Dual-Prime-Mover Powertrain for High-Torque Work Machines
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Solution Overview
Problem
Conventional work machines, such as agricultural tractors, face limitations in providing high output torque and traction beyond a defined limit, and traditional electric tractors lack sufficient power for various agricultural operations.
Innovation Solution
A powertrain system with two prime movers, sensors, and an engaging unit controlled by an ECU, allowing dynamic coupling and power transmission to meet torque requirements, avoiding overloading and overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single motor is used to power the work machine, then the device complexity is reduced, but the power and torque requirements for multiple working conditions cannot be met
Solution Approach 1:
The powertrain is segmented into two independent prime movers (first and second prime movers), each capable of independent operation. This allows the system to meet different power and torque requirements for various working conditions without requiring a single oversized motor, thus resolving the contradiction between device complexity and power capability.
Solution Approach 2:
The dual prime mover configuration provides multi-functionality, where the first prime mover can handle conditions requiring high torque at low speed, while the second prime mover handles conditions requiring different power characteristics. This universal design allows the work machine to effectively perform multiple agricultural operations with varying power demands.
2Force
If conventional methods (adding weight or 4WD) are used to increase traction, then traction is improved, but the engine fails to supply required torque beyond a defined limit
Solution Approach 1:
The system dynamically switches between different prime movers and power transmission paths based on real-time operational requirements. The ECU monitors conditions and engages the appropriate prime mover (first or second) to provide the necessary torque and power, enabling the system to supply required torque beyond the limits of conventional single-engine configurations.
Solution Approach 2:
The engaging unit acts as an intermediary mechanism that selectively connects either the first or second prime mover to the drive shaft. This allows smooth transition between different power sources without interrupting power transmission, enabling the system to maintain high traction and drawbar pull while accessing torque from the appropriate prime mover.
3Power
If oversize prime movers are used to meet peak power requirements, then the power requirements are satisfied, but the prime movers become overloaded and overheat during normal operation
Solution Approach 1:
The powertrain is divided into two prime movers with different power and torque characteristics, allowing each to operate within its optimal range. The ECU selects the appropriate prime mover based on operational demands, preventing either unit from being chronically overloaded. This segmentation enables peak power requirements to be met while maintaining reliability during normal operation.
Solution Approach 2:
The system changes operational parameters by switching between different prime movers with different power and torque characteristics. Instead of using a single oversized motor that operates inefficiently across all conditions, the system selects the optimal prime mover for each specific working condition, thereby avoiding overloading and overheating while meeting peak power demands.
4Device complexity
If manual gear shifting is used for power transmission, then the mechanism is simple, but the shifting process is not smooth and produces noise
Solution Approach 1:
The system replaces manual mechanical gear shifting with an electronically controlled engaging unit that uses actuated dog clutches. This substitution eliminates the need for manual intervention and provides smooth, noise-free engagement by using controlled mechanical latching mechanisms actuated by motors or solenoids, thereby improving ease of operation while maintaining relatively simple transmission mechanics.
5Device complexity
If manual gear shifting is used, then the mechanism is simple, but the shifting response is slow
Solution Approach 1:
The system replaces manual gear shifting with an electronically controlled engaging unit that receives commands from the ECU and actuates the appropriate dog clutch rapidly. This electronic control system eliminates the delays associated with manual operation, providing quick response time for gear changes while maintaining a relatively simple transmission mechanism through the use of direct-acting clutch mechanisms.
Data Source
AI summary
The present disclosure relates to a powertrain for a work machine (50). The powertrain (100) comprises a first prime mover (10), a second prime mover (12), a set of first gears (14a, 14b), a set of second gears (16a, 16b), an engaging unit (24), and an actuator (26). The first prime mover (10) configured to engage a first shaft (18). The second prime mover (12) configured to engage a power take off (PTO) shaft (20). The first gears (14a, 14a) mounted on the first shaft (18) and the second gears (16a, 16b) mounted on the PTO shaft (20). The actuator (26) configured to be in communication with the engaging unit (24), and further configured to selectively displace the engaging unit (24) from the idling configuration to the engaging configuration to engage with one of the second gears (16a, 16b). Advantageously, the engaging unit (24) facilitates the coupling of the second prime mover (12) with the first prime mover (10); therefore the powertrain (100) provides the desired torque to meet the requirements.