Hybrid Powertrain Controller for Combine Harvesters
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Solution Overview
Problem
Modern combine harvesters equipped with large internal combustion engines face inefficiencies and increased emissions due to operating at sub-optimal power levels during most phases of operation, which can lead to inadequate power output and reduced harvesting efficiency when downsizing the engine.
Innovation Solution
The intelligent hybrid powertrain system incorporates an electric drive subsystem with a motor/generator and a controller architecture that strategically switches between power assist and rapid charge modes to supplement engine power and recharge the battery, optimizing energy use and maintaining sufficient power during grain tank filling and unloading phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the internal combustion engine is downsized to improve fuel economy and reduce emissions, then fuel consumption and emissions decrease, but power output becomes insufficient during demanding operations
Solution Approach 1:
The patent combines the internal combustion engine with an electric motor to form a hybrid powertrain system. The electric motor is integrated with the engine through a coupling mechanism, allowing both power sources to work together to deliver combined power output during demanding operations while the engine can operate at efficient load points for improved fuel economy.
Solution Approach 2:
The patent introduces a battery system as an intermediary energy storage device between the engine and the electrical load. The battery can store excess energy when the engine is operating efficiently and provide supplemental power during high-demand periods, enabling engine downsizing while maintaining adequate power output.
2Object-generated harmful factors
If the internal combustion engine is downsized to reduce emissions, then harmful emissions decrease, but power availability during heavy loading conditions becomes insufficient
Solution Approach 1:
The hybrid powertrain merges the downsized internal combustion engine with an electric motor system. This combination allows the engine to operate at optimal efficiency points with reduced emissions while the electric motor provides supplemental power during heavy loading conditions such as high-yield crop harvesting and uphill operation.
Solution Approach 2:
The patent utilizes the ability to dynamically change the operational parameters of the powertrain system by switching between different power sources and operating modes. The control system can adjust the contribution of the engine versus the electric motor based on real-time operating conditions, allowing the downsized engine to maintain lower emissions while power availability is ensured through electric supplementation.
3Device complexity
If a single internal combustion engine powers all functions including propulsion and grain tank unloading, then the system structure remains simple, but the engine must be oversized to handle peak power demands during on-the-go unloading
Solution Approach 1:
The patent combines the propulsion system and grain tank unloading system through a hybrid powertrain architecture. The electric motor can independently power the grain tank unloading function during on-the-go operations, allowing the internal combustion engine to be downsized since it no longer needs to provide peak power for both propulsion and unloading simultaneously.
4Power
If the engine is sized for peak demand conditions to ensure adequate power output, then power availability is sufficient during demanding operations, but the engine operates at sub-optimal power levels during most phases reducing efficiency
Solution Approach 1:
The patent implements a dynamic powertrain system where the control system continuously adjusts the operational state of the engine and electric motor based on real-time power demands. This allows the downsized engine to operate dynamically at or near its optimal efficiency point across varying operating conditions, rather than being constrained to run at sub-optimal loads to match peak demand requirements.
Solution Approach 2:
The hybrid powertrain system enables continuous parameter changes in the power delivery characteristics by adjusting the contribution ratio between the engine and electric motor. This allows the engine to maintain optimal operating parameters across different phases of combine harvester operation, improving overall energy efficiency while ensuring adequate power availability through electric supplementation when needed.
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 enables engine downsizing, improving fuel economy, reducing emissions, and enhancing harvesting efficiency by maintaining optimal engine speed ranges and ensuring adequate power supply, while allowing for repeated combine harvest cycles.
Implementation Method 1
a motor/generator, which is configured to be selectively powered by the battery supply to supplement the engine power output
Implementation Method 2
powered by the engine to charge the battery supply
Implementation Method 3
an electric drive subsystem. The electric drive subsystem includes, in turn, a battery supply
Data Source
AI summary
Embodiments of an intelligent hybrid powertrain system include an engine, a controller architecture, and an electric drive subsystem having a battery supply and a motor/generator. The controller architecture is configured to: (i) monitor a current state of charge (SoC) of the battery supply when the combine harvester engages in a combine harvest cycle having a tank fill phase and a tank unload phase; (ii) during the tank fill phase, operate the motor/generator to supplement the engine power output and regulate a rate of battery discharge to prevent the current SoC of the battery supply from decreasing below a lower predetermined SoC threshold prior to completion of the tank fill phase; and (iii) during the tank unload phase, operate the motor/generator to charge the battery supply until the current SoC of the battery supply is equal to or greater than a first upper predetermined SoC threshold.