Electric Dump Truck Power Unit Layout for Fast Module Replacement
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Solution Overview
Problem
Existing dump trucks are predominantly powered by combustion engines, contributing to environmental pollution, and existing battery electric dump trucks face challenges in modular power unit replacement and integration with hydraulic systems, limiting their efficiency and versatility.
Innovation Solution
A battery electric dump truck design featuring a frame with modular, cantilevered mounts for power units, a split radiator system allowing easy power unit replacement, and integrated hydraulic systems powered by electric motors, along with additional battery units positioned between wheels, enabling flexibility and efficient maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a battery electric power unit is installed in a dump truck, then environmental pollution is reduced, but the complexity of power unit replacement and integration with hydraulic systems increases
Solution Approach 1:
The power unit is designed as a modular assembly comprising the battery, electric motor, and hydraulic pump as separate but integrated components. This segmentation allows the entire power unit to be replaced as a single module while maintaining simple integration with the hydraulic system through standardized connections.
Solution Approach 2:
The electric motor serves multiple functions: it acts as the propulsion motor for driving the dump truck and simultaneously functions as the drive for the hydraulic pump. This multi-functionality reduces the number of separate components needed and simplifies the overall system integration.
2Productivity
If the power unit is designed for quick replacement, then maintenance efficiency is improved, but the structural complexity of mounting systems increases
Solution Approach 1:
The power unit is pre-assembled with all necessary mounting interfaces, electrical connections, and hydraulic couplings before installation in the dump truck. The cantilevered mounts are pre-positioned on the vehicle frame, allowing the complete power unit to be quickly installed or removed without requiring complex assembly or disassembly operations.
3Use of energy by moving object
If additional battery units are positioned between wheels, then energy capacity is increased, but the available space for other components is reduced
Solution Approach 1:
Instead of placing additional battery units in the longitudinal direction or occupying the cargo area, the batteries are positioned in the vertical space between the wheel arches. This utilizes previously unused vertical volume, increasing energy capacity without encroaching on the space available for other components or cargo.
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
Facilitates quick and adaptable power unit replacement, reduces environmental impact, and enhances the efficiency and versatility of battery electric dump trucks, supporting high payload capacities and modular conversion between power sources.
Implementation Method 1
a radiator unit, wherein the radiator unit comprises two radiator columns spaced apart from each other
Implementation Method 2
a radiator unit, wherein the radiator unit comprises two radiator columns spaced apart from each other
Implementation Method 3
a power unit comprising a battery, the power unit providing electrical energy to at least one electrical propulsion motor
Implementation Method 4
a hydraulic pump operated by an electric motor, wherein the hydraulic pump and the electric motor are mounted to the power unit
Data Source
AI summary
The present disclosure relates to a battery electric dump truck, comprising a frame, a dump body pivotably mounted on the frame, a power unit comprising a battery, the power unit providing electrical energy to at least one electrical propulsion motor of the battery electric dump truck, and a hydraulic pump operated by an electric motor, wherein the hydraulic pump and the electric motor are mounted to the power unit.