Transmission PTO Charging Drive for Engine-Off Load Power
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Solution Overview
Problem
Existing vehicle systems face inefficiencies in electrifying loads and accessories, particularly in heavy-duty commercial vehicles, due to inefficiencies in power conversion, high voltage requirements, and integration challenges, as well as high costs and complexity in integrating electric systems with internal combustion engines and battery management.
Innovation Solution
A driveline PTO system that selectively provides power using driveline power or stored electrical power, with a motor/generator and planetary gear assemblies to manage gear ratios, allowing for various operating modes and reducing the need for redundant systems, enabling efficient integration and reduced battery requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If fully electric systems are used to power loads and accessories, then control capability and utilization of regenerative energy are improved, but system cost, complexity, and integration difficulty increase
Solution Approach 1:
The system divides the electrical power supply into two independent sources: a battery assembly for electrical power and a motor/generator coupled to the driveline for mechanical-to-electrical conversion. This segmentation allows each component to operate independently in its optimal regime, reducing overall system complexity while maintaining control capability.
Solution Approach 2:
The motor/generator serves multiple functions: it can operate as a motor to drive the driveline, as a generator to charge the battery, and as a coupling element between the battery and driveline. This multi-functionality eliminates the need for separate starting motor and alternator, reducing system complexity.
2Volume of moving object
If high voltage systems are used to power loads, then connection size and conduit size are reduced, but integration and testing work and safety requirements increase
Solution Approach 1:
The system uses a battery assembly operating at a first voltage level and incorporates a DC-DC converter to convert between different voltage levels. This allows the system to use higher voltage for power transmission (reducing conduit size) while maintaining compatibility with lower voltage accessories and reducing the complexity of high-voltage isolation requirements.
3Power
If large capacity battery systems are used to power loads, then power availability is improved, but vehicle weight and cost increase
Solution Approach 1:
The motor/generator is coupled to the driveline to continuously harvest regenerative energy during braking and coasting operations. This continuous energy recovery extends the effective power availability from the battery assembly without requiring a larger battery, thereby reducing weight while maintaining power capability.
4Loss of energy
If regenerative braking is implemented, then energy recovery is improved, but system complexity and integration difficulty increase
Solution Approach 1:
The system combines the regenerative braking function with the existing motor/generator that is already coupled to the driveline. The motor/generator operates in generator mode during braking to recover energy, merging the regenerative braking function with the existing powertrain components rather than adding a separate regenerative braking system.
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 system enhances fuel economy, reduces greenhouse gas emissions, and lowers costs by enabling efficient power management, reducing reliance on infrastructure, and supporting multiple load types with improved battery life and system efficiency.
Implementation Method 1
a motor/generator (112) electrically coupled to a battery assembly (116)
Implementation Method 2
a planetary gear assembly (108) structured to provide a first gear ratio between the motor/generator and the shared load, and structured to provide a second gear ratio between the driveline and the motor/generator
Data Source
AI summary
A system includes a PTO device that selectively couples to a driveline of a vehicle, a motor/generator electrically coupled to an electrical power storage system, and a shared load selectively powered by one of the driveline or the motor/generator. The PTO device further includes a coupling actuator that couples the shared load to the motor/generator at a first selected ratio in a first position, and couples the shared load to the driveline at a second selected ratio in a second position.