Electric Powertrain With Liquid-Cooled Sealed Components
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Solution Overview
Problem
Conventional work machines with internal combustion engines face challenges such as high exhaust emissions, limited fuel efficiency, and operational inefficiencies, especially in applications requiring high torque and traction, and are unsuitable for hostile environments due to air-cooled electric components and insufficient power density.
Innovation Solution
An electric powertrain system comprising an engine, generator, high-power-density electric motors, and a differential steering unit, with sealed, brushless, liquid-cooled components, and an energy storage system to manage torque and inertia, allowing for efficient and variable speed control, reduced emissions, and improved power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional air-cooled electric components are used in work machines, then the machine can operate in standard environments, but the components quickly fill with dirt or mud, preventing sufficient cooling and leading to premature part failure in hostile environments
Solution Approach 1:
The patent applies sealed enclosures with liquid cooling systems to protect electric components from environmental contamination. The sealed shell prevents dirt and mud from entering the cooling channels, while the liquid cooling system efficiently removes heat from the components, ensuring reliable operation in hostile environments.
Solution Approach 2:
The patent uses liquid cooling systems (hydraulic principle) to replace air cooling. The liquid coolant circulates through sealed channels, absorbing heat from electric components and transporting it to cooling exchangers, providing efficient thermal management that is not compromised by dusty or muddy environmental conditions.
2Force
If high final drive gear ratio is used to achieve high drawbar pull, then the machine can perform pushing and pulling functions, but a high amount of inertia is reflected back to the powertrain upon stopping
Solution Approach 1:
The patent converts the harmful inertial energy into useful electrical energy through regenerative braking. When the work machine decelerates, the electric motor operates as a generator, converting the kinetic energy from the high gear ratio into electrical energy that can be stored or used, thereby benefiting from rather than being harmed by the high inertia.
Solution Approach 2:
The patent implements energy recovery feedback where the powertrain system captures energy during deceleration and feeds it back into the system. The control system monitors the deceleration state and activates regenerative braking to recover energy, creating a closed-loop feedback mechanism that improves overall energy efficiency.
3Power
If conventional electric motors are used in work machines, then the machine can provide propulsion, but the motors lack sufficient power density for space-constrained applications
Solution Approach 1:
The patent employs advanced motor design with optimized magnetic circuits, high-energy-density permanent magnets, and improved winding configurations to increase power density. These parameter changes allow the motor to deliver higher power output from a reduced volume, meeting the space constraints of modern work machine designs.
Solution Approach 2:
The patent uses composite material structures in the motor construction, including high-strength lightweight alloys for the rotor and stator, and advanced magnetic materials with superior energy density. These composite materials enable the motor to achieve higher power-to-volume ratios while maintaining structural integrity.
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 electric powertrain system enhances fuel efficiency, reduces emissions, and provides high power density, enabling work machines to operate effectively in demanding conditions with reduced inertia and improved operator control, while maintaining efficient power delivery and cooling in hostile environments.
Implementation Method 1
a generator operably coupled to the engine and configured to convert at least a portion of the mechanical energy into electric energy
Implementation Method 2
The at least one electric motor is configured to provide torque for the plurality of driving members
Implementation Method 3
sealed, brushless, liquid-cooled components
Data Source
AI summary
An electric powertrain includes an engine configured to provide mechanical energy and a generator operably coupled to the engine and configured to convert at least a portion of the mechanical energy into electric energy. The electric powertrain further includes at least one electric motor operably coupled to the generator, a plurality of driving members, and at least one power electronics unit configured to control at least one of the engine and the generator. The at least one electric motor is configured to provide torque for the plurality of driving members.