Modular Excavator Drive Pods for High Power Under Weight Limits
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Solution Overview
Problem
Existing excavators require large, high-horsepower engines that increase costs and transportation challenges due to weight limitations, necessitating costly alternatives like rail transport for repairs or power adjustments.
Innovation Solution
A drive pod system comprising multiple drive pods with engines or motors, each with its own radiator and frame, coupled to a central gearbox, allowing for modular power adjustments and easy replacement or transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single large high-horsepower engine is used to drive the excavator, then sufficient power is available to move large quantities of ground material, but the weight increases causing transportation challenges and increased costs
Solution Approach 1:
The patent divides the single large engine into multiple smaller drive pods (typically three pods with engines of 300-500 horsepower each). This segmentation provides the necessary total horsepower (900-1500 hp) while reducing the weight of each individual component, making transportation more feasible and cost-effective without requiring specialized rail transport.
2Power
If a single large engine is used, then power requirements are met, but repair costs and complexity increase due to the critical nature of the single power source
Solution Approach 1:
By segmenting the power system into multiple independent drive pods, the patent enables individual pod replacement or repair without shutting down the entire excavator. If one pod fails, the others can continue operating, significantly reducing repair costs and downtime compared to a single-engine system where failure means complete shutdown.
Solution Approach 2:
Each drive pod is designed as a self-contained modular unit with its own engine, transmission, and control systems. This local quality allows independent maintenance and repair of individual pods without affecting the rest of the power system, making repairs more economical and less complex.
3Power
If engine power is increased to handle heavier excavation loads, then excavation capability improves, but transportation costs increase due to weight limits
Solution Approach 1:
The patent enables flexible power scaling by adding or removing drive pods based on excavation requirements. For lighter loads, fewer pods can be used to reduce weight and transportation costs. For heavier loads, additional pods can be added to increase horsepower without permanently increasing the base weight of the excavator, optimizing the power-to-cost ratio.
Solution Approach 2:
The modular drive pod system allows dynamic adjustment of power capacity. The excavator can be configured with different numbers of drive pods depending on the specific excavation task, enabling the power and weight to be optimized for each operation rather than being fixed at a high constant level.
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
Enables cost-effective power management and transportation by using smaller, less costly engines or motors, facilitating on-site repairs and compliance with weight limits, reducing operational expenses and enhancing flexibility.
Implementation Method 1
The first and second drive pods further include a first radiator and a second radiator to cool the first and second drive mechanisms, respectively.
Implementation Method 2
The first drive pod further includes a first transmission and the second drive pod further includes a second transmission, the first and second transmissions being coupled to drive shafts of the first and second drive mechanisms to the central gearbox, respectively.
Data Source
AI summary
A drive pod system for an excavator includes a first drive pod, a second drive pod, and a central gearbox. The first drive pod includes a first drive mechanism and a first drive pod frame, the first drive mechanism coupled to the first drive pod frame. The second drive pod includes a second drive mechanism and a second drive pod frame, the second drive mechanism coupled to the second drive pod frame. The central gearbox receives power produced by the first drive mechanism and the second drive mechanism and transfers the power to a ground manipulator apparatus of the excavator. The first and second drive pod frames are coupled to an excavator frame of the excavator.