Extended-Range Hybrid Crane Power Split for Efficient Travel and Lifting
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Solution Overview
Problem
Traditional cranes face inefficiencies in power management due to differing power demands for chassis travel and upper body operation, leading to high gasoline consumption, emissions, and structural challenges with double-engine configurations, while electric cranes have limited adaptability and battery life.
Innovation Solution
An extended-range hybrid power system with a power battery, all-in-one controller, first and second motors, and an engine, allowing for various operating and traveling modes to optimize power usage, including plug-in, pure electric, and hybrid modes for the upper body, and pure electric and extended-range modes for the lower body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single engine is used to provide power for both chassis travel and upper body operation, then the structural arrangement is simple, but the engine cannot operate within a high-efficiency range during upper body operation, leading to high gasoline consumption
Solution Approach 1:
The power system is segmented into two independent power sources: a chassis engine dedicated to traveling mechanism and an upper engine dedicated to upper operating mechanism. This segmentation allows each engine to operate independently according to its specific power demands, enabling the upper engine to maintain high-load operation within efficient ranges during upper body operations, thereby reducing overall gasoline consumption while keeping the structural arrangement relatively simple.
2Power
If a double-engine configuration is adopted to satisfy both traveling power and operating power requirements, then the power demands are met, but the overall cost and weight are increased
Solution Approach 1:
The system divides power provision into two specialized engines: chassis engine for traveling and upper engine for operating mechanisms. This segmentation ensures each engine is optimally sized for its specific function, avoiding the need for oversized engines that would increase weight, while still meeting all power demands.
Solution Approach 2:
The invention changes the operational parameters by allowing the upper engine to operate at high loads during upper body operations, which improves fuel efficiency and reduces the need for excessive engine capacity, thereby controlling weight while satisfying power requirements.
3Power
If the chassis engine operates at high power to meet traveling demands, then the traveling power requirement is satisfied, but the engine cannot operate within a high-efficiency range during upper body operation
Solution Approach 1:
The power system is divided into two independent engines with separate functions: the chassis engine handles traveling power demands and the upper engine handles upper body operation demands. This segmentation allows the upper engine to operate continuously at high loads within its efficient range during upper body operations, while the chassis engine maintains high power capability for traveling, thereby satisfying both power requirements while optimizing overall engine efficiency.
4Object-generated harmful factors
If pure electric cranes are used to reduce emissions, then environmental friendliness is improved, but the adaptability to road traveling and operation is poor due to short battery life
Solution Approach 1:
The invention introduces a hybrid power system that acts as an intermediary between pure electric and traditional engine-powered cranes. The system uses a power battery as the primary power source for zero-emission operation during upper body tasks, while incorporating a chassis engine that can provide extended-range power when battery charge is insufficient, thereby maintaining environmental friendliness while improving adaptability for both traveling and operation.
5Power
If the engine operates at low speed and low load during upper body operation, then power matching is achieved, but exhaust gas temperature is low causing carbon deposition and complex emission control
Solution Approach 1:
The invention changes the operational parameters of the upper engine by enabling it to operate at high loads during upper body operations, which maintains exhaust gas temperature above the carbon deposition threshold. The high-load operation mode improves combustion efficiency and prevents carbon buildup, while the separate engine configuration allows this high-load operation without compromising power matching for specific tasks.
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
Reduces gasoline consumption and emissions, improves adaptability, and enhances working efficiency by optimizing engine operation within high-efficiency ranges, while minimizing energy waste and noise.
Implementation Method 1
a power battery, an all-in-one controller, a first motor, a second motor and an engine
Implementation Method 2
the first motor is connected to a lower traveling mechanism
Implementation Method 3
the engine is connected to the second motor, and the second motor is connected to an upper operating mechanism
Implementation Method 4
the engine is connected to the second motor
Data Source
AI summary
The invention discloses an extended-range hybrid power system and a control method therefor, and a crane, and belongs to the technical field of construction machinery. The extended-range hybrid power system comprises a power battery, an all-in-one controller, a first motor, a second motor and an engine, wherein the first motor is connected to a lower traveling mechanism; the engine is connected to the second motor, and the second motor is connected to an upper operating mechanism; the power battery, the first motor and the second motor are connected to the all-in-one motor, and the all-in-one motor is connected to an external power supply.