Working Machine Thermal Management Using Hydraulic Waste Heat
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Solution Overview
Problem
Working machines powered by electrical energy face challenges in efficiently managing thermal energy for heating and cooling, particularly in hybrid and purely electric configurations, where reduced energy availability and quality impact operating efficiency and operator comfort.
Innovation Solution
A thermal management system that includes an electric energy storage unit, a hydraulic fluid circuit, an operator structure climate control assembly, a heat exchanger, and an energy distribution system. This system determines energy requirements for the operator structure and hydraulic fluid, selectively transferring thermal energy between them based on relative energy needs, and preheats them before operation to optimize efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electrical energy from batteries is used to provide heating or cooling, then operator comfort and hydraulic fluid temperature control are improved, but available energy for working operations is reduced
Solution Approach 1:
The system converts waste heat from the hydraulic fluid (which would otherwise be discarded) into a useful resource for heating the operator structure. The heat exchanger captures thermal energy from the hydraulic fluid that exceeds what is needed for hydraulic operation and transfers it to the operator structure climate control system, thereby eliminating the need to consume valuable electrical energy for heating while maintaining both hydraulic performance and operator comfort.
2Loss of energy
If waste heat from ICE is utilized for heating, then energy efficiency is improved, but this heat source is reduced or eliminated in hybrid and electric machines
Solution Approach 1:
The system enables the hydraulic fluid circuit to serve dual purposes: performing hydraulic work and providing thermal energy for climate control. The hydraulic fluid, which must be maintained within a specific temperature range for optimal performance, naturally generates excess heat during operation. This excess heat is captured and utilized by the operator structure climate control assembly, allowing the hydraulic system to self-service the heating needs without requiring separate waste heat sources from ICE.
3Use of energy by moving object
If thermal energy is transferred from hydraulic fluid to operator structure, then electrical energy consumption is reduced, but hydraulic fluid temperature control becomes more complex
Solution Approach 1:
The system merges the hydraulic fluid circuit with the operator structure climate control system through a heat exchanger, creating an integrated thermal management system. Rather than treating these as separate systems, the invention combines their thermal management functions, allowing the hydraulic fluid to directly contribute to operator structure heating. This integration reduces overall system complexity by eliminating the need for separate heating sources while maintaining independent control capabilities for both systems.
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
The system enhances the efficiency of working machines by utilizing excess thermal energy from the hydraulic fluid to heat the operator structure and vice versa, reducing the reliance on electrical energy for heating, and optimizing energy use by preheating only when necessary.
Implementation Method 1
a heat exchanger arranged to selectively add and/or remove thermal energy from the hydraulic fluid circuit for selectively warming and cooling the hydraulic fluid
Implementation Method 2
the thermal management system comprises an energy distribution system to selectively transfer thermal energy between the operator structure and the hydraulic fluid based on the relative values of the operator structure energy requirement and the hydraulic fluid energy requirement
Data Source
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AI summary
A working machine having a thermal management system with an energy distribution system to selectively transfer thermal energy between an operator structure and a hydraulic fluid, based on the relative values of an operator structure energy requirement and a hydraulic fluid energy requirement.