Swappable Battery Packs for Continuous Foundation Machine Operation
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Solution Overview
Problem
Foundation construction machines face limitations with existing electric storage systems that are bulky, heavy, and unable to provide a full work shift range, leading to restricted operation and increased costs due to the need for frequent recharging or external power sources.
Innovation Solution
An interchangeable electric storage system with modular, rechargeable units that can be quickly connected and disconnected from the machine, allowing for continuous operation during a work shift without downtime, and enabling efficient power use by swapping nearly depleted units with fully charged ones during breaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a fixed electric storage system is installed on the machine, then the machine can operate autonomously for a limited time, but the system becomes bulky and heavy, restricting machine mobility and requiring additional support structures
Solution Approach 1:
The electric storage system is divided into multiple modular battery packs that can be independently handled and replaced. Each pack is designed to be a separate replaceable unit, allowing the system to be segmented into manageable components rather than a single large fixed system.
Solution Approach 2:
The storage system transitions from a fixed configuration to a dynamic, interchangeable configuration. Battery packs can be quickly swapped during operation, allowing the system to adapt its capacity and weight based on operational needs rather than being constrained by a permanent installation.
2Duration of action of moving object
If a larger electric storage system is installed to extend operation time, then autonomous operation duration increases, but the system becomes even more bulky and requires reinforced support structures
Solution Approach 1:
Instead of installing one large storage system, the solution segments the total capacity into multiple smaller battery packs that can be combined or replaced individually, reducing the volume requirement for any single installation while maintaining total operational duration.
Solution Approach 2:
Depleted battery packs are discarded from service and replaced with charged packs. This allows the system to maintain extended operational capacity through rotation of packs rather than requiring all packs to be permanently mounted on the machine.
3Power
If the machine is equipped with a fixed storage system, then power supply is available, but the machine cannot operate at full nominal power due to weight and structural constraints
Solution Approach 1:
The system allows dynamic adjustment of power capacity by swapping battery packs. When full power is needed, multiple packs can be installed; when power needs are lower, fewer packs are used, allowing the structural system to operate within its capacity limits while still providing access to high power when required.
Solution Approach 2:
The total power capacity is segmented into discrete battery pack units. This allows the machine to be equipped with only the number of packs needed for the specific task, rather than being permanently constrained to a fixed power level that must accommodate maximum possible capacity.
4Duration of action of moving object
If external power sources are used to recharge the machine, then operation can continue, but this requires additional equipment and increases operational complexity
Solution Approach 1:
The recharging function is extracted from the machine itself and transferred to external charging infrastructure. Rather than incorporating complex onboard charging equipment, the system simply replaces depleted packs with charged ones, eliminating the need for onboard power conversion and charging management systems.
5Productivity
If the machine is designed for frequent recharging, then continuous operation is possible, but this requires multiple storage systems and increases overall system weight
Solution Approach 1:
The system enables continuous operation by discarding depleted battery packs and recovering (replacing them with) charged packs. This allows the machine to maintain productivity through pack rotation rather than carrying excessive weight of multiple full-capacity systems simultaneously.
Solution Approach 2:
The weight burden of multiple storage systems is extracted from the machine by placing charged packs in external storage locations. The machine only carries the packs currently in use, while depleted packs are removed and replaced, eliminating the need to permanently carry backup weight.
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 continuous operation for multiple work shifts with uninterrupted power, maximizing productivity and reducing operational costs by allowing machines to operate at nominal power levels without restrictions, while minimizing the need for external power sources.
Implementation Method 1
an interchangeable electric storage system (5), coupled to a rear end of the upper structure
Data Source
AI summary
A foundation construction machine includes a self-moving assembly for moving the machine on the ground, an excavation tool, at least one actuator for moving the excavation tool, at least one electric motor for supplying power to at least one movement of the machine. At least one interchangeable electric storage system is configured to assume a working condition, in which the interchangeable electric storage system is mechanically and electrically connected to the machine, and a replacement condition, in which interchangeable electric storage system is at least mechanically disconnected from the machine. Handling equipment is for bringing the at least one interchangeable electric storage system from the working condition to the replacement condition.