Ultra-capacitor Buffer for Heavy Equipment Engine Power
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Solution Overview
Problem
Heavy equipment used in mining and construction, such as power shovels and excavators, face inefficiencies in energy management due to repetitive work cycles, leading to suboptimal fuel economy and increased emissions when responding to rapid changes in electrical demand.
Innovation Solution
An energy management system incorporating a bus, engine, generator, and ultra-capacitor, with a controller that adjusts the engine's power output to optimize fuel economy by supplementing power from the generator with stored energy from the ultra-capacitor, allowing for smoother power transitions and reduced engine stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the engine increases power output rapidly to meet sudden electrical demand, then the electrical demand is satisfied, but fuel economy deteriorates and emissions increase
Solution Approach 1:
The ultra-capacitor stores energy in advance during periods of low demand so that it can be rapidly discharged to meet sudden power demands without requiring the engine to increase power output rapidly, thereby avoiding fuel economy deterioration and increased emissions
Solution Approach 2:
The ultra-capacitor acts as an intermediary energy storage device between the engine and the electrical load, absorbing power fluctuations and allowing the engine to operate more smoothly while still meeting peak power demands
2Speed
If the engine responds quickly to changes in electrical demand, then the system responsiveness is improved, but engine stress increases
Solution Approach 1:
The ultra-capacitor is pre-charged during low-demand periods and rapidly discharges during high-demand periods, providing the immediate power response needed while preventing rapid engine power changes that would increase engine stress and reduce reliability
Solution Approach 2:
The ultra-capacitor serves as a buffer between the engine and the electrical demand, absorbing sudden power requirements and allowing the engine to respond more gradually, thereby reducing engine stress while maintaining system responsiveness
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 system improves fuel efficiency, reduces emissions, and extends the life of the engine by managing energy demand through optimized power output adjustments, ensuring efficient operation during repetitive work cycles.
Implementation Method 1
an ultra-capacitor, and a controller. The bus is for providing electricity to the actuator... The ultra-capacitor is configured to receive electricity from the bus for storage of energy, and is further configured to provide electricity to the bus to supplement the electricity provided by the generator
Data Source
AI summary
An energy system for heavy equipment having an actuator for operating a tool includes a bus, an engine, a generator, an energy storage device, and a controller. The bus is for providing electricity to the actuator as a function of operation of the tool. The engine is for providing a power output and the generator is coupled to the engine and configured to provide electricity to the bus. The energy storage device is configured to receive electricity from the bus for storage of energy, and is further configured to provide electricity to the bus to supplement the electricity provided by the generator. The controller is configured to change the power output of the engine as a function of electrical demand on the bus. In response to a change in the electrical demand, the controller is configured to change the power output of the engine at a rate that is less than a maximum capability of the engine.