Electric Refuse Vehicle DC-DC Converter Voltage Management
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Solution Overview
Problem
Refuse collection vehicles powered by fossil fuels have low fuel efficiency and high carbon emissions, and they often rely on hydraulic systems that require extensive maintenance, are noisy, and consume power at idle, making them candidates for electrification.
Innovation Solution
The development of an electric refuse collection vehicle equipped with a wheeled chassis, a battery pack, and a DC-DC converter, which provides electrical power to electric propulsion motors, packer motors, and tailgate motors, replacing hydraulic systems with electric actuators and utilizing commercially available high-power motors and motor controllers operating at different voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hydraulic systems are used in refuse collection vehicles, then powerful actuation is achieved, but maintenance requirements increase and noise increases
Solution Approach 1:
The patent replaces hydraulic systems with electric motors and drive mechanisms. Specifically, electric motors are used to power the compaction mechanism, tailgate operation, and vehicle propulsion, eliminating hydraulic fluid, pumps, and associated maintenance while providing comparable or superior actuation power with reduced noise and improved reliability
2Power
If hydraulic systems are used in refuse collection vehicles, then actuation is achieved, but power consumption at idle increases
Solution Approach 1:
The electric motors are controlled to operate only when needed rather than running continuously at idle. The system uses sensors and control logic to activate motors during specific operations (compaction cycles, tailgate movement) and shut them down during idle periods, eliminating continuous power consumption while maintaining actuation capability when required
3Adaptability or versatility
If electric motors operating at different voltages are used, then compatibility with existing high-power motor systems is achieved, but voltage conversion complexity increases
Solution Approach 1:
The patent employs DC-DC converters as intermediary devices between different voltage systems. These converters efficiently transform voltage levels to accommodate various electric motors (propulsion, compaction, tailgate) operating at different voltages, managing the complexity through standardized conversion modules rather than direct complex wiring arrangements
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 electric refuse collection vehicle improves fuel efficiency, reduces carbon emissions, decreases maintenance needs, and enhances operational quietness by leveraging electric propulsion and actuators, while maintaining compatibility with existing high-power motor systems.
Implementation Method 1
The DC-DC converter is connected to the battery pack and provides electrical power to the electric packer motor and to the electric tailgate motor at one or more DC voltages different than a voltage provided by the battery pack to the DC-DC converter
Data Source
AI summary
A refuse collection vehicle includes a wheeled chassis, a battery pack, a refuse collection body, and a DC-DC converter. The wheeled chassis has an electric propulsion motor connected to a road wheel of the chassis. The battery pack has multiple battery cells and provides electrical power to the propulsion motor. The refuse collection body is carried by the chassis and defines a refuse storage compartment. The refuse collection body includes a refuse packer driven by an electric packer motor. The refuse collection body also includes a powered tailgate driven by an electric tailgate motor. The DC-DC converter is connected to the battery pack and provides electrical power to the electric packer motor and to the electric tailgate motor at one or more DC voltages different than a voltage provided by the battery pack to the DC-DC converter.