Rail Treatment Machine Power Control for Base and Peak Loads
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Solution Overview
Problem
Existing rail-movable rail processing machines face limitations in energy supply due to limited capacity of energy storage units, which restrict operation to low-energy consumption tasks and predictable peak loads, and frequent charging/discharging reduces the service life of energy storage devices, especially in environments without contact lines or with toxic emissions from internal combustion engines.
Innovation Solution
A method utilizing a fuel cell as a permanent energy source to cover base loads and an energy storage device as a buffer to manage peak loads, with a battery management system coordinating energy sources to maintain optimal operation and efficiency, allowing the machine to operate independently of external power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an energy storage unit designed as an accumulator is used to supply electrical power to work drives, then the rail vehicle can operate without external power sources, but the limited capacity restricts operation to low energy consumption tasks and predictable peak loads
Solution Approach 1:
The energy supply system is segmented into multiple independent energy storage units with different characteristics (accumulator and capacitor) rather than relying on a single energy storage device. This segmentation allows each unit to handle different types of loads - the accumulator for base load and the capacitor for peak loads - thereby increasing the overall adaptability and energy availability of the system.
Solution Approach 2:
The patent employs a composite energy storage system combining two different energy storage technologies (accumulator and capacitor) into a hybrid architecture. This composite approach leverages the strengths of each technology - the high energy density of the accumulator and the high power density of the capacitor - to achieve both extended operational capacity and the ability to handle peak loads.
2Manufacturing precision
If the energy storage device is frequently charged and discharged to cover peak loads, then the working units can maintain required processing quality, but the service life of the energy storage device is reduced considerably
Solution Approach 1:
The energy supply function is segmented between two energy storage units: the accumulator handles the base load and slow variations, while the capacitor specifically handles peak loads and rapid power demands. This segmentation protects the accumulator from frequent charging/discharging cycles, thereby extending its service life while still maintaining the ability to cover peak loads for consistent processing quality.
Solution Approach 2:
The capacitor acts as an intermediary energy storage device between the accumulator and the peak load demands. It absorbs the shock of frequent charging/discharging cycles by handling peak power requirements, thereby protecting the accumulator from degradation while ensuring that peak loads are still covered to maintain processing quality.
3Adaptability or versatility
If internal combustion engines are used to generate electrical power, then the rail vehicle can operate independently, but toxic emissions are generated making them unsuitable for underground track systems
Solution Approach 1:
The patent replaces the mechanical internal combustion engine system with an electrochemical energy storage system (accumulator and capacitor). This substitution eliminates the harmful emissions associated with combustion engines while maintaining operational independence. The electrochemical system provides the same function of generating electrical power without the harmful byproducts.
4Device complexity
If a single energy storage device is used to cover both base load and peak loads, then the system is simpler, but the energy storage capacity must be oversized leading to increased weight and reduced efficiency
Solution Approach 1:
The energy storage system is segmented into two specialized units: an accumulator optimized for base load coverage and a capacitor optimized for peak load handling. This segmentation allows each component to be right-sized for its specific function, avoiding the need for an oversized single energy storage device. The total weight is reduced because each component only needs to handle its designated portion of the load spectrum.
Solution Approach 2:
The patent changes the parameters of the energy storage system by using two different technologies with different characteristics rather than one oversized device. The accumulator provides high energy density for sustained base load operation, while the capacitor provides high power density for brief peak loads. This parameter diversification optimizes the overall system weight and efficiency.
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 low-maintenance, environmentally friendly operation with consistent machining quality by minimizing efficiency losses and extending the service life of energy storage devices, enabling operation on both tracks and roads without external power dependencies.
Implementation Method 1
a permanent energy source, an electrical energy storage device and a current collector for providing traction current are provided for the electrical supply of the traction drive motor and the working unit... wherein the permanent energy source is a fuel cell
Implementation Method 2
an electrical energy storage device... wherein the permanent energy source, the energy storage device, the current collector providing the traction current, the traction drive motor and the working unit are connected to a common direct current network via power converters
Data Source
Figure 1
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AI summary
A description is given of a rail treatment machine able to be moved on rails, having at least one drive motor (4) and having at least one working unit (1) for treating rails, wherein a permanent energy source, an electrical energy store (3) and a current collector for providing traction current are provided in order to supply electric power to the drive motor (4) and the working unit (1), wherein the permanent energy source, the energy store (3), the current collector providing the traction current, the drive motor (4) and the working unit (1) are connected to a common DC grid (9) via converters. In order to provide a rail treatment machine able to be moved on rails that allows low-maintenance and environmentally friendly deployment of working units with greatly varying peak loads, without having to accept losses in terms of treatment quality, it is proposed for the permanent energy source to be a fuel cell (2) that feeds at least one base load of the working unit (1) into the DC grid (9) via the converter, and for buffer energy of the energy store (3) acting as buffer store to be able to be fed into the DC grid (9) via the associated converter in order to cover peak loads at least of the working unit (1).