Hybrid Work Machine Power System Integration
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Solution Overview
Problem
Existing work machines face challenges in efficiently integrating and cooling hybrid power systems, which include motors, inverters, batteries, and engines, due to spatial and thermal management demands.
Innovation Solution
A work machine design featuring a rotary electrical device, an electric power controller, and a cooling fan configuration that supports both air and water cooling systems, with elastic mount devices for structural support and thermal management, allowing for efficient power transmission and cooling of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hybrid power systems (motor, inverter, battery, engine) are integrated into work machines, then power source versatility and operational efficiency are improved, but device complexity and spatial arrangement challenges increase
Solution Approach 1:
The patent combines the inverter and rotary electrical device into a single integrated housing structure. The inverter is disposed within the housing of the rotary electrical device, merging two complex components into one unified assembly. This reduces the number of separate components that need to be arranged and integrated into the work machine, thereby reducing system integration complexity while maintaining hybrid power system versatility
Solution Approach 2:
The housing of the rotary electrical device serves multiple functions: it encloses and protects the rotary electrical device components, houses the inverter within it, provides mounting surfaces for both the rotary electrical device and inverter, and acts as a structural component of the overall power system. This multi-functionality reduces the need for separate structural elements, simplifying the overall system integration
2Adaptability or versatility
If multiple components (engine, rotary electrical device, actuator) are arranged in the work machine, then functional capabilities are improved, but spatial arrangement and layout challenges worsen
Solution Approach 1:
The inverter and rotary electrical device are merged into a single housing assembly, occupying a more compact space than if they were separate components. This integrated arrangement allows for more efficient use of available space in the work machine, accommodating all necessary functional components (engine, rotary electrical device, actuator) within a reduced overall footprint
Solution Approach 2:
The inverter is nested within the housing of the rotary electrical device, with the inverter disposed inside the rotary electrical device housing. This nesting arrangement allows smaller components to be placed within the structural envelope of larger components, maximizing space utilization and reducing the total volume required for all components
3Temperature
If cooling systems are added to manage thermal loads, then thermal management effectiveness is improved, but device complexity and dust accumulation issues worsen
Solution Approach 1:
A dust cover is introduced as an intermediary component that seals the housing of the rotary electrical device. This dust cover prevents dust and contaminants from entering the cooling system and accumulating on heat-generating components, thereby maintaining thermal management effectiveness without requiring complex filtration or maintenance systems. The elastomeric material of the dust cover provides effective sealing while accommodating thermal expansion and vibration
4Reliability
If elastic mount devices are used for supporting components, then vibration isolation and reliability are improved, but structural complexity increases
Solution Approach 1:
The mounting structures for the rotary electrical device and inverter are integrated into the housing itself. The housing provides mounting surfaces and structural support for both components, eliminating the need for separate mounting brackets or fixtures. This integrated mounting approach reduces structural complexity while maintaining vibration isolation through the housing's inherent structural design and material properties
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 design enables effective thermal management and power transmission, enhancing the operational efficiency and reliability of hybrid work machines by integrating hybrid power systems while minimizing dust and heat-related issues.
Implementation Method 1
The cooling fan is provided behind the engine in the front-rear direction to generate an air flow at least from the rotary electrical device to the cooling fan
Implementation Method 2
The rotary electrical device is provided in front of the engine in a front-rear direction of the work machine to move the machine body and has a water cooling structure
Implementation Method 3
The second mount device includes a first elastic body provided directly on the first lateral extension. The third mount device includes a second elastic body provided directly on the second lateral extension
Data Source
AI summary
A work machine includes a machine body, an engine, a rotary electrical device, and an electric power controller. The engine is provided on the machine body to move the machine body. The rotary electrical device is provided on the machine body to move the machine body. The electric power controller is disposed above the rotary electrical device in a height direction along a height of the work machine to control the rotary electrical device.