Hybrid Pipelayer Power Control Strategy for Cab Conditioning
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Solution Overview
Problem
Pipelayers often spend a significant amount of operational time idling, leading to inefficiencies and increased fuel consumption, as existing counterweight arrangements and power systems do not effectively manage energy usage during these periods.
Innovation Solution
A hybrid power system in a pipelayer that includes a diesel engine as a primary power source and batteries as a secondary power source, with a control system that switches between the two based on battery power thresholds to optimize energy use, particularly for the cab conditioning system, ensuring continuous operation and reducing idle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the diesel engine runs continuously to power the cab conditioning system, then the system reliability is improved, but the fuel consumption increases and operational efficiency decreases
Solution Approach 1:
The system dynamically switches between diesel engine and battery power sources based on real-time power level monitoring. The controller activates battery power when charge exceeds threshold levels, and switches to diesel engine when battery power depletes, creating a dynamic power management strategy that optimizes fuel consumption while ensuring continuous cab conditioning operation
Solution Approach 2:
The system changes the power source parameter based on battery charge state. By monitoring battery power levels and comparing against predetermined thresholds, the system transitions between different power delivery modes (battery-only, hybrid, or diesel-only), optimizing the energy parameters to reduce fuel consumption during adequate battery charge conditions
2Loss of energy
If the diesel engine is stopped to reduce fuel consumption, then energy efficiency is improved, but the cab conditioning system may fail to operate
Solution Approach 1:
The battery serves as an intermediary energy storage device between the diesel engine and the cab conditioning system. It stores excess energy when the diesel is off and provides power when needed, acting as a buffer that allows the diesel engine to remain stopped longer while ensuring the cab conditioning system never fails due to power shortage
Solution Approach 2:
The system performs preliminary charging of the battery during periods when cab conditioning is not needed or when diesel is available, storing energy in advance. This preliminary energy accumulation allows the diesel engine to be stopped for extended periods without risking cab conditioning system failure
3Productivity
If the battery power capacity is increased to extend idle periods, then the operational efficiency is improved, but the device complexity and weight increase
Solution Approach 1:
Rather than designing a battery system with excessive capacity to cover all possible idle scenarios, the system uses a moderately sized battery combined with a predetermined power threshold strategy. This partial action approach achieves sufficient operational efficiency improvement without the disproportionate complexity and weight of an oversized battery system
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 hybrid power system reduces fuel consumption and optimizes energy use by switching to battery power when sufficient and recharging when needed, thereby enhancing operational efficiency and reducing idle time.
Implementation Method 1
The counterweight includes a battery box including at least one battery
Implementation Method 2
a first power source including an engine
Data Source
AI summary
A pipelayer includes a frame, a plurality of ground engaging members movably supporting the frame, a prime mover, and a boom assembly and a counterbalance assembly supported on the frame. The boom assembly includes a boom. The counterbalance assembly including a counterweight, the counterweight being movably supported on the frame to counterbalance the boom assembly. The counterweight includes a battery box including at least one battery. A control strategy is also disclosed.