Mobile Crusher DC Powertrain for Multi-Source Energy Integration
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Solution Overview
Problem
Existing rock crusher powertrain systems face challenges in integrating multiple power sources, such as grid power, generators, and batteries, to achieve flexibility, zero-emission mobility, and operational efficiency, particularly when transitioning to DC electrical systems from traditional AC systems.
Innovation Solution
A DC electrical powertrain system for mobile crushers, comprising a DC electrical supply network, batteries, a power distribution unit, and a control unit that manages charging and discharging cycles, along with multiple motors and inverters, to seamlessly integrate and manage power from various sources, ensuring efficient and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If AC power systems are used to power mobile crushers, then power can be distributed over long distances with minimal loss, but energy conversion and storage efficiency deteriorates when integrating renewable energy sources or batteries
Solution Approach 1:
The patent transitions the electrical system from AC to DC architecture, fundamentally changing the electrical parameter type. This DC electrical system enables direct connection to battery energy storage without AC-to-DC conversion losses, thereby improving energy conversion efficiency while maintaining system functionality
Solution Approach 2:
The DC electrical system serves multiple functions simultaneously: it powers the crusher operations, charges battery energy storage, and integrates renewable energy sources. This multi-functional DC architecture eliminates the need for separate AC-to-DC conversion systems, reducing overall system complexity despite the transition from traditional AC infrastructure
2Adaptability or versatility
If traditional AC power systems are used in rock crushers, then the system is well-established and can effectively distribute power, but flexibility and operational efficiency deteriorate when integrating multiple power sources
Solution Approach 1:
By changing the electrical system parameter from AC to DC, the system gains inherent flexibility to integrate multiple power sources including batteries and renewable energy. DC architecture naturally accommodates variable power inputs without the synchronization and conversion requirements of AC systems, thereby improving adaptability while maintaining operational efficiency through direct power delivery
3Reliability
If AC electrical systems are used for mobile crushers, then power distribution is established and reliable, but energy conversion efficiency deteriorates particularly when integrating batteries
Solution Approach 1:
The transition to DC electrical system maintains reliability through stable voltage control and protection systems while dramatically improving energy conversion efficiency. DC architecture eliminates AC-to-DC conversion losses when charging batteries, and the system incorporates regenerative braking that converts kinetic energy directly to DC electrical energy for storage, thereby optimizing overall energy utilization while preserving operational reliability
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
The DC powertrain system enhances energy efficiency, flexibility, and reliability by optimizing power distribution and thermal management, allowing continuous operation across diverse environments and power conditions.
Implementation Method 1
a DC electrical supply network; a plurality of motors connected to the DC electrical supply network
Implementation Method 2
a plurality of batteries connected to the DC electrical supply network, providing electrical energy
Data Source
AI summary
An electrical powertrain system for a mobile crusher is disclosed. The electrical powertrain system comprises a DC electrical supply network, a plurality of motors connected to the DC electrical supply network and configured to drive a plurality of machine operations, a plurality of batteries connected to the DC electrical supply network, providing electrical energy, a power distribution unit (PDU) managing DC power to different components of the mobile crusher, and a control unit configured to manage a charging and discharging cycles of the plurality of batteries for operation of the plurality of machine operations.