Linear Electric Piling Hammer With Regenerative Braking
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Solution Overview
Problem
Hydraulic piling hammers suffer from low energy efficiency (around 70%), hydraulic oil disposal issues, limited energy transfer, and reduced effectiveness in tilted processing due to gravity misalignment.
Innovation Solution
A piling hammer utilizing a linear electric machine with a mover connected to a ram block, controlled by a processor to determine and deliver kinetic energy for striking, and featuring regenerative braking to recover energy, reducing eddy currents and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If hydraulic type hammers are used for driving piles, then the hammer can deliver striking force to the pile, but energy efficiency is low (around 70%) and hydraulic oil disposal and pollution problems occur
Solution Approach 1:
The patent replaces the hydraulic system with a linear electric machine (electromagnetic system) to drive the ram block. The linear electric machine converts electrical energy directly into mechanical motion, eliminating the need for hydraulic oil and associated pollution problems while improving energy efficiency through direct energy conversion.
Solution Approach 2:
The patent changes the fundamental operating principle from hydraulic pressure-driven motion to electromagnetic force-driven motion. This parameter change in the driving mechanism enables direct electrical-to-mechanical energy conversion, improving overall energy efficiency from around 70% to significantly higher levels while eliminating hydraulic fluid requirements.
2Power
If hydraulic type hammers are used, then striking force can be delivered, but the speed of the striking hammer is limited to slightly higher than free fall and energy transfer is limited
Solution Approach 1:
The linear electric machine replaces the gravity-dependent hydraulic system, enabling active acceleration of the ram block at speeds exceeding free fall. The electromagnetic force can accelerate the ram block much faster than gravity alone, delivering higher kinetic energy and improving energy transfer to the pile.
Solution Approach 2:
The linear electric machine accelerates the ram block to high speeds before impact, storing kinetic energy in advance. This preliminary acceleration phase allows the system to build up significant energy that is then transferred to the pile during the striking phase, overcoming the energy transfer limitations of passive free-fall systems.
3Power
If very heavy striking hammers are required for large sized piles, then sufficient energy can be delivered, but the weight and complexity of the hammer increases
Solution Approach 1:
The linear electric machine provides active force generation, replacing the need to rely solely on gravitational potential energy from heavy masses. The electromagnetic system can generate sufficient striking force with lighter ram blocks by applying high acceleration forces, reducing the weight requirement while maintaining or increasing striking energy for large piles.
4Adaptability or versatility
If tilted processing is performed with hydraulic hammers, then piles can be driven at angles, but effectiveness is reduced since gravity does not act in the same direction as the striking hammer moves
Solution Approach 1:
The linear electric machine generates force through electromagnetic interaction rather than relying on gravity. This allows the system to deliver full striking force in any orientation, including tilted positions, since the electromagnetic force can be directed along the intended motion path regardless of gravitational orientation, maintaining effectiveness in tilted processing applications.
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
Improves energy efficiency, reduces hydraulic oil reliance, and maintains effectiveness in tilted operations by optimizing energy transfer and recycling kinetic energy.
Implementation Method 1
a linear electric machine (390, 392) with a mover (334, 101) connected to a ram block (332) for striking a pile (310)
Implementation Method 2
determine a recoiled kinetic energy from striking the pile (310) using a ram block (332) connected to a mover (334, 101) of a linear electric machine (390, 392); determine at least a portion of the determined recoiled kinetic energy for regenerative braking of the mover (334, 101)
Data Source
AI summary
There is provided a piling hammer comprising a linear electric machine comprising a mover connected to a ram block for striking a pile, a processor operatively connected to the linear electric machine and configured to determine a recoiled kinetic energy from striking the pile using a ram block connected to a mover of the linear electric machine, determining at least a portion of the determined recoiled kinetic energy for regenerative braking of the mover to a peak position, control the linear electric machine to decelerate the mover to the peak position based on the determined at least a portion of the determined recoiled kinetic energy.