Mobile Crusher Drive With Variable Gearbox for Fuel Efficiency
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Solution Overview
Problem
Current material crushing systems face inefficiencies due to combustion engines operating at maximum performance, leading to high fuel consumption and CO2 emissions, especially in applications with varying power requirements, and existing solutions are complex and prone to failure.
Innovation Solution
A switchable gearbox with a variable gear ratio is connected between the combustion engine and the drive train, allowing the engine to operate at a lower speed range while maintaining the same output speed, optimizing efficiency and reducing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the combustion engine operates at maximum performance to ensure sufficient power in all applications, then the power requirement is met, but fuel consumption and CO2 emissions increase unnecessarily
Solution Approach 1:
The patent applies dynamics by making the gear ratio variable rather than fixed. The transmission device can change its gear ratio dynamically based on the actual power requirements of the crushing unit, allowing the engine to operate at optimal efficiency points while still meeting power demands when needed.
Solution Approach 2:
The patent changes the parameter of gear ratio from a fixed value to a variable parameter. By adjusting the gear ratio according to the actual load conditions, the system enables the engine to operate in more efficient operating ranges while maintaining the required power output at the drive train.
2Device complexity
If a fixed gear ratio is used between the combustion engine and the crusher, then the system design is simple, but the engine cannot operate efficiently in varying power requirements
Solution Approach 1:
The transmission device is designed with variable gear ratios, transforming a static system into a dynamic one that can adapt to changing operational requirements. This allows the engine to maintain efficient operation across different power demands while the transmission automatically adjusts the gear ratio accordingly.
3Power
If the combustion engine speed is increased to meet high power requirements, then sufficient power is delivered, but efficiency decreases due to high engine speeds
Solution Approach 1:
The patent utilizes parameter changes by adjusting the gear ratio to decouple engine speed from drive train output speed. This allows the engine to operate at lower, more efficient speeds while still delivering the required power to the crushing unit through appropriate gear multiplication.
Data Source
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AI summary
The invention relates to a drive for a mobile material processing plant (1), in particular for a rock crusher, comprising an internal combustion engine (12) which drives a mechanical drive train (14) on the drive side thereof, wherein the drive train (14) has an output side with at least one output, wherein at least one crushing unit (10) and preferably a generator (18) for generating electrical energy, in particular for use in the material processing plant (1), and/or at least one hydraulic system with a hydraulic pump (19.1, 19.2) are driven by means of the output(s). For the benefit of optimized operation of the material processing plant, the invention provides that the internal combustion engine (12) is coupled to the drive train (14) via a switchable transmission (13) with a variable transmission ratio.