Modular E-PTO Housing for Fast-Swap Refuse Vehicle Hydraulics
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Solution Overview
Problem
Existing electric refuse vehicles face challenges in efficiently integrating and servicing hydraulic power systems, leading to increased downtime and reduced fleet efficiency.
Innovation Solution
A modular electric power take-off (E-PTO) system is introduced, which includes a motor, inverter, battery, and hydraulic pump housed in a removable modular housing, with a junction box for external coupling to the vehicle's HV system, allowing easy installation and removal, and a switch for energy exchange control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hydraulic power system is integrated into the vehicle body, then the system stability is improved, but the servicing time increases and fleet efficiency decreases
Solution Approach 1:
The hydraulic power system is segmented into a modular E-PTO unit that can be independently removed and serviced. The modular housing contains all hydraulic components (pump, motor, battery, inverter) as a self-contained assembly that detaches from the vehicle body through external coupling mechanisms, allowing rapid replacement without disassembling the entire vehicle system.
Solution Approach 2:
The hydraulic power system is extracted from the permanent vehicle structure and placed in a removable modular housing. This extraction allows the system to be taken out for servicing or replacement by simply disconnecting external couplings (electrical, hydraulic, and mechanical), significantly reducing servicing time while maintaining system stability during operation.
2Reliability
If the E-PTO system components are permanently installed, then the system reliability is improved, but the adaptability and flexibility decrease
Solution Approach 1:
The E-PTO system transitions from a static permanent installation to a dynamic removable configuration. The modular housing with external couplings enables the system to be easily installed or removed based on operational requirements, allowing the vehicle to adapt to different hydraulic power needs while maintaining reliable connections during active use.
Solution Approach 2:
The modular E-PTO system design with standardized external couplings (electrical, hydraulic, mechanical) creates a universal interface that can accommodate different vehicle configurations and hydraulic power requirements. The same modular unit can be installed on different vehicle types or removed when not needed, providing versatility without compromising system reliability.
3Ease of operation
If multiple connection points are provided for E-PTO components, then the ease of connection is improved, but the device complexity increases
Solution Approach 1:
Multiple separate connection points (electrical, hydraulic, mechanical) are merged into a single modular E-PTO unit with integrated housing. All connections are consolidated at one location on the vehicle body, allowing the entire hydraulic power system to be connected or disconnected as a single assembly rather than requiring separate connections for each component, thereby reducing overall system complexity.
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 modular E-PTO system reduces fleet downtime by enabling quick swapping and servicing, enhancing operational efficiency and flexibility in integrating hydraulic power systems.
Implementation Method 1
a motor, an inverter, a battery, and a hydraulic pump positioned within the modular housing
Implementation Method 2
drive the hydraulic pump to provide pressurized hydraulic fluid to one or more hydraulic systems
Data Source
AI summary
A modular electric power take-off (E-PTO) system for a refuse vehicle includes a modular housing. The modular E-PTO also includes a motor, an inverter, a battery, and a hydraulic pump positioned within the modular housing. The modular housing is removably coupled with a front of a waste receptacle or a hopper of the waste receptacle of a refuse vehicle.