Electric Actuator Integration for Durable Construction Equipment
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Solution Overview
Problem
Existing construction equipment faces challenges in replacing hydraulic cylinders with electric actuators due to issues such as deformation, wear, and breakage under applied forces, and existing electric cylinder designs fail to provide performance similar to hydraulic systems.
Innovation Solution
Integration of electric actuators within the construction equipment, featuring a rod, sliding member, and electric motor, with guiding means and a connecting rod articulated to move elements relative to each other, utilizing proven components like ball screws or roller screws for robustness and efficiency, and enabling energy recovery through regenerative braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If hydraulic cylinders are replaced with electric cylinders, then the equipment can be fully electrified and quieter operation is achieved, but the electric cylinders are exposed to deformation, wear, and breakage under applied forces
Solution Approach 1:
A connecting rod is introduced as an intermediary element between the electric actuator and the first element. The connecting rod is articulated at both ends, allowing it to transmit forces while accommodating relative movement and reducing direct stress on the electric actuator components, thereby protecting them from deformation and breakage
Solution Approach 2:
The articulated connection design provides inherent stress distribution and force cushioning before extreme loads reach the electric actuator. The geometry of the connecting rod arrangement allows forces to be distributed across multiple contact points and angles, preventing sudden shock loads that could cause breakage
2Loss of energy
If electric actuators are used to replace hydraulic cylinders, then energy recovery through regenerative braking is enabled, but the actuator components are exposed to shocks and potential breakage
Solution Approach 1:
The connecting rod acts as a protective intermediary that isolates the electric actuator from external shocks. By articulating the connection points, the system allows shock absorption through controlled movement rather than direct transmission to the actuator components, reducing breakage risk while maintaining energy recovery functionality
Solution Approach 2:
The articulated connecting rod system introduces dynamic flexibility to the force transmission path. Instead of rigid connections that transmit all shocks directly, the articulated joints allow controlled movement and force redistribution, dynamically adapting to load variations and protecting the actuator from extreme shock loads
3Device complexity
If traditional electric cylinder designs are used with motors inside the rod, then compact integration is achieved, but the design remains fragile and exposed to deformation and breakage
Solution Approach 1:
The connecting rod serves as an external intermediary that transfers forces away from the electric actuator body. This allows the actuator to be integrated into the equipment structure without being directly exposed to high stress zones, protecting it from deformation and breakage while maintaining compact design
Solution Approach 2:
The force transmission function is extracted from the electric actuator body and transferred to the external connecting rod mechanism. This separation allows the actuator to focus on motor function while the connecting rod handles the mechanical force transmission, reducing stress on the actuator components and preventing breakage
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 provides a robust, efficient, and economical replacement for hydraulic cylinders, enhancing durability and performance while allowing for fully electric construction equipment, with energy recovery capabilities during downhill movements.
Implementation Method 1
an electric motor, for converting electrical power into a movement of the sliding member along the longitudinal axis
Data Source
AI summary
A construction equipment includes an electric actuator including a rod extending along a longitudinal axis, a sliding member movable along the rod, an electric motor for converting electrical power into a movement of the sliding member along the longitudinal axis, a connecting rod including a first end which is articulated on sliding member and a second end which is articulated on a first element of the construction equipment in order to move the first element relative to a second element or inversely and guiding means for guiding the movement of the sliding member the longitudinal axis. The electric motor, the rod and the sliding member are integrated into the second element of the construction equipment.