle with meeting increased performance and emissions requirements, particularly due to the limitations of single IC engines and battery-based hybrid systems.
Innovation Solution
A dual IC engine system with motor/generators for power management, where one engine drives primary loads and the other handles propulsion and external loads, with electrical coupling and intelligent power management to balance loads and optimize engine performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single IC engine is used to drive all loads, then the device complexity is reduced, but the engine speed stability deteriorates under sudden loads
Solution Approach 1:
The power unit is segmented into two separate IC engines: a first IC engine dedicated to driving drivetrain loads and a second IC engine dedicated to driving auxiliary loads. This segmentation allows each engine to operate independently and maintain stable speed under their respective load conditions, preventing the speed instability that would occur with a single engine handling all loads simultaneously.
2Power
If battery-based hybrid systems are used to supplement power, then the power capability is increased, but the weight and cost increase significantly
Solution Approach 1:
The patent replaces the battery-based energy storage system with a mechanical power multiplication system using two IC engines. Instead of using electrical energy storage and conversion, the system directly combines the mechanical output of two engines to provide increased power capability, thereby avoiding the weight penalty associated with large battery systems.
3Power
If engine displacement is increased to meet higher power demands, then the power output is improved, but the emissions increase
Solution Approach 1:
The power requirement is segmented between two smaller IC engines rather than one large engine. Each engine operates at its optimal displacement and load range, allowing for more efficient combustion and lower emissions per unit of power produced, while collectively meeting the total power demand.
Solution Approach 2:
The system changes the operational parameters by using two engines operating at moderate loads rather than one engine operating at high load. This parameter change allows each engine to operate in a more efficient regime with better emissions characteristics, as high-load operation is a major source of emissions from single large engines.
4Device complexity
If the IVT ratio changes slowly to reduce engine load, then the device complexity is reduced, but the engine speed drop increases
Solution Approach 1:
The patent replaces reliance on slow IVT ratio changes with direct mechanical power addition from the second IC engine. When sudden load increases cause engine speed to drop, the second engine can immediately provide additional mechanical power to the drivetrain, rapidly counteracting the speed drop without requiring slow transmission ratio adjustments.
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
This configuration provides sustained increased power capability while meeting stringent emissions requirements, reducing the risk of engine overload and improving responsiveness to load changes, thus enhancing the operational efficiency and productivity of work machines.
Implementation Method 1
a first motor/generator is mechanically coupled with the first power unit, and a second motor/generator is mechanically coupled with the second power unit
Data Source
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AI summary
An agricultural harvester includes a first power unit having a first rated output. The first power unit is couplable with a first primary load, including a threshing system load. A second power unit has a second rated output. The second power unit is couplable with a second primary load, including a propulsion load. A first motor/generator is mechanically coupled with the first power unit, and a second motor/generator is mechanically coupled with the second power unit. The second motor/generator is configured to electrically drive at least one external load. The second motor/generator and the first motor/generator are electrically coupled together.