Multi-Input Range Box for Extended Constant Power Speed
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Solution Overview
Problem
Current electro-mechanical drives face challenges in extending speed range while maintaining constant power, often resulting in heavy, costly, and inefficient systems, with difficulties in sustaining high holding torques at low speeds and seamless range shifts.
Innovation Solution
A multi-input range box driven by two or more identical electric drives, where motors are synchronized and power is transferred through a sequence of tasks to maintain constant power delivery without interruptions, by increasing current in one motor to carry the load, disconnecting it, synchronizing its speed, and reconnecting it to a different transfer mechanism, ensuring equal torque distribution among motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hydrostatic drives are used to extend speed range, then constant power over greater speed range is achieved, but system weight and cost increase
Solution Approach 1:
The patent replaces the hydrostatic (hydraulic) drive system with an electro-mechanical system using multiple electric motors and a range box with transfer mechanisms. This substitution eliminates hydraulic fluid, pumps, and motors while maintaining the ability to achieve extended speed range through electrical control and mechanical gear shifting.
Solution Approach 2:
The patent divides the drive system into multiple identical electric motors (typically two or three) that can operate independently or in combination. Each motor is paired with a transfer mechanism that can connect to different speed ranges, allowing the system to segment the speed range achievement across multiple simpler units rather than requiring a single complex hydraulic system.
2Adaptability or versatility
If electro-mechanical devices are used to extend speed range, then constant power is maintained, but difficulty is encountered in sustaining high holding torques at speeds close to zero
Solution Approach 1:
The patent combines multiple electric motors to work together on the same load. When high holding torque is needed at low speeds, multiple motors can operate simultaneously, with their torques additive, thereby achieving the required high torque output that a single motor could not provide alone. The transfer mechanisms allow these motors to be connected in parallel to the load through different gear ratios.
3Adaptability or versatility
If a range box driven by a single electric drive is used, then speed range is extended, but seamless range shifts are difficult to achieve
Solution Approach 1:
The patent uses multiple motors where one motor (or a combination of motors) can be preliminarily prepared and synchronized to the target speed range before the actual range shift occurs. The transfer mechanism is designed to allow one motor to take over the load while another motor is being repositioned or reconfigured, ensuring that the transition between speed ranges is seamless without interruptions or shocks to the load.
4Adaptability or versatility
If conventional electro-mechanical drives are used, then constant power is provided over limited speed range, but system complexity increases when attempting to extend speed range
Solution Approach 1:
The patent employs multiple identical electric motors that are universally designed to perform the same function. Each motor is paired with a transfer mechanism that can connect to different speed ranges, allowing the same motor design to serve multiple purposes across different operating conditions. This universality reduces the need for specialized components for each speed range, thereby managing system complexity while achieving extended speed range capability.
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
Enables constant power delivery over an extended speed range without interruptions, reducing system complexity and maintaining efficiency by ensuring all motors contribute to power delivery rather than acting as brakes, thus overcoming limitations of existing technologies.
Implementation Method 1
a plurality of electric drive motors... Transform Electrical Energy to Mechanical Energy
Data Source
AI summary
Embodiments of the invention comprise a multi-input range box driven by multiple electric drives. Range shifting involves momentarily increasing the current through all but a given motor, to a level that will carry the entire load, comprising specified constant power. Simultaneously, torque of the given motor is reduced to zero. The given motor is then disconnected from supplying power, is synchronized to the input speed of the new speed range, and is then engaged for the new range. The above sequence is then repeated for each remaining motors, in turn. The motor current is re-equalized for all of the motors, after all the motors have been connected to provide power at the new range. Thus, there is no interruption in power flow during a range shift, and the motors are always used to deliver power, rather than to serve as a brake.