Hybrid Planer Powertrain With Battery Boost for Peak Load
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Solution Overview
Problem
Internal combustion engines in machines like cold planers face issues with high emissions, noise, and inefficient fuel consumption due to continuous operation during idle times, which impact performance and operational costs.
Innovation Solution
A hybrid powertrain system is introduced, incorporating a motor-generator within the driveline, utilizing an energy storage system with batteries or capacitors to power hydraulic systems electrically, allowing smaller engines and reducing mechanical power reliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an internal combustion engine is used to power the planer, then reliable power is provided, but fuel costs increase and emissions are generated
Solution Approach 1:
The power system is segmented into two independent power sources: an internal combustion engine and an electric motor powered by an energy storage system. This allows the engine to be sized for average power requirements while the electric motor provides supplemental power during peak demands, reducing overall fuel consumption while maintaining reliability.
Solution Approach 2:
The energy storage system is charged during idle times or low power demand periods when the engine is running at efficient operating levels. This preliminary energy accumulation allows the electric motor to provide power during peak demands without requiring the engine to continuously operate at high fuel consumption levels.
2Power
If an internal combustion engine operates continuously to meet peak power demands, then sufficient power is available, but fuel costs and emissions increase
Solution Approach 1:
The power system merges two power sources: the internal combustion engine and the electric motor. The engine handles base load and average power requirements efficiently, while the electric motor provides supplemental power during peak demands. This combination allows peak power availability without continuous high fuel consumption.
Solution Approach 2:
The system dynamically switches between power sources based on real-time power demands. The controller monitors load requirements and automatically adjusts the contribution of each power source, allowing the engine to operate at efficient levels during low demand while the electric motor supplements during high demand periods.
3Power
If the internal combustion engine runs at high power levels to meet varying demands, then sufficient power is provided, but noise levels increase
Solution Approach 1:
The electric motor replaces the internal combustion engine for specific functions, particularly during low-power operations and hydraulic pump operation. This substitution eliminates noise from the engine during these periods, reducing overall noise pollution while maintaining power availability when needed.
4Power
If a larger engine is used to provide higher horsepower ratings, then peak power demand is met, but fuel consumption during idle times increases
Solution Approach 1:
The power system is segmented such that the internal combustion engine is sized for average power requirements rather than peak demands. The electric motor provides the supplemental power needed for peak demands, allowing the engine to operate at efficient levels during idle times without sacrificing peak power capability.
Solution Approach 2:
The electric motor serves multiple functions: it powers the hydraulic pumps during low-power operations, provides supplemental power during peak demands, and can operate independently during idle times. This multi-functionality allows the engine to be downsized while maintaining overall system 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 system enables fuel savings, reduced noise emissions, and increased horsepower without larger engines by using stored energy for power boosts, enabling efficient operation and improved machine performance.
Implementation Method 1
a generator mechanically coupled with the internal combustion engine; an energy storage system including an energy module having at least one energy storage cell, wherein the energy module is electrically coupled with the generator and configured to receive power from and be charged by the generator
Implementation Method 2
an electric motor in electrical communication with the energy module, the electric motor mechanically coupled with the rotor/cutter
Data Source
AI summary
A hybrid powertrain system of a planer, the hybrid powertrain system comprising an internal combustion engine, a rotor/cutter mechanically coupled with the internal combustion engine, a generator mechanically coupled with the internal combustion engine, an energy storage system including an energy module having at least one energy storage cell, wherein the energy module is electrically coupled with the generator and configured to receive power from and be charged by the generator, an electric motor in electrical communication with the energy module, the electric motor mechanically coupled with the rotor/cutter, and a powertrain controller in electrical communication with the internal combustion engine and the energy storage system. The powertrain controller is configured for controlling delivery of electrical power from the energy storage system to the rotor/cutter while controlling delivery of mechanical power from the internal combustion engine to the rotor/cutter.