Flywheel Housing Generator for Road Paver Drive
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Solution Overview
Problem
Conventional road finishers face challenges with large and heavy generators that require significant space and difficulty in achieving optimal speed, leading to inefficient power output and starting issues, especially in adverse weather conditions.
Innovation Solution
The generator is integrated into the flywheel or clutch housing, allowing for a compact and powerful setup that operates at optimal relative speed, with a ring generator design and planetary gear stage to manage power efficiently, and a switchable clutch for decoupling during starting and transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the generator is placed at the end of a drive train connected to the power output area of the crankshaft, then the generator can be driven by the internal combustion engine, but the generator becomes large and heavy requiring significant installation space
Solution Approach 1:
The generator is merged with the pump transfer case by mounting it directly on the housing of the pump transfer case. This integration allows the generator to share the same installation space as the pump transfer case, significantly reducing the overall volume required for these components while maintaining the generator's power output capability
Solution Approach 2:
The pump transfer case housing serves dual purposes: it functions as the pump transfer case itself and simultaneously as the mounting structure for the generator. This multi-functionality eliminates the need for separate mounting space for the generator, resolving the space constraint
2Power
If the generator is driven by the crankshaft or pump transfer case via belt drive, then the generator can be powered, but unwanted lateral loads occur on the output shaft of the pump transfer case or crankshaft
Solution Approach 1:
The belt drive mechanism is extracted and replaced with a direct mechanical connection. The generator is driven directly by the output shaft of the pump transfer case through a coupled connection, eliminating the intermediate belt drive that caused lateral loads. This direct connection transmits only axial forces, removing the harmful lateral load component
3Speed
If a gear stage is added between the crankshaft and generator to optimize generator speed, then the generator can operate at optimal speed, but the starting power requirement increases making it difficult to start the prime mover
Solution Approach 1:
A switchable clutch is introduced to dynamically control the connection between the generator and the drive train. During engine starting, the clutch disconnects the generator from the crankshaft, allowing the engine to start without the generator's starting power load. During normal operation, the clutch engages to allow the generator to run at its optimal speed, which may differ from the engine's nominal speed
4Volume of moving object
If the generator shares a power-split pump transfer case with other functional units, then space is saved, but the power output of the generator becomes limited
Solution Approach 1:
The drive train is segmented into independent power transmission paths. The generator is connected to the output shaft of the pump transfer case through a dedicated coupling, allowing it to receive power independently from the other functional units driven by the pump transfer case. This segmentation enables the generator to achieve its full power output without being constrained by the power splitting required for other hydraulic functions
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 configuration saves space, enhances power output, improves starting behavior, and reduces fuel consumption by allowing the generator to operate directly at the source with low losses, while maintaining a compact primary drive unit.
Implementation Method 1
The generator (R) is integrated into the flywheel or clutch housing (20)... The generator is a ring generator (R) excited by permanent magnets... The rotor (28) is designed as a hollow ring rotor
Implementation Method 2
The generator (R) is a ring generator (R) excited by permanent magnets with a hollow ring rotor (28) for passing through the output train (29) to the pump transfer case (30)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
In a road paver (F) with an internal combustion engine (M), in particular a diesel engine, as the primary drive unit (P), the crankshaft (22) of which leads to a power output area in a clutch or flywheel housing (20), and a generator driven by the primary drive unit (P) at least for supplying electrical heating devices (H) of the road paver (F) and a pump distribution gearbox (30) are provided, a permanent magnet excited generator (R) is installed on or in the clutch or flywheel housing (20) or on its stage, through which a drive train (29) connected or connectable to the power output area leads to the pump distribution housing (30).