External Electric Vibration Exciter Layout for Compact Vibratory Hammers
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Solution Overview
Problem
Existing vibration generators in vibratory hammers face inefficiencies due to hydraulic systems, which incur significant energy losses and require complex maintenance, and alternative electric systems like permanent magnet synchronous motors are bulky and environmentally problematic.
Innovation Solution
A vibration exciter with a compact design using electric motors and drive gearboxes externally connected to shafts, eliminating the need for hydraulic systems and utilizing smaller, lighter electric motors with drive gearboxes to achieve high efficiency and reduce size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hydraulic motors are used to drive the vibration generator, then high power and torque density are achieved, but energy efficiency is low and the system requires complex maintenance
Solution Approach 1:
The patent replaces the hydraulic drive system with an electric motor system. The electric motor directly drives the vibration generator, eliminating the need for hydraulic pumps, hoses, and control blocks. This substitution resolves the contradiction by providing high power density like hydraulic systems while achieving superior energy efficiency through direct electric drive, eliminating energy losses in the hydraulic circuit.
2Power
If hydraulic systems are used, then high power and torque density are achieved, but the system becomes complex and requires intensive maintenance
Solution Approach 1:
The patent extracts and removes the entire hydraulic system from the vibration generator. By taking out the hydraulic pumps, hoses, control blocks, and associated components, the system is simplified to essentially just the electric motor and the vibration generator mechanism. This extraction resolves the contradiction by maintaining the high power density capability while eliminating the complex hydraulic infrastructure that requires intensive maintenance.
3Loss of energy
If permanent magnet synchronous motors are used, then electric drive efficiency is achieved, but the motors become bulky and require rare earth metals
Solution Approach 1:
The patent changes the motor type parameters by using asynchronous motors or reluctance motors instead of permanent magnet synchronous motors. These alternative motor types do not require rare earth metals and can be designed with different geometric parameters to achieve the required power density. This parameter change resolves the contradiction by maintaining energy efficiency while avoiding the use of bulky motors and rare earth metals.
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 solution achieves high efficiency and compactness while minimizing energy losses and environmental impact, allowing for precise operation near obstacles and reducing maintenance needs.
Implementation Method 1
The vibration is characterized by a linear motion and is generated by pairs of counter-rotating eccentric masses within a vibrator drive
Implementation Method 2
By forming at least one drive unit (6) comprising an electric motor (61) and a drive gearbox (63) connected to it
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a vibration exciter for a vibratory hammer (4), comprising an exciter housing (51) in which an exciter gearbox (53) is arranged, the gearbox comprising at least two shafts (54) arranged parallel to each other, which are rotatably mounted in bearings (58) received by the exciter housing (51) and which are connected to at least one drive by which they are set in rotation, as well as at least two unbalanced masses (56) which are attached to one or more of the shafts (54), wherein the at least one drive is formed by a drive unit (6) comprising an electric motor (61) and a drive gearbox (63) connected thereto, wherein the at least one drive unit (6) is arranged on the outside of the exciter housing (51) such that it is offset in the direction of the axes of rotation of the shafts (54) relative to the bearings (58) received by the exciter housing (51) and is not positioned axially between two bearings (58) of a shaft.and wherein the drive gear (63) is connected to at least one of the shafts (54).