Energy Storage System for Heavy Equipment Power Management
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Solution Overview
Problem
Heavy equipment such as power shovels and excavators often operate with oversized engines due to non-uniform peak power demands, leading to increased initial purchasing, operating, and maintenance costs, as well as reduced machine life, as they underutilize available power in repetitive work cycles.
Innovation Solution
An energy storage system comprising a power source, an electrical generator, and a controller that converts mechanical power into electrical power, stores it, and supplies it to auxiliary loads, with the controller determining power demands and regulating power distribution to prolong energy use by disabling or adjusting power supply based on pre-determined thresholds and load characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an oversized engine is used to meet peak power demands, then the machine can handle maximum power requirements, but the engine underutilizes available power during most operations, increasing operating costs and reducing machine life
Solution Approach 1:
The power delivery system is segmented into multiple sources: a smaller base engine and an energy storage device. The base engine operates at optimal efficiency for sustained loads, while the energy storage device handles peak power demands, allowing each component to operate in its optimal range rather than one oversized engine operating inefficiently throughout
Solution Approach 2:
The energy storage device is pre-charged during low-demand periods when the base engine operates efficiently, storing energy for later use during peak demand periods. This preliminary energy accumulation allows the system to meet peak demands without requiring an oversized base engine
2Power
If an oversized engine is used to meet peak power demands, then the machine can handle maximum power requirements, but the initial purchasing cost, operating cost, and maintenance cost increase
Solution Approach 1:
Instead of purchasing one large expensive engine, the system purchases a smaller base engine and a separate energy storage device. The combined capability meets peak demands, but the individual components are more cost-effective, reducing initial capital expenditure
Solution Approach 2:
The energy storage device serves as a temporary power source during peak demands, providing short-duration high power output when needed, then recharging during lower demand periods. This allows the system to access peak power capability without the permanent cost of an oversized engine
3Quantity of substance
If the electrical generator continuously charges the energy storage device, then the energy storage device maintains full charge, but during peak power demand the generator cannot keep up with both charging and meeting auxiliary load demands
Solution Approach 1:
The controller dynamically manages power flow based on real-time conditions, switching the electrical generator between charging mode and direct power delivery mode. During peak demands, the generator directly powers auxiliary loads while the energy storage device supplements power, rather than attempting to continuously charge during high-demand periods
Solution Approach 2:
The controller monitors the state of charge of the energy storage device and the power demands of auxiliary loads, adjusting the generator's operation accordingly. When the energy storage device is full or when peak demand occurs, the controller redirects generator output to meet immediate auxiliary load requirements rather than overcharging
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 reduces the engine size required, improves fuel efficiency by matching power output to demand, and extends the operational life of the machine by optimizing energy usage and reducing peak power demands, resulting in significant energy savings and cost reductions.
Implementation Method 1
The electrical generator converts at least a portion of the mechanical power into electrical power
Data Source
AI summary
An energy storage system associated with a machine having a work tool and one or more auxiliary loads includes a power source which generates mechanical power. An energy storage device supplies power to the one or more auxiliary loads. An electrical generator is operably coupled to the power source and converts at least a portion of the mechanical power into electrical power. The electrical generator supplies the electrical power to the energy storage device. A controller is communicably coupled to the power source, the work tool, the energy storage device, and the electrical generator. The controller determines a power demand of the work tool. The controller then compares whether the determined power demand exceeds a pre-determined threshold power. The controller disables the electrical generator from supplying the electrical power to the energy storage device if the power demand exceeds the pre-determined threshold power.