Mixer Drum Electric Drive With Mains and Battery Power
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Solution Overview
Problem
Mixer trucks face issues with noise pollution and excessive exhaust emissions due to the operation of main combustion engines during loading, unloading, and transportation, which limits the use of start-stop systems for reducing fuel consumption and emissions.
Innovation Solution
A drive train system for mixer vehicles comprising an electric motor connected to a power mains via a mains connector, with an optional generator and battery pack, allowing the electric motor to be powered directly from the mains during loading and unloading, and independently during transport, thereby reducing engine operation and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the main engine is kept running during stops to power the PTO for mixer drum rotation, then the mixer drum can be operated during waiting periods, but noise pollution and exhaust emissions increase significantly
Solution Approach 1:
The power supply system is segmented into multiple independent sources: battery pack for low-power operations (transport, waiting), generator for medium-power operations (loading, unloading), and mains power for high-power operations. This segmentation allows the main engine to be shut off during low-power periods, eliminating noise and emissions during these times while maintaining mixer drum operation capability.
Solution Approach 2:
An intermediary power management system with controller, switch system, and electrical circuit is introduced to coordinate between multiple power sources (battery, generator, mains). This intermediary manages power flow automatically, selecting the appropriate power source based on operational requirements, thereby enabling engine shutdown during battery-powered operations while ensuring seamless power transition when high power is needed.
2Power
If the main engine is run at high revolutions during loading and unloading to provide sufficient power to the PTO, then the mixer drum can effectively push load inward or outward, but noise and emissions increase during these operations
Solution Approach 1:
Multiple power sources (battery pack, generator, mains power) are merged into a unified power supply system that can deliver high power output. During loading and unloading operations, the system combines battery power with generator output or mains power to achieve the required high power levels for the PTO, enabling the main engine to operate at lower revolutions and thus reducing noise and emissions while maintaining sufficient mixer drum power.
Solution Approach 2:
The power supply system is designed with multi-functionality, where the same electrical circuit and controller can accommodate different power sources and operational modes. The system universally supports battery-only mode, generator-assisted mode, and mains-powered mode, allowing flexible adaptation to different operational requirements without needing separate dedicated systems for each power level.
3Object-generated harmful factors
If a battery pack is used to power the mixer drum during transport and waiting, then the main engine can be switched off to reduce fuel consumption and emissions, but extremely bulky and heavy battery packs are required
Solution Approach 1:
The power supply configuration is made dynamic rather than static. The system automatically adapts its power source composition based on operational needs: using battery pack alone during low-power transport and waiting phases, combining battery with generator during medium-power loading/unloading, and utilizing mains power when available. This dynamic approach allows a smaller, lighter battery pack to suffice compared to a standalone battery system that would need to handle all power requirements.
Solution Approach 2:
Instead of relying solely on the battery pack for all power needs (which would require excessive battery capacity and weight), the system applies partial battery action during low-power operations and supplements with generator or mains power during high-power operations. This partial use of battery power allows for a more reasonable, lighter battery pack design while still achieving the goal of reducing fuel consumption during transport and waiting periods.
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 enables reduced noise and emissions during operation by allowing the main engine to be shut off during stops and high-revolution operations, while maintaining drum rotation, and provides a backup power source for extended use.
Implementation Method 1
feeding electric power from said power mains to an electric motor for driving the mixer drum and driving the mixer drum by means of the electric motor
Implementation Method 2
a generator (8) for generating electric power
Implementation Method 3
a battery pack (9) for supplying electric power
Data Source
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AI summary
The invention relates to a mixer vehicle. Such mixer vehicle can for instance be a concrete mixer truck. The mixer vehicle comprises a mixer drum. Further, the mixer vehicle comprises a drive train for driving said mixer drum. The drive train comprises an electric motor and a mains connector for connecting the electric motor to a power mains. Consequently, the power mains can be used for driving the mixer drum, for instance when loading the mixer drum at a concrete batching plant and/or when unloading the mixer drum at a construction site. Besides, the drive train comprises at least one of a generator for generating electric power and a battery pack.