Interchangeable Power Source Control for Construction Machines
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Solution Overview
Problem
Conventional machines with hydraulic power sources, such as hydraulic excavators, require complex systems associated with internal combustion engines, including fuel storage, fuel supply, and exhaust aftertreatment systems, which are inefficient and emit undesirable emissions, and lack flexibility for alternative power sources like battery-powered systems.
Innovation Solution
A machine configuration and control system enabling interchangeable power sources, including an undercarriage, upper structure, and a swing frame that supports multiple power sources like internal combustion engines, batteries, and fuel cells, with a control system that standardizes power output and operation across different power sources using a power system electronic control module and display controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an internal combustion engine is used as the power source, then the machine can operate with proven technology and sufficient power, but the machine requires complex systems (fuel storage, fuel supply, exhaust aftertreatment, cooling) and produces undesirable emissions
Solution Approach 1:
The machine is designed with a universal power source interface that can accommodate multiple types of power sources (internal combustion engine, battery, fuel cell). The control system automatically detects the connected power source type and adjusts operating parameters accordingly, allowing a single machine platform to serve multiple power source configurations without requiring separate specialized designs for each power source type.
2Power
If an internal combustion engine is used as the power source, then the machine can provide sufficient power, but the machine generates undesirable emissions and has reduced efficiency
Solution Approach 1:
The control system dynamically adjusts operating parameters such as power output levels, speed ranges, and operational modes based on the detected power source type. When a battery or fuel cell is detected, the system optimizes parameters to maximize efficiency and minimize emissions, whereas with an internal combustion engine, parameters are adjusted to balance power output with acceptable emission levels, thereby adapting the machine's operational characteristics to the specific power source being used.
3Productivity
If the machine is designed for a specific power source, then the control system can be optimized for that power source, but the machine lacks flexibility to use alternative power sources
Solution Approach 1:
The control system is designed to dynamically adapt its behavior based on the detected power source type. Upon detecting a power source, the system automatically reconfigures control parameters, power management strategies, and operational modes to match the characteristics of that specific power source. This dynamic adaptation allows the same control hardware and software to efficiently manage different power source types without requiring separate dedicated control systems for each power source type.
Data Source
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AI summary
A machine control system controls operation of any one of a plurality of interchangeable power sources (33) mounted on a machine (2). The machine includes an undercarriage supporting ground engagement members (4) that propel the machine (2) and an upper structure (6) rotatably supported on the undercarriage. The upper structure includes a swing frame (22) that supports an operator cab (24), an interchangeable power source (33), hydraulic components, and electrical components. The machine control system includes a processor configured to receive variables, control parameters, and standards associated with operation of each of the plurality of power sources from one or more of sensors, input devices, output devices, and memory communicatively coupled to the processor, utilize control logic, machine operational inputs and outputs, sensed and processed signals associated with position, movement, and operation of the machine, and one or more of stored, sensed, and processed data, variables, control parameters, and standards to process outputs and operating characteristics specific to each of the plurality of power sources, and standardize the power output by each of the power sources to provide a normalized, consistent control and operation of systems of the machine regardless of which of the power sources is mounted on the machine.