Working Machine Energy Return Threshold Control
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Solution Overview
Problem
Electric off-highway working machines face challenges in maintaining productivity due to the risk of fully discharging their batteries or depleting hydrogen stores while operating on worksites, leading to insufficient energy to return to charging points.
Innovation Solution
A control system that calculates a travel energy threshold based on the distance to a charging location and the current energy level of the machine, providing alerts and activating restricted or limp home operation modes to ensure the machine can safely return to a charging point, thereby preventing full discharge and optimizing on-site working time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the working machine operates continuously on the worksite, then productivity is improved, but the risk of full battery discharge increases
Solution Approach 1:
The control system performs preliminary calculation of the travel energy threshold required to return to the charging location before the machine actually needs to return. By comparing this pre-calculated threshold with the current energy level, the system proactively identifies when the machine should return, preventing the harmful state of full discharge while maximizing productive operation time.
2Reliability
If the machine returns to charging point frequently, then battery discharge risk is reduced, but productivity decreases
Solution Approach 1:
The control system continuously monitors the current energy level and compares it against the pre-calculated travel energy threshold. This feedback mechanism provides real-time information about the machine's energy status relative to its ability to return, enabling operators to make informed decisions about when to return for charging, thus optimizing the balance between reliability and productivity.
3Reliability
If the control system provides early alert, then safe return is ensured, but working time is reduced
Solution Approach 1:
The system calculates the travel energy threshold in advance based on the distance to the charging location and machine characteristics. By providing the alert when the current energy level reaches this pre-determined threshold, the system ensures safe return capability while minimizing unnecessary early returns, thus optimizing the balance between reliability and time loss.
Data Source
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AI summary
A control system is provided for an off-highway working machine comprising a ground engaging propulsion structure for propelling the working machine, a body supported on the ground engaging propulsion structure, a drive arrangement, and a transmission operable to transmit drive to the ground engaging propulsion structure. The control system calculates a travel energy threshold required to enable the working machine to travel to the charging location, and provide an alert based on the travel energy threshold.