PTO Generator Pump Drive to Eliminate Hydraulic Leaks
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Solution Overview
Problem
Conventional semi-truck pump systems, such as wet kits and direct drive systems, suffer from hydraulic leaks, mechanical failures, user errors, and high maintenance costs, leading to significant downtime and repair expenses.
Innovation Solution
A computer-controlled power takeoff (PTO) driven motorized pump system that includes a generator connected to a PTO, a first controller converting AC to DC power, and a second controller inverting DC back to AC to power a motor, with integrated sensors and computing systems for automated control and safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a wet kit system is used, then the PTO can drive the hydraulic pump to power the vacuum pump, but hydraulic leaks and line ruptures occur frequently requiring excessive diagnostics and repairs
Solution Approach 1:
The patent replaces the hydraulic mechanical system with an electric system. A PTO-driven generator produces electricity that powers an electric motor, which in turn drives the vacuum pump. This substitution eliminates hydraulic lines, hydraulic pumps, and hydraulic motors, thereby eliminating the source of hydraulic leaks and line ruptures while maintaining power transmission capability.
2Power
If a direct drive system is used, then the PTO can directly drive the vacuum pump through a driveline, but the long rotating driveline poses safety risks and is susceptible to damage
Solution Approach 1:
The patent replaces the long rotating driveline with an electric power transmission system. The PTO drives a generator that produces electricity, which is then used to power an electric motor connected to the vacuum pump. This eliminates the long rotating driveline, U-joints, and carrier bearings, removing the safety hazards associated with exposed rotating machinery while maintaining efficient power transmission.
3Power
If conventional pump systems are used, then the pump can be mechanically connected to the PTO, but the complexity of the system makes it prone to user error and requires careful control and monitoring
Solution Approach 1:
The patent replaces complex mechanical linkages with an electric control system. The PTO-driven generator and electric motor are controlled through electrical switches and circuitry, which are inherently simpler and more reliable than mechanical linkages. This substitution reduces the complexity of control and monitoring required, making the system more resistant to user error.
4Power
If wet kit systems are used, then the hydraulic pump can drive the vacuum pump, but the system has a limited service life of only 1,000 to 2,000 hours due to complexity and design deficiencies
Solution Approach 1:
The patent replaces the hydraulic system with an electric system consisting of a PTO-driven generator and an electric motor. This substitution eliminates the hydraulic pump, hydraulic motor, and associated components that have limited service lives. The electric system has fewer moving parts and no hydraulic fluid degradation issues, resulting in significantly extended service life.
5Power
If direct drive systems are used, then the PTO can drive the vacuum pump through a gear box, but the service life is limited to 3,000 to 4,000 hours due to mechanical wear and damage
Solution Approach 1:
The patent replaces the mechanical direct drive system with an electric system. The PTO drives a generator that produces electricity, which powers an electric motor connected to the vacuum pump. This eliminates the driveline, U-joints, carrier bearings, and gear box that are subject to mechanical wear and damage, thereby extending the service life of the 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
Reduces hydraulic line ruptures, mechanical failures, and user errors, extending pump life up to three times, minimizing repair costs and downtime, and enhancing fuel efficiency.
Implementation Method 1
a generator that is mechanically connected to a power takeoff (PTO)... a first controller that receives AC power from the generator
Implementation Method 2
a first controller that receives AC power from the generator and converts the AC power to DC power
Implementation Method 3
a second controller directly coupled to the first controller and providing AC power to a motor that is mechanically connected to a pump
Data Source
AI summary
A computer-controlled motorized pump system is provided. A generator is mechanically connected to a power takeoff. A first controller receives AC power from the generator and converts the AC power to DC power and provides DC power to a computing system that has one or more processors and one or more computer-readable hardware storage media and a user interface. A second controller is directly coupled to the first controller and provides AC power to a motor. The motor is mechanically connected to a pump, and the motor is in communication with, or controlled by, the computing system.