Hydraulic Heat Recovery for Working Machine Cab Heating
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Solution Overview
Problem
Hybrid and electric working machines face challenges in efficiently managing thermal energy for heating and cooling, leading to reduced productivity and operating efficiency due to the limited availability and quality of energy for heating or cooling, especially when electrical energy from batteries is used, which can compromise working operations.
Innovation Solution
A thermal management system that utilizes a hydraulic fluid heat exchanger and heat pump circuit to efficiently transfer and manage heat energy within the working machine, including the use of excess heat from the hydraulic fluid to warm or cool the operator structure and dissipate excess heat, optimizing the use of heat energy and reducing the reliance on electrical energy for heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electrical energy from batteries is used to provide heating or cooling, then operator comfort and component operating temperature can be maintained, but available energy for working operations is reduced, compromising working efficiency
Solution Approach 1:
The system captures waste heat from the hydraulic fluid that would otherwise be dissipated to the atmosphere and converts it into a useful resource for heating the operator structure and hydraulic fluid, transforming a harmful thermal byproduct into a beneficial energy source
Solution Approach 2:
A heat exchanger is introduced as an intermediary device to transfer thermal energy from the hydraulic fluid to the operator structure and hydraulic fluid reservoir, enabling thermal energy recovery without direct thermal contact between systems
2Temperature
If waste heat from hydraulic fluid is dissipated to atmosphere, then hydraulic fluid temperature can be controlled, but useful heat energy is lost that could be used for heating operator structure
Solution Approach 1:
The system transforms the harmful effect of waste heat dissipation into a beneficial resource by capturing and redirecting the thermal energy to heat the operator structure and hydraulic fluid, eliminating energy loss while maintaining temperature control
Solution Approach 2:
The thermal management system performs multiple functions simultaneously: it controls hydraulic fluid temperature, heats the operator structure, and recovers waste heat energy, replacing the need for separate heating and cooling systems
3Loss of energy
If a smaller ICE is used in hybrid configuration to reduce fuel consumption, then emissions and fuel usage are reduced, but power output is insufficient for full machine operation
Solution Approach 1:
The system merges two power sources (smaller ICE and battery electric motor) into a hybrid powertrain that combines their outputs, allowing the machine to achieve sufficient total power while the smaller ICE reduces fuel consumption and emissions during electric-only or hybrid operation modes
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 the efficient use of excess heat energy from the hydraulic fluid to maintain optimal operating temperatures for the machine's components and operator comfort, reducing the need for electrical energy and enhancing the overall efficiency and productivity of the working machine by minimizing energy consumption for heating and cooling.
Implementation Method 1
a heat exchanger arranged to selectively remove or supply heat energy from or to the hydraulic fluid circuit
Implementation Method 2
a thermal management system connecting the heat exchanger to the operator structure heater and/or cooler and/or the device to direct excess heat energy to atmosphere and/or liberate heat energy from atmosphere to transfer heat from and/or to the hydraulic fluid
Implementation Method 3
an electric heater arranged to supply heat energy to the thermal management system to pre-heat the hydraulic fluid and//or the operator structure
Implementation Method 4
a hydraulic fluid heat exchanger immersed in the hydraulic fluid
Data Source
Figure 1
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AI summary
A working machine comprising a hydraulic fluid circuit an operator structure and a thermal management system. The thermal management system connects an operator structure heater and a heat exchanger arranged to selectively remove heat energy from the hydraulic fluid circuit, so as to be capable transferring heat from the hydraulic fluid to the operator structure.