Hybrid Crusher Drive Layout for Peak Load Energy Efficiency
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Solution Overview
Problem
Existing mineral processing plants face inefficiencies due to oversized motor generators, leading to unfavorable energy efficiency, especially in modes requiring generator operation without external power supply.
Innovation Solution
Separate electric motor and generator components, allowing optimization for specific requirements, and use of a clutch system to disconnect or connect them as needed, along with an energy storage device for peak load management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a motor generator is used to drive the crushing device in mobile operation mode, then the plant can operate without external power supply, but the motor generator becomes oversized and inefficient
Solution Approach 1:
The patent divides the drive system into two separate components: a motor generator for electric power supply and a separate electric motor for direct crushing device drive. This segmentation allows each component to be optimized for its specific function, preventing the motor generator from being oversized when used alone in mobile mode.
Solution Approach 2:
The electric motor is designed to serve multiple functions: it can drive the crushing device directly in mobile operation mode, and it can also function as a generator during regenerative braking or peak load scenarios. This multi-functionality eliminates the need for a separate generator, improving overall system efficiency.
2Reliability
If the motor generator is oversized to handle peak loads, then the plant can operate independently, but drag power losses increase during normal operation
Solution Approach 1:
The patent implements a dynamic clutch system that can disconnect the electric motor from the crushing device during normal operation, allowing the motor to be uncoupled and avoided drag power losses. During peak loads or mobile operation, the clutch engages to provide additional drive capability, ensuring reliable independent operation when needed.
3Use of energy by moving object
If a separate electric motor is added to the system, then the crushing device can be optimized for average power requirements, but the system complexity increases
Solution Approach 1:
The patent merges the electric motor and generator into a single integrated unit that can function in both modes. The electric motor is mechanically coupled to the crushing device through a clutch, and electrically coupled to the generator through a power electronics system, combining multiple functions into a unified component to reduce overall system complexity.
4Power
If the internal combustion engine drives the generator continuously, then electric power is supplied to auxiliary units, but the engine cannot be optimized for average power requirements
Solution Approach 1:
The system implements self-service through regenerative braking and peak load capture. During braking or peak demand, the electric motor generates electricity that is fed back into the power electronics system, reducing the burden on the internal combustion engine and allowing it to operate at more efficient average power levels throughout the day.
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
Enhances energy efficiency by avoiding drag losses and optimizing power transmission, enabling emission-free operation and compact design.
Implementation Method 1
a clutch (19) is provided, by means of which the electric motor (20) can be mechanically disconnected from the generator (15) and/or the internal combustion engine (10)
Implementation Method 2
a generator (15) is provided, which is mechanically coupled to the internal combustion engine (10) to drive this generator
Implementation Method 3
an electric motor (20) separate from the generator (15), which electric motor is mechanically coupled to the crushing device (13)
Implementation Method 4
an internal combustion engine (10)
Data Source
AI summary
A mineral processing plant for crushing mineral material or the like, using a crushing device and an internal combustion engine. In a first mode of operation an internal combustion engine is mechanically coupled to the crushing device to drive the latter. A generator is provided, which is mechanically coupled to an internal combustion engine to drive this generator, and the generator is coupled to one or more auxiliary units to supply to supply electric power thereto. An electric motor is provided separately from the generator, which electric motor is mechanically coupled to the crushing device in a second operating mode to drive the crushing device.