Hybrid Construction Machine Power Unit Layout
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Solution Overview
Problem
Conventional hybrid hydraulic shovels face difficulties in mounting a power unit comprising an engine, hydraulic pump, and generator/motor on the swiveling frame of mini-shovels with minimal tail swing or minimal swing radius, due to dimensional restrictions, making hybridization challenging for these machines.
Innovation Solution
A hybrid construction machine design that efficiently utilizes space by placing the generator/motor above the hydraulic pump and overlapping with it when viewed from above, allowing for a downsized engine and auxiliary devices, and using a gear box to support the power unit, enabling standardization of the swiveling frame and hydraulic pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the upper swing structure is designed with minimal tail swing radius or minimal swing radius to operate in restricted worksites, then the machine can operate in small or restricted worksites, but the dimensional restrictions make it difficult to mount a power unit comprising engine, hydraulic pump, and generator/motor
Solution Approach 1:
The generator/motor is positioned vertically above the hydraulic pump, utilizing the vertical dimension rather than horizontal space. This allows the power unit components to be stacked in the vertical direction, accommodating the minimal swing radius dimensional constraints while still including all necessary components (engine, hydraulic pump, generator/motor) in the power unit
Solution Approach 2:
The generator/motor is placed within the vertical space above the hydraulic pump, creating a nested arrangement where components are arranged in layers. The engine is positioned horizontally, the hydraulic pump below, and the generator/motor vertically above the pump, efficiently utilizing the limited space within the swiveling frame
2Length of stationary object
If the engine and auxiliary devices are downsized to fit the minimal swing radius configuration, then the machine fits in restricted worksites, but the power output may be insufficient
Solution Approach 1:
The generator/motor serves dual functions as both a generator and a motor. When operating as a motor, it provides additional power assistance to the hydraulic pump, compensating for the downsized engine's reduced power output. This merging of functions allows the system to maintain sufficient power while using a smaller engine that fits the minimal swing radius constraints
3Ease of manufacture
If a gear box is introduced to support the power unit and enable standardization, then the swiveling frame and hydraulic pipes can be standardized, but the device complexity increases
Solution Approach 1:
The gear box serves multiple functions: it supports the power unit structurally, transmits power between components, and enables standardization of the swiveling frame and hydraulic pipe connections. By designing the gear box as a multi-functional component, the patent achieves standardization benefits while managing the added complexity through consolidated functionality
Data Source
AI summary
Provided is a hybrid construction machine capable of facilitating the hybridization (conversion, redesigning, etc. into a hybrid construction machine) even for construction machines of the minimal tail swing radius type or the minimal swing radius type. A hybrid mini-shovel of the minimal tail swing radius type comprises an engine, a hydraulic pump whose input shaft is coaxially connected to the output shaft of the engine, a generator/motor whose rotating shaft is connected to the output shaft of the engine and the input shaft of the hydraulic pump via a gear mechanism, and a battery which receives and supplies electric power from/to the generator/motor. The generator/motor is placed at a vertical position where its lower end is situated above the shaft center of the input shaft of the hydraulic pump, and when viewed from above at a horizontal position where it overlaps with the hydraulic pump.