Gearbox Waste-Heat Heating for Electric Railway Compartments
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Solution Overview
Problem
Modern electric railway vehicles without combustion engines face challenges in maintaining adequate compartment heating, particularly in cold conditions, as waste heat from traction motors is insufficient and relying on high electrical energy consumption is costly and ecologically harmful.
Innovation Solution
Utilize waste heat from the gearbox of an electric traction system to heat compartments via a fluid stream circulated through a circulation duct system, controlled by a temperature-regulated pump and heat exchangers, enhancing sustainability and cost-efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high amounts of electrical energy are used to heat the compartment (e.g., using heat pumps), then the desired temperature level can be reached, but the operation becomes cost-intensive and ecologically harmful
Solution Approach 1:
The patent converts the harmful waste heat generated by the electric traction motor into a beneficial heating source for the passenger compartment. The heat exchanger captures thermal energy that would otherwise be dissipated, transforming an environmental burden into a useful resource for maintaining comfortable temperatures in cold conditions.
Solution Approach 2:
The heating system utilizes the railway vehicle's own operational byproducts (waste heat from the traction motor) to satisfy its heating requirements. This self-service approach eliminates the need for external energy inputs, making the system autonomous and independent of additional electrical energy consumption.
2Use of energy by moving object
If waste heat from traction motors is used for heating, then electrical energy consumption is reduced, but the heat generation is not sufficiently continuous due to different load cycles
Solution Approach 1:
The patent ensures continuous heat generation by designing the heat exchanger system to operate continuously alongside the traction motor, capturing waste heat across all load cycles. The thermal mass of the gearbox oil and the continuous circulation system maintain steady heat availability even when motor load fluctuates, ensuring uninterrupted heating capability.
3Loss of energy
If waste heat from the gearbox is used for heating, then sustainability and cost-efficiency are improved, but the device complexity increases due to additional heat exchangers and circulation systems
Solution Approach 1:
The heat exchanger serves multiple functions: it acts as a thermal interface between the gearbox and the heating system, functions as a temperature control element, and integrates with the existing lubrication system. This multi-functionality reduces the need for separate dedicated components, thereby limiting the increase in overall system complexity.
4Temperature
If a fluid stream circulation system is implemented to transport waste heat, then heating effectiveness is improved, but the device complexity and initial cost increase
Solution Approach 1:
The patent introduces a heat transfer fluid as an intermediary medium between the gearbox (heat source) and the passenger compartment (heat destination). This fluid circulates through the heat exchanger, absorbing thermal energy from the gearbox and delivering it to the compartment, thereby enabling efficient heat transport without requiring direct thermal contact between the moving gearbox and the heating system.
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
Provides sustainable and cost-effective heating by utilizing gearbox waste heat, ensuring continuous operation and preventing overheating, while reducing electrical energy consumption and prolonging gearbox component life.
Implementation Method 1
a first heat exchanger, arranged in and/or on the gearbox and/or connected to a gearbox oil circuit, wherein the first heat exchanger is configured to transmit waste heat of the gearbox to a fluid stream
Implementation Method 2
a second heat exchanger, configured to transmit heat from the fluid stream to a passenger compartment and/or driver compartment of the railway vehicle
Implementation Method 3
a circulation duct system, configured to circulate the fluid stream between the first heat exchanger and the second heat exchanger
Data Source
Figure 1
AI summary
It is proposed a railway vehicle, comprising - an electric traction motor, - a gearbox, configured to transmit a traction torque from the electric traction motor to a drive wheel of the railway vehicle, - a first heat exchanger, arranged in and/or on the gearbox and/or connected to a gearbox oil circuit, wherein the first heat exchanger is configured to transmit waste heat of the gearbox to a fluid stream, - a second heat exchanger, configured to transmit heat from the fluid stream to a passenger compartment and/or driver compartment of the railway vehicle, - a circulation duct system, configured to circulate the fluid stream between the first heat exchanger and the second heat exchanger. Furthermore, a production method and a use of the railway vehicle according to the invention are proposed.