Dual Power Transfer Case for Track Maintenance
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Solution Overview
Problem
Track maintenance machines operating on non-electrified tracks rely exclusively on combustion engines for energy, limiting versatility and increasing noise and energy consumption, especially in environments like tunnels.
Innovation Solution
Incorporating an electric motor as an alternative drive connected to a transfer case, with an electric energy storage device or generator for energy supply, and a control device for seamless switching between combustion engine and electric motor, allowing energy sourcing from both engines and a catenary system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a combustion engine is used exclusively for energy supply, then the machine can operate on non-electrified tracks, but noise emissions and energy consumption increase
Solution Approach 1:
The track maintenance machine is equipped with a dual energy supply system that can operate in multiple modes: electric motor mode when connected to catenary, combustion engine mode for non-electrified tracks, and hybrid mode for transitional operations. This multi-functionality allows the machine to adapt to different track infrastructure conditions while optimizing noise emissions by using the electric motor in tunnel environments where noise is particularly harmful.
2Object-generated harmful factors
If an electric motor is added as an alternative drive, then environmental friendliness and noise reduction improve, but device complexity increases
Solution Approach 1:
The electric motor and combustion engine are merged into a single integrated drive system sharing common components such as the transfer case, hydraulic pumps, and final drive mechanisms. The control system automatically manages the switching between power sources and coordinates their operation, reducing the overall complexity that would otherwise result from having completely separate drive systems. This merging allows the machine to benefit from both electric and combustion propulsion without duplicating entire subsystems.
3Adaptability or versatility
If switching between combustion engine and electric motor is implemented, then operational flexibility improves, but risk of drive interruption increases
Solution Approach 1:
The control system performs preliminary actions by continuously monitoring the operational state, energy availability, and performance parameters of both the electric motor and combustion engine. Before switching between power sources, the system pre-coordinates the transition by adjusting clutch engagement, synchronizing rotational speeds, and preparing the hydraulic system to maintain continuous operation. This preliminary preparation ensures seamless transitions that prevent drive interruptions and maintain operational reliability throughout the switching process.
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
Enables efficient, environmentally friendly energy supply with reduced noise and energy consumption, ensuring continuous operation without interruptions, particularly beneficial for continuous track maintenance tasks like tunnel operations.
Implementation Method 1
an electric motor (13) which can be connected to the transfer case (7) as an alternative drive
Implementation Method 2
a generator (16) for alternative energy supply of the intermediate circuit (12)
Data Source
AI summary
A track maintenance machine includes a machine frame being movable on a track, a plurality of working units, and a combustion engine to be connected by a clutch to a transfer case. Hydraulic pumps for supplying a plurality of hydraulic drives of a hydraulic system are connected to the transfer case. An electric motor is provided as an alternative drive of the transfer case for permanent energy supply of the working units and drives. The electric motor is coupled to an intermediate circuit to be supplied with electric energy by a vertically adjustable pantograph to be applied to a catenary of the track. A generator or an electric energy storage device is provided for alternative energy supply of the intermediate circuit. A method for operation of an energy supply system is also provided.