Electric Construction Machine Propulsion Control for Current Overload
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Solution Overview
Problem
Electric construction machines face challenges with varying loads, which can exceed their intended maximum, leading to excessive current draw and potential damage to batteries and other components, especially when operating in rough terrain.
Innovation Solution
The implementation of a control method that monitors current draw and adjusts propulsion and component movement variables based on predefined thresholds and durations, reducing power output when excessive current is detected and increasing it when current levels return to acceptable ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electric construction machine operates at maximum power output to handle heavy loads and rough terrain, then the productivity and load handling capability are improved, but the batteries and components may be damaged due to excessive current draw
Solution Approach 1:
The control circuit continuously monitors current draw from the batteries and provides feedback to the control method. When the monitored current exceeds a threshold for a specified duration, the system automatically reduces the propulsion variable to prevent damage, creating a closed-loop feedback mechanism that balances power output with component protection.
Solution Approach 2:
The system dynamically adjusts the propulsion variable based on real-time current conditions. Rather than operating at a fixed maximum power level, the propulsion variable is modulated according to the monitored current draw and duration, allowing the system to adapt its power output to protect components while maintaining productivity when conditions permit.
2Device complexity
If simple protective measures are used to prevent overloading, then the device complexity is reduced, but the protection effectiveness against battery and component damage may be insufficient
Solution Approach 1:
The control circuit provides continuous feedback on current draw, enabling the control method to make informed decisions about power reduction. This feedback mechanism enhances protection effectiveness without requiring complex mechanical protective devices, achieving reliable overload protection through intelligent control rather than mechanical complexity.
Solution Approach 2:
The system changes operational parameters (propulsion variable) based on monitored conditions rather than using fixed protective mechanisms. By adjusting the propulsion variable dynamically in response to current draw and duration thresholds, the system achieves effective protection with minimal additional hardware complexity.
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
This control method effectively prevents overloading and potential damage to batteries and components, while also reducing the need for additional protective measures like gear transmission systems, thereby enhancing the durability and operational efficiency of electric construction machines.
Implementation Method 1
an electric motor adapted to be powered by the one or more batteries
Data Source
AI summary
A construction machine is disclosed having a body, one or more movement elements, and a control panel comprising a propulsion controller operable between a lower propulsion controller limit and an upper propulsion controller limit. The construction machine further comprises: a propulsion electric motor adapted to drive the one or more movement elements, one or more batteries adapted to power the propulsion electric motor, a control circuit adapted to receive a propulsion controller input indicative of a state of the propulsion controller between the lower propulsion controller limit and the upper propulsion controller limit, and to operate the propulsion electric motor in accordance with a propulsion variable based on the propulsion controller input. While operating the propulsion electric motor in accordance with the propulsion variable, the control circuit is further adapted to: receive a propulsion current signal indicative of an amount of current drawn by the propulsion electric motor, and in accordance with the propulsion current signal satisfying propulsion reduction criteria, reduce the propulsion variable by a propulsion reduction amount such that the propulsion variable is below a maximum propulsion variable.