Modular Track-Working Machine for Peak Power Efficiency
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Solution Overview
Problem
Existing track preparation machines face inefficiencies due to idling of mechanically or hydraulically driven tools during power peaks, requiring oversized internal combustion engines for short bursts of power, and lack ergonomic separate transport of working and energy modules.
Innovation Solution
A track preparation machine with a detachable energy module featuring an internal combustion engine coupled to a generator for charging an electrical energy store, including a supercapacitor for high power density and rapid discharge, allowing separate transport and efficient power peak coverage, and a brushless electric motor for low-maintenance and adaptable control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an internal combustion engine is designed to deliver maximum power for short bursts, then peak power requirements are met, but the engine must idle during non-peak periods reducing efficiency
Solution Approach 1:
The power delivery function is segmented between two systems: the combustion engine handles average base load power delivery, while the electrical energy storage device handles peak power demands. This segmentation allows each component to operate optimally without the other compromising efficiency.
Solution Approach 2:
The electrical energy storage device is pre-charged during periods of low power demand (when the engine operates efficiently at average load) so that it can immediately deliver peak power when needed, eliminating the need for the engine to idle or oversize for peak demands.
2Device complexity
If the machine is designed as a single integrated unit, then structural simplicity is achieved, but transport and positioning become less ergonomic
Solution Approach 1:
The machine is divided into two separable modules: a working module containing the machine frame and working tool, and an energy module containing the combustion engine and electrical energy storage device. This segmentation enables independent transport of each module to appropriate locations before coupling.
Solution Approach 2:
A coupling device serves as an intermediary mechanism between the working module and energy module, enabling easy connection and disconnection while maintaining alignment and mechanical integrity during transport and operation.
3Power
If a hydraulic drive system is used, then mechanical power transmission is achieved, but the drive idles during non-working periods reducing overall efficiency
Solution Approach 1:
The hydraulic drive system is replaced with an electric motor driven by electrical energy from the storage device. This substitution eliminates hydraulic fluid circulation during idle periods, as the electric motor can simply be disconnected or put into standby mode without continuous energy consumption.
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 solution enables high overall efficiency by using stored energy for power peaks, reducing idling, and allowing ergonomic separate transport, with the internal combustion engine optimized for average performance and the supercapacitor supporting machine operation with recurring power peaks, resulting in lower noise emissions and fuel consumption.
Implementation Method 1
the electrical energy storage device includes a supercapacitor. This enables high power density in a small space and with low weight. Furthermore, a supercapacitor allows for rapid discharge and a sufficient number of charge and discharge cycles
Implementation Method 2
it is advantageous for the electrical energy storage system to include a battery. This allows electrical energy to be stored for extended machine operation
Implementation Method 3
The energy module comprises a combustion engine coupled to a generator, and the generator is connected to a charging unit for the electrical energy storage device
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a track-working machine (1) which can be displaced manually on a track (2), having an operating module (3), which comprises a handle (9), a work tool (14), which is driven by a drive (13), and a machine frame (10), which can be guided on a rail (7) of the track (2), wherein the operating module (3) is connected in a releasable manner to an energy module (4). The energy module (4) here comprises an electrical energy store (25) and output contacts (20), wherein the output contacts (20) are connected in a releasable manner to input contacts (19) of the operating module (3), and wherein the operating module (3) comprises, as its drive (13), an electric motor (15), which is supplied with electrical energy from the energy store (25). This solution gives rise to a high overall efficiency level, because the energy which is available in the energy store (25) serves, for the most part, to cover power peaks.