Synchronous Machine Heating Mode for Gearbox Lubricant Warm-up
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Solution Overview
Problem
In vehicles equipped with synchronous machines, cold start-ups and low ambient temperatures lead to increased friction losses and mechanical wear in the gearbox due to suboptimal lubricant temperature, reducing the service life of components and overall vehicle range.
Innovation Solution
A method and device that operate the synchronous machine in a heating mode during specific start-up conditions, increasing current-related thermal losses to rapidly heat the lubricant, thereby reducing mechanical wear and extending component life without additional hardware costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the synchronous machine operates in energy-efficient mode to minimize thermal losses, then energy efficiency is improved, but the lubricant heating speed deteriorates
Solution Approach 1:
The control device dynamically adjusts the operating mode of the synchronous machine based on real-time temperature conditions. During cold start-up, the system transitions from energy-efficient mode to heating mode, and switches back when optimal temperature is reached, making the energy efficiency adaptable to operational requirements
Solution Approach 2:
The control device changes the operating parameters of the synchronous machine by adjusting at least one operating variable to a heating value during cold start-up conditions, thereby increasing thermal losses and accelerating lubricant heating without permanent modification to the machine structure
2Use of energy by moving object
If the synchronous machine operates in energy-efficient mode, then energy consumption is reduced, but mechanical wear increases
Solution Approach 1:
The control device performs preliminary heating action during cold start-up by adjusting operating variables before the vehicle is driven. This preliminary thermal preparation ensures optimal lubricant temperature is achieved in advance, preventing excessive mechanical wear during subsequent operation
Solution Approach 2:
The invention converts the harmful effect of thermal losses (which are normally minimized for efficiency) into a beneficial heating function. By deliberately increasing thermal losses during cold start-up, the system transforms waste heat into a useful resource for lubricant heating, thereby reducing mechanical wear
3Use of energy by moving object
If the synchronous machine operates in energy-efficient mode, then operational cost is reduced, but service life of gearbox components deteriorates
Solution Approach 1:
The control device implements preliminary heating during cold start-up conditions, ensuring the lubricant reaches optimal temperature before the gearbox is subjected to full operational loads. This preliminary thermal preparation extends the service life of gearbox components without impacting long-term operational efficiency
4Use of energy by moving object
If the synchronous machine operates in energy-efficient mode, then energy efficiency is improved, but vehicle range deteriorates
Solution Approach 1:
The control device applies periodic heating action only during cold start-up conditions, then transitions to energy-efficient mode for normal operation. This periodic intervention minimizes energy consumption while ensuring optimal lubricant temperature, thereby preserving vehicle range without compromising long-term operational 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
This approach ensures sustainable operation by rapidly achieving optimal lubricant temperature, reducing mechanical wear, and enhancing the overall range of the vehicle while maintaining driving performance and efficiency.
Implementation Method 1
heat-up of the lubricant by thermal losses in the synchronous machine, specifically current-related thermal losses
Data Source
AI summary
A device is provided for activating a synchronous machine arranged in a vehicle. The vehicle has a gearbox and driven wheels in operative connection therewith. The synchronous machine is designed to drive the driven wheels via the gearbox. In the vehicle there is a lubricating unit, which is designed to lubricate the gearbox by way of a lubricant, for this purpose the lubricant flowing through the gearbox and at least part of the synchronous machine. The device is configured to operate the synchronous machine in a heating operating mode, which is different from a customary driving operating mode, when there are defined conditions that require heating when starting. At least one operating variable of the synchronous machine is set in the heating operating mode specifically such that, in the synchronous machine, there is a greater current heat loss in comparison with the customary driving operating mode, in order in this way to heat up the lubricant in the heating operating mode.