Mobile Rock Crusher Drive With Variable Transmission
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Solution Overview
Problem
Existing material processing plants, such as mobile crushing machines, face inefficiencies due to fixed transmission ratios between the internal combustion engine and crusher units, leading to high fuel consumption and CO2 emissions when operating at varying power requirements.
Innovation Solution
Implementing a shiftable transmission with a variable transmission ratio between the internal combustion engine and the drive train to optimize the engine's operating point for specific applications, maintaining constant crusher speed and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a fixed transmission ratio is provided between the internal combustion engine and the crusher, then the crusher speed can be maintained constant, but the fuel consumption and CO2 emissions increase when operating at varying power requirements
Solution Approach 1:
The patent applies a variable transmission ratio between the internal combustion engine and the drive train, allowing the transmission ratio to be dynamically adjusted based on power requirements. This enables the engine to operate at optimized speeds across different load conditions while maintaining constant crusher speed, thereby reducing fuel consumption and CO2 emissions without sacrificing adaptability
2Power
If the internal combustion engine is designed to provide maximum power in the required speed range, then sufficient performance is offered for high power requirements, but fuel consumption and CO2 emissions increase in applications demanding only a fraction of maximum performance
Solution Approach 1:
The variable transmission ratio allows the engine to operate at lower speeds with optimized power output matched to actual load requirements. By adjusting the transmission ratio dynamically, the system maintains sufficient power delivery for high-demand applications while enabling energy-efficient operation during low-demand periods, reducing unnecessary fuel consumption and CO2 emissions
3Loss of energy
If a shiftable transmission with variable transmission ratio is implemented, then fuel consumption and CO2 emissions are reduced by allowing the engine to operate at lower speeds with higher efficiency, but the device complexity increases
Solution Approach 1:
The shiftable transmission with variable transmission ratio introduces dynamic adjustment capability between the engine and drive train. This allows the system to optimize engine operating points across varying power requirements, achieving significant reductions in fuel consumption and CO2 emissions. The increased device complexity is justified by the substantial energy efficiency improvements and environmental benefits
Data Source
AI summary
A drive for a mobile material processing plant, in particular for a rock crusher, includes an internal combustion engine that drives a mechanical drive train on its drive end, wherein the drive train has an output end having at least one output, wherein the output(s) are used to drive at least one crusher unit and preferably one generator for generating electrical energy, in particular for use in the material processing plant and/or at least one hydraulic system having a hydraulic pump. For the benefit of optimized operation of the material processing plant, according to the disclosure provision is made for the internal combustion engine to be coupled to the drive train via a shiftable transmission having a variable transmission ratio.