Hybrid Power Controller Segmentation for Energy Efficiency
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Solution Overview
Problem
Conventional machines with both electric and hydraulic devices face challenges in controlling electric and hydraulic power effectively, leading to inefficiencies and undesirable performance.
Innovation Solution
A system and method involving a controller that receives request and operation signals from both electric and hydraulic devices, using a control strategy with subsystem and supervisory controls to determine and provide control signals for optimal power management, including range signals for acceptable power levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If both electric and hydraulic devices are used to perform working functions, then energy efficiency is improved through recaptured energy utilization, but power control complexity increases
Solution Approach 1:
The control system is segmented into multiple independent controllers: an electric device controller (58a) that manages electric motor/generator operations, a hydraulic device controller (58b) that manages hydraulic pump/motor operations, and a supervisory controller (58c) that coordinates between them. This segmentation allows each controller to specialize in specific device management while the supervisory controller optimizes overall energy utilization, resolving the complexity issue through modular architecture.
Solution Approach 2:
The system dynamically switches between electric and hydraulic power sources based on real-time operational demands and recaptured energy availability. The supervisory controller continuously monitors system state and adjusts power distribution dynamically, allowing the machine to adapt to varying load conditions and maximize energy efficiency without requiring complex manual intervention.
2Power
If power supply to electric and hydraulic devices is increased, then machine performance is improved, but energy consumption increases
Solution Approach 1:
The supervisory controller (58c) implements feedback control by continuously monitoring the operational state of electric and hydraulic devices, recaptured energy levels in storage devices (42, 54), and power demand. Based on this feedback, the controller optimizes power distribution in real-time, increasing power supply when recaptured energy is available and performance is prioritized, while reducing power consumption when energy resources are limited.
Solution Approach 2:
The system changes operational parameters such as motor speed, pump displacement, and power distribution ratios based on real-time conditions. The supervisory controller adjusts these parameters dynamically to achieve optimal balance between machine performance and energy consumption, allowing high performance when energy is abundant and efficient operation when energy is constrained.
Data Source
AI summary
Disclosed is a system for controlling power in a machine. The system includes a controller configured to determine a level of power to be provided or consumed by at least one of an electric device and a hydraulic device based on request signals, operation signals, and a control strategy for controlling at least one of electric power and hydraulic power for the machine, and provide control signals for controlling operation of the at least one device. The control strategy includes a subsystem control and a supervisory control. The subsystem control includes at least one of electric and hydraulic subsystem controls for controlling operation of at least one of an electric device and a hydraulic device. The subsystem control is configured to provide range signals indicative of at least one of a range of acceptable electric power levels and a range of acceptable hydraulic power levels, and the supervisory control is configured to determine the control signals.