Electric PTO Thermal Flow Monitoring for Inverter Overheating

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing electric refuse vehicles face challenges in effectively managing thermal energy within their electric power take-off systems, which can lead to overheating and potential system failures.

Innovation Solution

The implementation of a thermal management system with a heat dissipation device, thermal sensors, flow meters, and a controller to monitor and regulate cooling fluid flow, ensuring the system operates within safe parameters and shuts down if critical conditions are detected.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the electric power take-off system operates at high power, then the hydraulic power output is improved, but thermal energy accumulation increases leading to overheating

Engineering Contradiction:
Improvehydraulic power outputVSAvoidthermal energy
Core Design Contradiction:
PowerVSTemperature

Solution Approach 1:

The patent converts the harmful thermal energy generated during high-power operation into a monitored parameter that triggers protective actions. By using thermal sensors to detect temperature rise and flow meters to monitor cooling fluid flow, the system transforms the harmful effect of heat generation into a controllable variable that initiates shutdown sequences before damage occurs, thereby benefiting from high-power operation while mitigating thermal risks.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent implements a feedback control system where thermal sensors continuously monitor temperature levels and flow meters monitor cooling fluid flow rates. This data is fed back to the controller, which adjusts system operation accordingly - maintaining high power output when thermal conditions are acceptable and initiating shutdown procedures when thermal thresholds are exceeded, thus resolving the contradiction between power output and thermal management.

Inventive Principle:
Principle #23Feedback

2Reliability

If thermal management monitoring is continuously performed, then system reliability is improved, but device complexity increases

Engineering Contradiction:
Improvesystem reliabilityVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent enables the system to monitor and manage its own thermal conditions through self-contained sensing and control capabilities. The thermal sensors, flow meters, and controller work together as an integrated self-monitoring system that automatically detects thermal issues and initiates protective shutdowns without external intervention, thereby improving reliability while keeping the added complexity manageable through automation.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent replaces complex mechanical thermal management systems with electronic sensing and control mechanisms. Instead of using elaborate mechanical cooling systems or manual monitoring, the invention uses electronic thermal sensors and microcontroller-based monitoring to achieve reliable thermal management with reduced mechanical complexity, substituting mechanical approaches with electronic control solutions.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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 solution effectively prevents overheating and ensures the reliable operation of the electric power take-off system by promptly addressing thermal issues, thereby maintaining the functionality of the refuse vehicle's hydraulic and electrical subsystems.

Implementation Method 1

a heat dissipation device in thermal communication with the inverter

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a thermal fluid pump configured to pump cooling fluid through the conduits

Methodology Applied
Scientific EffectPumping: Pump

Implementation Method 3

a thermal sensor configured to detect thermal energy within the inverter

Methodology Applied
Scientific EffectThermal detection: Thermography

Data Source

PatentUS20250289653A1System and method for electronic power take-off controls
Publication Date: 2025.09.18 OSHKOSH CORPORATION
  • US20250289653A1 patent drawing
  • US20250289653A1 patent drawing
  • US20250289653A1 patent drawing

AI summary

An electric power take-off system includes a motor configured to convert electrical power received from a battery into hydraulic power, an inverter configured to provide electrical power to the motor from the battery, a heat dissipation device in thermal communication with the inverter, wherein the heat dissipation device includes a thermal fluid pump configured to pump cooling fluid through a plurality of conduits, a flow meter configured determine a flow rate through the plurality of conduits, and a controller configured to receive data from the flow meter and provide operating parameters to the heat dissipation device, wherein the controller is further configured to determine if the data from the flow meter is less than a critical operating condition and decrease the hydraulic power provided by the electric power take-off system in response to determining that the data from the flow meter is less than the critical operating condition.