Working Machine Thermal Management for Cab and Hydraulic Fluid
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Solution Overview
Problem
Working machines powered by batteries or hybrid configurations face inefficiencies in thermal management, leading to reduced productivity and compromised efficiency due to limited energy availability and reduced waste heat utilization for heating or cooling, particularly affecting operator comfort and hydraulic fluid viscosity.
Innovation Solution
A thermal management system that transfers thermal energy between the operator structure and hydraulic fluid based on energy requirements, using a heat exchanger and energy distribution system to optimize heating and cooling, and incorporates a coolant circuit and electric heater to pre-condition the hydraulic fluid and operator structure before operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electrical energy from batteries is used to provide heating or cooling, then operator comfort and hydraulic fluid temperature control are improved, but available energy for working operations is reduced
Solution Approach 1:
The system converts waste heat from the hydraulic fluid (which would otherwise be discarded) into a useful resource for heating the operator structure. The heat exchanger captures thermal energy from the hydraulic fluid that exceeds what is needed for optimal viscosity, and transfers it to the operator structure, thereby eliminating the need to consume valuable electrical energy for heating while still providing operator comfort.
2Loss of energy
If waste heat from ICE is utilized for heating, then energy efficiency is improved, but this heat source is reduced or eliminated in hybrid and electric configurations
Solution Approach 1:
The system enables the hydraulic fluid to serve dual purposes: performing work through hydraulic actuators and simultaneously providing thermal energy for operator comfort. The heat exchanger allows the hydraulic fluid to 'self-service' by transferring its own excess thermal energy to the operator structure, eliminating dependence on external heat sources from ICE or dedicated heating systems.
3Device complexity
If thermal energy is transferred based on temperature difference alone, then heat transfer simplicity is maintained, but energy efficiency is compromised when temperature gradients are insufficient
Solution Approach 1:
The control system monitors both the temperature and thermal energy content of the hydraulic fluid and operator structure, dynamically adjusting the thermal management strategy. When the hydraulic fluid has excess thermal energy above what is needed for optimal viscosity, the system activates heat transfer to the operator structure. This parameter-based control ensures efficient energy utilization without requiring complex additional hardware.
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
Enhances efficiency by optimizing thermal energy usage, maintaining optimal hydraulic fluid viscosity and operator comfort without relying on electrical energy, reducing energy waste, and improving overall machine performance.
Implementation Method 1
a heat exchanger arranged to selectively add and/or remove thermal energy from the hydraulic fluid circuit
Implementation Method 2
the thermal management system comprises an energy distribution system to selectively transfer thermal energy between the operator structure and the hydraulic fluid
Data Source
AI summary
A working machine having a thermal management system with an energy distribution system to selectively transfer thermal energy between an operator structure and a hydraulic fluid, based on the relative values of an operator structure energy requirement and a hydraulic fluid energy requirement.