Parallel Hybrid Drive System for Mobile Waste Shredders
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Solution Overview
Problem
Mobile shredding machines face inefficiencies and throughput limitations due to the high noise levels, poor energy efficiency, and inability to handle sudden power peaks with existing hydraulic drive systems, which also pose environmental risks.
Innovation Solution
A mobile waste shredding device with a parallel hybrid drive system comprising an internal combustion engine, two powertrains, an energy converter, an auxiliary motor, and an energy store, allowing for efficient energy storage and supply during periods of high and low power demand, and enabling continuous speed and torque adjustments through a continuously variable transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a hydraulic drive system is used to adapt the diesel engine speed to the shredding shaft speed, then speed variability and torque control are achieved, but energy efficiency deteriorates to approximately 0.14 to 0.24
Solution Approach 1:
The patent replaces the hydraulic drive system with a direct mechanical coupling between the diesel engine and the shredding shaft. This eliminates the hydraulic pumps and motors that caused significant energy losses, while speed adaptation is achieved through a continuously variable transmission (CVT) mechanism that mechanically couples the components without hydraulic intermediaries.
Solution Approach 2:
The patent extracts and removes the hydraulic drive components (pumps, motors, and associated fluid system) from the power transmission chain. By taking out these inefficient components, the system achieves direct mechanical power transmission, improving energy efficiency from 0.14-0.24 to approximately 0.8-0.9 while maintaining speed control capabilities through alternative means.
2Force
If a hydraulic drive system is used for power transmission, then torque control is achieved, but noise levels increase significantly
Solution Approach 1:
The patent substitutes the hydraulic transmission system with a direct mechanical coupling and CVT mechanism. This eliminates the hydraulic pumps and motors that generate high noise levels, while torque control is maintained through mechanical means including the CVT ratio adjustment and direct engine-to-shaft power transmission.
3Power
If the diesel engine operates at high speed to provide power, then power output is achieved, but CO2 emissions increase
Solution Approach 1:
The patent implements a dynamically adaptable power transmission system using a continuously variable transmission (CVT) mechanism. This allows the system to optimize the engine operating point dynamically, keeping the diesel engine operating at its most efficient and lowest-emission speed range while still delivering the required power output to the shredding shaft through variable ratio transmission.
Solution Approach 2:
The patent changes the operating parameters of the diesel engine by using a CVT mechanism that can adjust the effective speed ratio between engine and shaft. This parameter adjustment allows the engine to operate at optimal efficiency points, reducing CO2 emissions while maintaining required power output through variable transmission ratio control.
4Speed
If a hydraulic drive system is used, then speed control is achieved, but device complexity increases
Solution Approach 1:
The patent extracts and removes the complex hydraulic drive system including pumps, motors, valves, and fluid circuitry. Speed control is achieved through a simpler mechanical continuously variable transmission (CVT) mechanism that provides continuous speed adjustment without the complexity of hydraulic systems, reducing overall device complexity while maintaining speed control capability.
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 solution significantly improves energy efficiency, reduces noise emissions, and enhances throughput capacity by compensating for power peaks, leading to a smaller diesel engine requirement and lower CO2 emissions, with efficiency improvements from 0.4-0.6 to 0.8-0.9 and a noise reduction of at least 5 dB(A).
Implementation Method 1
at least one energy converter coupled to the internal combustion engine in the first powertrain for converting mechanical energy of the internal combustion engine into storable energy
Implementation Method 2
at least one auxiliary motor supplied with the storable energy in the first powertrain for introducing mechanical energy into the first powertrain
Data Source
AI summary
A waste shredding device including at least one shredding shaft; an internal combustion engine; a first and a second powertrain between the internal combustion engine and the shredding shaft; at least one energy converter coupled to the internal combustion engine in the first powertrain for converting mechanical energy of the internal combustion engine into storable energy; and at least one auxiliary motor supplied with the storable energy in the first powertrain for introducing mechanical energy into the first powertrain. The waste shredding device additionally includes an energy store for storing at least part of the storable energy in the event of periods with low power demand and for at least partially supplying the at least one auxiliary motor with the storable energy in the event of periods of high power demand.