Integrated Fluid Handling Apparatus with Electric Motor Cooling
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Solution Overview
Problem
Existing fluid handling systems in mobile equipment face challenges in fuel efficiency, noise reduction, and emission control, particularly when using fossil fuel engines for hydraulic pumps, which consume fuel and produce emissions when stationary, and struggle with packaging and heat management in tight spaces.
Innovation Solution
An integrated fluid handling apparatus that includes a fluid pump mechanism, a power take-off device mechanism, and an electric motor generator mechanism within a unitary housing, allowing for rotational power transfer and heat exchange using hydraulic fluid, with a clutch for alternating modes of operation to reduce fuel consumption and noise, and utilizing hydraulic fluid for cooling to enhance packaging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a fossil fuel engine is used to drive the hydraulic pump, then the hydraulic system can be powered, but fuel consumption increases and noise and emissions are generated
Solution Approach 1:
The system dynamically switches between engine-driven pump operation and electric motor operation based on vehicle operating conditions. The controller activates the electric motor to drive the hydraulic pump during low-power or stationary conditions, eliminating the need for continuous engine operation and reducing fuel consumption while maintaining hydraulic system power availability.
Solution Approach 2:
The electric motor is designed to perform dual functions: serving as a propulsion motor during vehicle operation and as a hydraulic pump driver during stationary or low-power conditions. This multi-functionality allows the system to power the hydraulic system without requiring separate dedicated engine operation, thereby reducing overall fuel consumption.
2Power
If the fossil fuel engine is run during stationary operation to power the hydraulic system, then hydraulic power is available, but noise and combustion fumes are generated
Solution Approach 1:
The system replaces the mechanical combustion engine with an electric motor to drive the hydraulic pump during stationary operation. This substitution eliminates combustion-related noise and emissions while maintaining hydraulic power availability, as the electric motor can be powered by the vehicle's electrical system or battery without requiring engine operation.
3Temperature
If separate cooling systems are provided for the electric motor and hydraulic system, then cooling effectiveness is maintained, but device complexity and size increase
Solution Approach 1:
The system merges the cooling functions for the electric motor and hydraulic system into a single integrated cooling circuit. The hydraulic fluid serves dual purposes: as the working fluid for the hydraulic pump and as the cooling medium for the electric motor. This is achieved by routing the hydraulic fluid through heat exchange passages in the electric motor housing, eliminating the need for separate cooling systems and reducing overall system complexity.
4Volume of stationary object
If hydraulic fluid flow passages are integrated into the electric motor housing, then heat exchange is improved and size is reduced, but manufacturing complexity increases
Solution Approach 1:
The hydraulic fluid flow passages are nested within the electric motor housing structure. The cooling channels are formed as integral features of the motor housing, with the hydraulic fluid flowing through passages that are contained within or attached to the motor housing. This nesting approach allows heat exchange between the hydraulic fluid and motor components while maintaining a compact integrated design, though it does increase manufacturing complexity.
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 integrated system reduces fuel consumption and noise, minimizes size and leakage, and effectively manages heat, enhancing packaging efficiency and reducing emissions by utilizing hydraulic fluid for cooling and power transfer, while allowing for efficient operation in both stationary and mobile applications.
Implementation Method 1
The electric motor generator may include heat exchange fluid flow passages that are connected to and establish a fluid flow path to the lower pressure fluid inlet, so that inlet flow to the fluid pump removes heat from the electric motor generator.
Data Source
AI summary
An integrated fluid handling apparatus 10 includes a power take off device 108 having a rotating power take off mechanism 122, a hydraulic pump 104 having a rotating fluid pump mechanism 146, a flow torque tube 106, and an electric motor/generator 102 having a rotating electric power conversion mechanism 173. A rotational power transfer system includes connector devices 128, 138, 166 and 172 that are drivingly connected to and that drivingly connect the mechanisms 122, 146 and 173 in one mode of operation. The electric motor/generator 102 includes heat exchange fluid flow passages that establish a fluid flow path to the inlet of the pump. The mechanisms 122, 146 and 173, and the connector devices 128, 138, 166 and 172 are assembled and used as a whole within a housing, without externally exposed mechanical drive connections and without externally exposed fluid connections, between such mechanisms and devices.