Industrial EV Traction Power Interface for Charging While Moving
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Solution Overview
Problem
Industrial electric vehicles (IEVs) face challenges with limited operational range, long downtime for recharging, and high initial costs due to inefficient charging and the need for large, expensive batteries. Additionally, existing power systems, such as trolley or power rail systems, may not be feasible in all industrial settings due to layout changes, harsh conditions, or other constraints.
Innovation Solution
The proposed solution involves an electrical traction system for IEVs, which includes an electrical energy storage device, a DC drivetrain bus, an electric power converter, electric motors, traction inverters, and an electrical interface assembly. This system allows for efficient charging and power reception from both stationary and moving power sources, including conductor arrangements and stationary power supply modules, using pin-type connector receivers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If battery capacity is increased to extend operational range, then operational range is improved, but vehicle cost and weight increase
Solution Approach 1:
The patent combines two power supply methods: onboard battery and external overhead conductor. The vehicle can draw power from overhead conductors during operation, merging external power supply with onboard storage to extend operational range without proportionally increasing battery capacity and weight.
Solution Approach 2:
The system dynamically switches between different power sources (battery and overhead conductor) based on operational needs. The vehicle can transition from battery-only operation to hybrid operation when overhead power is available, optimizing the balance between weight and range.
2Loss of time
If battery capacity is increased to reduce recharging frequency, then downtime is reduced, but vehicle cost increases
Solution Approach 1:
The overhead conductor system enables continuous power supply during vehicle operation, eliminating the need to stop for recharging. Power transfer occurs while the vehicle is moving, ensuring continuous useful action without interruption.
Solution Approach 2:
The system performs preliminary power transfer during vehicle operation rather than waiting for battery depletion. By charging the battery during movement through the overhead conductor, the system prepares power in advance, reducing subsequent downtime.
3Loss of energy
If trolley or power rail systems are implemented for power supply, then power transfer efficiency is improved, but infrastructure complexity and adaptability worsen
Solution Approach 1:
The vehicle is designed with dual power reception capability: it can operate with onboard battery alone or connect to overhead conductors when available. This multi-functional design allows the same vehicle to adapt to different infrastructure conditions without requiring specialized modifications.
Solution Approach 2:
The overhead conductor system is deployed only in specific areas where high power transfer efficiency is needed, while other areas rely on battery operation. This localized approach optimizes power transfer efficiency where necessary while maintaining infrastructure flexibility elsewhere.
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 system enables IEVs to be powered electrically with low downtime and in a cost-effective manner, reducing the need for oversized battery capacities. It allows for efficient high-power charging while stationary and simultaneous power reception while moving, enhancing productivity and operational efficiency in industrial settings.
Implementation Method 1
an electrical energy storage device having a storage electrical potential
Implementation Method 2
an electric power converter provided between the electrical energy storage device and the DC drivetrain bus
Implementation Method 3
at least one traction inverter provided between the DC drivetrain bus and the at least one electric motor for driving the at least one electric motor
Implementation Method 4
at least one electric motor, at least one traction inverter provided between the DC drivetrain bus and the at least one electric motor for driving the at least one electric motor
Data Source
AI summary
An electrical traction system for an industrial electric vehicle is described. The electrical traction system includes an electrical energy storage device having a storage electrical potential, a DC drivetrain bus having at a drivetrain electrical potential, an electric power converter provided between the electrical energy storage device and the DC drivetrain bus, at least one electric motor, at least one traction inverter provided between the DC drivetrain bus and the at least one electric motor for driving the at least one electric motor, and an electrical interface assembly directly connected to the DC drivetrain bus for receiving an electric power from an electrical power supply system. The electrical interface assembly includes at least one interface for receiving power while the industrial electric vehicle is stationary, and for receiving power while the industrial electric vehicle is moving.