Hybrid Electric Loader Powertrain for Extended Endurance
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Solution Overview
Problem
Hydraulic loaders face issues with high component requirements, short lifespan, oil leakage, and limited battery capacity in multiple degrees of freedom numerical controlled link mechanism electric loaders, necessitating large batteries and inconvenient charging infrastructure.
Innovation Solution
A range-extended numerical controlled link mechanism electric loader with a drive system comprising an engine, generator, battery, motor, clutch, and planetary gear system, allowing five working modes to optimize power distribution and extend battery life through external charging and engine-assisted power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If batteries of very big capacities are used to satisfy requirements of endurance mileages and digging working time, then the service life of batteries deteriorates due to deep discharge
Solution Approach 1:
The power supply system is segmented into multiple components: small-capacity batteries for electric mode operation, and a hybrid system comprising engine and generator for hybrid mode operation. This segmentation allows the small batteries to operate without deep discharge while the hybrid system provides extended range, resolving the contradiction between duration and battery service life
Solution Approach 2:
The hybrid system is designed to perform multiple functions: it can operate in pure electric mode using batteries, in hybrid mode using both batteries and generator, or in engine-only mode. This multi-functionality allows the system to meet extended endurance requirements without relying solely on large-capacity batteries that would suffer from deep discharge
2Duration of action of moving object
If high power charging stations or battery swapping stations are required, then the device complexity and infrastructure requirements increase
Solution Approach 1:
The loader is equipped with a self-contained hybrid power system that includes its own engine and generator, enabling it to recharge batteries autonomously during operation or when stationary. This self-service capability eliminates the need for external high-power charging stations or battery swapping infrastructure, reducing device complexity and infrastructure requirements while maintaining extended endurance capability
3Ease of operation
If the loader is moved by trailer trucks when charging is not convenient, then the productivity and operational flexibility deteriorate
Solution Approach 1:
The hybrid system dynamically switches between different power sources and operating modes based on real-time conditions. When charging is convenient, the system charges batteries; when charging is not convenient, the engine-generator automatically takes over to provide power, allowing continuous operation without being moved by trailer trucks. This dynamic adaptability maintains both operational flexibility and productivity
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
The loader achieves flexible motion control, extended endurance mileage, reduced battery size requirements, and efficient operation without needing large charging facilities, overcoming hydraulic loader deficiencies and ensuring continuous operation.
Implementation Method 1
a generator (26), wherein a rotation shaft of the engine is connected with a clutch C3, the clutch C3 is connected with an end of a main shaft of the generator
Implementation Method 2
at least one battery (27), a motor (30), the at least one clutch, an electric control module, a power distribution mechanism and a reducer
Implementation Method 3
The power distribution mechanism comprises a planetary gear system, a planet pinion carrier of the planetary gear system is connected with a drive shaft of the reducer
Data Source
AI summary
A range-extended numerical controlled link mechanism electric loader comprising a vehicle-loaded rechargeable energy storage device, a vehicle-loaded auxiliary power supply device, a motor, a reducer, a numerical controlled link lever loading mechanism and a rack. The vehicle-loaded rechargeable energy storage device comprises at least a battery, an electric control module, and at least one charging port; the vehicle-loaded auxiliary power supply device comprises an engine and a generator; by cooperation of the vehicle-loaded rechargeable energy storage device and the vehicle-loaded auxiliary power supply device the loader can have five different working modes: low speed mode, high speed mode, hybrid low speed mode, hybrid high speed mode and energy recycling mode, by the different working modes, the wheels can be driven to rotate or the drive levers can be driven to conduct loading work.