Electric Semi-Trailer Dump Drive Without Wet Kit Hydraulics
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Solution Overview
Problem
Conventional semi-truck and trailer dump systems face issues such as restricted operator mobility, hydraulic leaks, system failures due to temperature sensitivity, and maintenance challenges associated with wet kit systems, which hinder efficient and safe material dumping.
Innovation Solution
An electrically driven dump system utilizing a DC-to-DC voltage converter, energy storage element, and a controller to convert DC power into AC power, powering a motor connected to a hydraulic pump, allowing wireless control and reducing the need for mechanical connections to the semi-truck's PTO, thus eliminating hydraulic lines and associated issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wet kit system with PTO and hydraulic lines is used, then the dump system can be powered mechanically, but hydraulic leaks and system failures occur due to temperature sensitivity and long hydraulic lines
Solution Approach 1:
The patent replaces the mechanical PTO-driven hydraulic pump system with an electric motor-driven pump system. The electric motor is powered by the truck's electrical system through a DC-to-DC converter and energy storage element, eliminating the need for mechanical connections to the PTO and long hydraulic lines, thereby reducing hydraulic leaks and improving reliability
Solution Approach 2:
The patent extracts and eliminates the wet kit system components (PTO connection, hydraulic pump, long hydraulic lines) from the dump system, replacing them with an electrically-driven pump system that eliminates the source of hydraulic leaks
2Ease of operation
If input receivers are wired inside the semi-truck cab, then the dump system can be controlled, but operator mobility is restricted
Solution Approach 1:
The patent replaces wired mechanical control systems with wireless control systems. The controller communicates wirelessly with the electric motor and pump system, allowing operators to control the dump system from various locations without being constrained by wired receivers in the cab
Solution Approach 2:
The controller is designed to perform multiple functions including wireless communication, power conversion control, and dump system operation, enabling versatile control options that improve operator mobility while managing system complexity
3Length of stationary object
If hydraulic pumps are positioned proximate to the PTO, then mechanical power can be transferred, but long hydraulic lines are required extending from the semi-truck to semi-trailer
Solution Approach 1:
The patent replaces the mechanical PTO-power transmission system with an electrical power transmission system. The electric motor is positioned on the semi-trailer and powered through electrical cables from the semi-truck, eliminating the need for long hydraulic lines and their associated reliability issues
Solution Approach 2:
The patent introduces electrical cables as an intermediary power transmission medium between the semi-truck and semi-trailer, replacing the problematic long hydraulic lines and enabling reliable power transmission without the drawbacks of extended hydraulic connections
4Ease of repair
If wet kit systems are used, then the dump system can operate hydraulically, but excessive diagnostics and repairs are required due to hydraulic line ruptures
Solution Approach 1:
The patent replaces the hydraulic wet kit system with an electrically-driven system, eliminating hydraulic lines that are prone to rupture and require extensive diagnostics and repairs. The electric motor and pump system requires minimal maintenance and eliminates time loss associated with hydraulic system repairs
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 enables increased operator mobility, reduces hydraulic leaks by up to 80%, and minimizes maintenance costs by eliminating the need for wet kit systems, ensuring safer and more efficient material dumping operations.
Implementation Method 1
a DC-to-DC voltage converter configured to receive input DC voltage from a battery bank and output increased DC voltage
Implementation Method 2
an energy storage element configured to receive the increased DC voltage from the DC-to-DC voltage converter
Implementation Method 3
a controller configured to receive DC power from the energy storage element and convert the DC power into AC power
Implementation Method 4
a motor configured to receive AC power from the controller, the motor being mechanically connectable to a pump
Data Source
AI summary
A system for electrically powering a semi-trailer dump system includes a DC-to-DC voltage converter configured to receive input DC voltage from a battery bank and output increased DC voltage, an energy storage element configured to receive the increased DC voltage from the DC-to-DC voltage converter, a controller configured to receive DC power from the energy storage element and convert the DC power into AC power, and a motor configured to receive AC power from the controller, the motor being mechanically connectable to a pump for controlling the dumping system.