Dual-Mains Energy Supply for Construction Machine Power Limits
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Solution Overview
Problem
Construction machines often face limitations in electrical power supply due to standard connection capacities, typically restricted to 32 A and 16 A, which restrict the maximum power output for electrical loads, necessitating innovative solutions to optimize energy distribution.
Innovation Solution
An energy supply device with a controllable DC/DC converter and multiple network connections, including a galvanically isolating transformer, dynamically allocates power from secondary connections to an intermediate circuit, maximizing total power output by combining multiple power sources and managing power demand through a control apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If standard connection capacities (32 A and 16 A) are used, then the device structure remains simple and easy to implement, but the maximum power output for electrical loads is restricted
Solution Approach 1:
The patent combines multiple network connections (first network connection with 32 A capacity and second network connection with 16 A capacity) into a unified power supply system. The DC/DC converter merges the power from both connections at the intermediate circuit level, allowing the system to achieve a maximum power output corresponding to the sum of both connections (48 A equivalent), thereby resolving the contradiction between simple structure and limited power output.
Solution Approach 2:
The patent implements dynamic power allocation through the DC/DC converter, which can dynamically adjust the power distribution from the first and second network connections based on the actual power demand of the electrical load. The control apparatus continuously monitors the power requirement and dynamically controls the converter to optimize power utilization, enabling the system to adapt between using only the first connection, only the second connection, or both connections simultaneously according to demand.
2Productivity
If multiple network connections are combined to increase power output, then the available total electric power is optimized, but the device complexity increases due to additional converters and control mechanisms
Solution Approach 1:
The DC/DC converter is designed as a multi-functional component that performs multiple tasks: it rectifies AC voltage from the second network connection, converts it to DC voltage, regulates the voltage level to match the intermediate circuit, and dynamically controls power distribution based on load demand. This universal design consolidates multiple functions into a single device, reducing overall system complexity while maintaining the ability to combine multiple power sources.
Solution Approach 2:
The control apparatus implements a feedback mechanism that continuously monitors the power drawn at the first network connection and the power requirements of the electrical load. Based on this feedback, the control apparatus dynamically adjusts the DC/DC converter operation to optimize power transmission from the second network connection, ensuring efficient power utilization without requiring complex manual intervention or oversimplified control logic.
3Adaptability or versatility
If a DC/DC converter is used to dynamically allocate power, then the power distribution is optimized according to demand, but the device complexity and control requirements increase
Solution Approach 1:
The control apparatus implements a self-service mechanism where the system automatically monitors its own power consumption at the first network connection and autonomously determines when and how much power to transmit from the second network connection through the DC/DC converter. The control apparatus compares the drawn power against a threshold value and automatically activates or deactivates the converter without external intervention, providing adaptability while keeping control logic manageable.
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 allows for increased electrical power yield, enabling construction machines to operate at maximum capacity by dynamically reallocating power from secondary connections, thereby overcoming the limitations of standard connection capacities.
Implementation Method 1
a galvanically isolating transformer (15), wherein a first winding, or primary winding (15a), of the galvanically isolating transformer (15) is connected to the second network connection (7), and a second winding, or secondary winding (15b), of the galvanically isolating transformer (15) is connected to the second rectifier (9)
Implementation Method 2
a second rectifier (9) that is designed to rectify an AC voltage, which corresponds to an AC voltage present at the second network connection (7), or is based thereon
Implementation Method 3
a controllable unidirectional or bidirectional DC/DC converter (10), to a first side of which the voltage rectified by means of the second rectifier (9) is applied, and a second side of which is connected to the intermediate circuit (3). The DC/DC converter (10) is designed to transmit electrical energy/power from the second rectifier (9) in the direction of the intermediate circuit (3) as required.
Data Source
AI summary
An energy supply device for supplying electric loads with electric energy, includes a DC link; a first mains connection to which a first AC voltage grid can be connected as intended; a first rectifier which is designed to rectify an AC voltage corresponding to an AC voltage across the first mains connection or based thereon and to feed the rectified voltage into the DC link; a second mains connection to which a second AC voltage grid can be connected as intended; a second rectifier which is designed to rectify an AC voltage corresponding to an AC voltage across the second mains connection or based thereon; a controllable DC-to-DC converter to a first side of which a voltage rectified by means of the second rectifier is applied, and a second side of which is connected to the DC link; a first current converter which is fed from the DC link and is designed to supply a first electric load with electric energy; a power measuring apparatus which is designed to measure electric power consumed at the first mains connection; and a control apparatus which has a data link to the power measuring apparatus and which is designed to control the DC-DC converter according to the electric power consumed at the first mains connection.