Working Machine Powertrain With Series Battery Units for Lower HV Cost
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Solution Overview
Problem
Electrically driven working machines, such as wheel loaders and excavators, face higher production costs and increased electrical system costs due to higher mechanical power requirements compared to passenger cars, leading to higher operating voltages and subsequently higher costs per unit.
Innovation Solution
A drivetrain for working machines comprising at least one electric motor and an electric energy storage device with two individual storage units connected in series, allowing for cost-effective operation by utilizing existing passenger car components and enabling efficient charging and power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher operating voltages are used to meet the mechanical power requirements of working machines, then the required power is achieved, but the costs of the electrical system increase
Solution Approach 1:
The energy storage device is divided into multiple individual storage units (e.g., two or more battery modules) that are connected in series. This segmentation allows the system to achieve the required high operating voltage through series connection of standard-voltage units, avoiding the need for a single complex high-voltage system. Each storage unit can be independently manufactured using standard passenger car components, reducing overall system cost while achieving the necessary voltage level for high mechanical power output.
2Adaptability or versatility
If electrically driven working machines are produced in lower quantities, then the market demand is matched, but the cost per unit increases
Solution Approach 1:
The energy storage device is designed using standard passenger car battery components that can be universally applied across different working machine models and production volumes. By utilizing off-the-shelf storage units from the passenger car industry, the system benefits from existing mass production economies without requiring dedicated high-volume production lines for working machines. This universal approach allows flexible production quantities while maintaining cost efficiency through standardized component procurement.
3Power
If higher mechanical power requirements are met by increasing voltage, then the power demand is satisfied, but the manufacturing costs increase
Solution Approach 1:
The high-voltage requirement is met by segmenting the energy storage system into multiple series-connected standard-voltage battery units. This approach achieves the necessary voltage level for high mechanical power output without requiring expensive custom high-voltage battery development. The segmented architecture allows use of standardized, cost-effective passenger car battery components while still delivering the high power performance needed for working machines.
Solution Approach 2:
The energy storage device copies the proven design and manufacturing approach from passenger car batteries, adapting it for working machine applications. By replicating the successful standard-voltage battery architecture and using identical or similar components from the passenger car industry, the system achieves high mechanical power capability at lower manufacturing costs, leveraging existing mass production expertise and supply chains.
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 solution reduces manufacturing costs for battery-electrically operated working machines without compromising performance or operating time, while allowing for reduced charging time and flexible operation modes by using existing passenger car components and parallel charging.
Implementation Method 1
an electric energy storage device (12), in particular a rechargeable battery, is provided
Implementation Method 2
The energy storage device comprises at least two individual storage units (12', 12'') connected electrically in series
Data Source
AI summary
A drivetrain for a working machine, including at least one electric motor and an electric energy storage device. The at least one electric motor is configured to provide mechanical power and the energy storage device is configured to supply the at least one electric motor with electrical power. The energy storage device includes at least two individual storage units electrically connected in series.