Regenerative Winch Energy Routing for Container Handling Vehicles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rechargeable power sources in container handling vehicles face issues such as overcharging, which can lead to safety hazards like fires and reduced battery durability, and inefficiencies with capacitors requiring frequent charging and significant space.
Innovation Solution
A system with a regenerative energy circuit that directs harvested energy to either a rechargeable battery or a capacitor based on their charge levels, ensuring optimal maintenance and storage of energy, preventing overcharging, and using supercapacitors to maintain vehicle operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If energy is harvested and stored in a rechargeable battery, then energy availability is improved, but overcharging can occur leading to safety hazards and reduced battery durability
Solution Approach 1:
The system continuously monitors the charge level of the rechargeable battery and uses this feedback to control the regenerative energy circuit. When the battery reaches a predetermined charge level, the system automatically stops charging or redirects energy to the capacitor, preventing overcharging and extending battery life while maintaining energy availability.
Solution Approach 2:
The control circuit acts as an intermediary between the regenerative energy circuit and the battery. It manages the energy flow, deciding when to charge the battery and when to redirect energy to the capacitor, thereby protecting the battery from overcharging while ensuring continuous energy supply.
2Speed
If a capacitor is used for energy storage, then charging speed is improved, but significant space is required and frequent charging is needed
Solution Approach 1:
The system merges two different energy storage technologies - a rechargeable battery and a capacitor - into a hybrid energy management system. The capacitor provides rapid charging capability for immediate power needs, while the battery provides sustained energy storage, together reducing the total space required compared to using either system alone.
Solution Approach 2:
The system uses the capacitor for partial energy storage - specifically for rapid charging and immediate power delivery - while relying on the battery for the bulk energy storage. This partial use of the capacitor's high-speed charging capability optimizes the overall space utilization while maintaining fast charging benefits.
3Loss of energy
If regenerative energy circuit is implemented, then energy efficiency is improved, but complex energy management is required to prevent overcharging
Solution Approach 1:
The control circuit implements continuous feedback monitoring of battery charge levels and energy generation from the regenerative braking process. This feedback enables automatic adjustment of energy routing, simplifying the management complexity while maintaining high energy efficiency by preventing overcharging and optimizing energy storage.
Solution Approach 2:
The energy management system is designed to operate autonomously, with the control circuit automatically managing energy flow between the regenerative circuit, battery, and capacitor without requiring external intervention. The system self-regulates based on predetermined charge levels, reducing operational complexity while maximizing energy recovery.
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
Ensures safe and efficient energy storage by maintaining battery health and providing sufficient power for vehicle operations, reducing downtime and ensuring optimal energy management.
Implementation Method 1
a driver circuit with a controller controlling the motor, wherein the driver circuit further comprises a regenerative energy circuit configured to harvest energy from the motor when the lifting frame is lowered into the storage system
Data Source
AI summary
A container-handling vehicle for handling storage containers in a three-dimensional grid of an underlying storage system, comprising: at least one lifting device for lifting storage containers from and lowering storage containers to the underlying storage system, said lifting device comprises a lifting frame for gripping a storage container, a winch system for lifting and lowering the lifting frame, a motor to drive the winch system and a driver circuit with a controller controlling the motor; and at least first and second rechargeable power sources for providing power to the motor, wherein the driver circuit further comprises a regenerative energy circuit configured to harvest energy from the motor when the lifting frame is lowered 10 into the storage system and where the driver circuit is configured to direct harvested energy to the rechargeable power sources according to levels of charge in the rechargeable power sources.