Interchangeable Power Modules for Electric Machine Downtime
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Solution Overview
Problem
Existing electric machines face challenges such as prolonged downtime due to battery charging times, limited power sources, and reduced infrastructure compatibility, which hinder their efficiency and versatility in construction and mining applications.
Innovation Solution
The implementation of an electric machine design featuring interchangeable power modules and bays, allowing for various power sources to be seamlessly integrated, including batteries, ultracapacitors, fuel cells, and generator modules, which can be easily swapped or charged, enabling flexible power management and reduced downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries are used to power an electric machine, then environmental advantages and torque profile are improved, but charging time increases leading to machine downtime
Solution Approach 1:
The power source is divided into separate battery modules that can be independently removed and replaced. Each module contains its own battery cells and can be quickly swapped without waiting for charging, allowing one module to be used while another is charged or replaced.
Solution Approach 2:
The system changes from a single fixed power source to multiple interchangeable power modules with different capacities and charging states. This allows selection of modules based on immediate power needs and charging availability, transforming the time parameter from a constraint to a manageable variable.
2Device complexity
If a single power source is used in an electric machine, then system simplicity is maintained, but power source versatility and adaptability are reduced
Solution Approach 1:
The power bay is designed with a universal interface that can accommodate multiple types of power modules including batteries, ultracapacitors, fuel cells, and generator modules. This single bay design serves multiple functions by accepting different power source types while maintaining a consistent mechanical and electrical interface.
Solution Approach 2:
The system transitions from a static single power source configuration to a dynamic multi-module configuration where modules can be added, removed, and reconfigured based on operational requirements. The controller dynamically manages power distribution among multiple modules.
3Object-generated harmful factors
If battery power sources are used, then emissions are reduced, but infrastructure options and power source replacement flexibility are limited
Solution Approach 1:
The power system is segmented into interchangeable modules that can be independently selected and replaced. This segmentation allows the machine to adapt to different infrastructure conditions by swapping modules rather than being locked into a single power source type.
Solution Approach 2:
The system enables parameter changes in power source type, capacity, and energy density by replacing modules. This allows optimization for different operational scenarios such as extended runtime, rapid discharge, or available charging infrastructure without changing the fundamental machine design.
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 enhances the operational efficiency and versatility of electric machines by allowing quick power source changes, minimizing downtime, and accommodating diverse power sources, thereby improving worker and capital efficiency and equipment uptime.
Implementation Method 1
Inverters convert direct current (DC) power from the power storage units to alternating current (AC) power to drive the electric motors
Implementation Method 2
The drive motor is configured to propel the electric machine using the power received from the electrical module
Data Source
AI summary
An electric machine and method for powering the electric machine using interchangeable power modules that are configured to be interchangeably placed within power bays of the electric machine is disclosed. The electric machine includes an electrical module that is configured to receive power from one or more of the power modules placed in the power bays and transform, such as from DC to multi-phase alternating current (AC), and provide the power to one or more motors of the electric machine. The power modules may be of the same dimensions, same electrical interfaces, and/or same power output (e.g., type, magnitude) as each other to enable the interchangeability of the power modules. The power modules may be ones that generate power or ones that store energy. In some cases, the generating power modules may charge the energy storage power modules, while the energy storage power modules power the electric machine.