Making the entire electrical, cellular and off-road device viable is a complex engineering proposition. One of the cornerstones of this technique is to find a way to recharge the vehicle’s batteries. The use of a diesel generator makes no sense when one of the number one objectives of the all-electric concept is to propose a greener technique with a minimal carbon footprint.
When our corporate Envision Solar took on the challenge, through the construction of what we call the autonomous renewable electric vehicle charger or EV ARC 2020, we learned two main problems. The first was to make sure he painted in all climates and conditions. The timing was to ensure that it would operate at maximum power while still being undeniable and reliable.
That’s how we solve those problems.
The design of a cell charger that works in all climates, from the bloodless winter in New York to the afternoons in the Nevada desert, is not insignificant. It deserves to work in excessive situations and when there is no sunlight to force the solar panels. This meant that force would also have to be stored for use at all times, which would lead to batteries and all complex appliances needed to administer them, as well as related electronic devices to store, face and supply usable electrical power to autocellulars and machinery used through our customers.
Batteries and related electronic paints are successfully and safely maximized in an express temperature diversity we call the Goldilocks area (neither too hot nor too much without blood, just). Fortunately, this diversity is wide, starting at 32 degrees F (0 degrees Fahrenheit) and ending at less than 104 degrees Fahrenheit (40 degrees Fahrenheit). As a general rule, the way to keep an object at a somewhat constant temperature is to heat it when it has no blood and cool it when it is too hot. However, such energy-intensive processes would create unacceptable parasitic consumption in a limited source of electrical energy (solar energy). Using all the energy produced through the solar panel to keep the Goldilocks domain impassable. We had to design a product that could passively have its own temperature.
THE EV ARC. Envision Solar
The law of the moment of thermodynamics and entropy at our disposal. Asking how to exploit them to our advantage, when it’s an advantage, and diminish their effects when they ran opposite us. The law of thermodynamics says that hot elements are constantly cooled (abandoning thermal energy and moving to a state of entropy). This law is the explanation for why ice cubes melt (when the ambient heat moves towards them) and the hot soup cools (giving heat to suit the conditions of the environment). Keeping soup warm in a blood-free environment is simple; isolation does the trick. Thermos are not smart, but they are smart to slow down the thermodynamics law of the moment. Cooling a soup in a warm environment is a little more complicated, as any child who has blown the soup with impatience from their spoon on the table can be noticed.
In the end, we combined three passive methods of cooling—convection, conduction and phase changing—to handle hot conditions. For the cold, we reduced airflow, added insulation and used the heat generated by EV ARC’s normal operations. All together, these methods let the charger operate anywhere in the U.S.
The next challenge we had to overcome was more basic and involved the fundamentals of solar power. It boils down to maximizing efficiency. There are two ways to do this: make the panels larger, or make them denser in terms of the number of power-producing cells per inch. Enlarging the solar panels was never an option because the EV ARC had to be mobile and fit in a single parking space. This meant we had to somehow increase the energy density, or at least the effective density of the solar array.
The time of day with the highest energy density is typically around noon (or thereabouts) when the sun is at its highest point in the sky. This lets photons hit the array as perpendicularly as possible, maximizing its production. To get more “noon,” we had to add solar tracking. It keeps the array properly aimed toward the sun during the as much of the day as possible. This, in effect, shifts noon and extends the window of maximum effectiveness.
There is already a wide variety of tracking technologies on the market ranging from the fundamentally excessive to the excessively complex. However, the more complex the technology, the more complex it becomes. As in many engineering spaces, complexity increases the likelihood of failure and higher costs.
We also found out that photovoltaic cells are fairly insensitive to pointing accuracy. In fact, you get most production gains by keeping the modules within 20 deg. of pointing directly at the sun. Any more accuracy leads to significant increase in complexity, risk, and cost but only a marginal increase in electrical generation.
The EV ARC is self-contained and fits in a single parking space.Envision Solar
We soon settled on a simple and highly robust tracking solution that would provide almost all the gains with a far lower likelihood of failure. Our engineers devised simple but sufficient tracking algorithms to control the most reliable hardware in a patented EnvisionTrak solar tracker.
EnvisionTrak tilts the matrix to keep it directed towards the sun. But instead of rotating or rolling the table, as it is not unusual with maximum tracking devices, we bend the column well to the maximum sensitive table. This is important for parking because, although the column redirects the network, it constantly maintains the alignment of the network with the parking space, regardless of where the vehicle is going.
Network rotation would cause it to invade adjacent parking spaces, or worse, in traffic lanes (which is illegal if it’s also a chimney lane). Subsystem panels generate 25% more electrical power than a constant grid, and more electrical power means miles traveled or hours of operation of the appliance.
When it comes to switching to electrified structure equipment, the greatest attention is not the capacity of the equipment, but how to load it.
In general, when a construction project is at the stage where dirt is being moved, there is no utility grid electricity at the site, or certainly not enough to fuel construction equipment. Using classic, stationary solar panels to charge equipment involves another construction project and would require more land or encroach on the job site. And most solar installations only work when connected to the grid and the sun is shining. There is no charging at night or during inclement weather.
The EV ARC requires little space (just a parking space worth) and no construction at all. It is delivered to site, ready to operate and gets moved to the next job site as soon as it is no longer needed at the first. Because it generates and stores all its own electricity, it can charge at any time—not just when the sun is shining.
Because EV ARC is mobile and will travel and be used in a wide variety of places, it had to comply with equipment regulations and structural codes in any jurisdiction…essentially everywhere. So, the array could not be too large, though it needed as many photocells as possible.
Making a large array from subassemblies was out because that added more complexity and longer set-up/takedown times. One solution is to fold the array up into a compact package for transportation. But folding structures usually aren’t strong and stiff enough to withstand harsh weather, particularly wind and snow when unfolded.
As any good engineer knows, the weakest part of any chain is its weakest link. In the case of folding arrays, that would be the hinges. They had to be as structurally sound as the array’s other structures.
The engineering team realized that the hinge only needed its highest structural integrity when the array was deployed. So, the team invented a hinge that is most stable in the locked-out position, meaning it’s at its strongest when it needs to be. When the array is packed for travel, the hinges play a small role as the array is supported by other elements. The array packed for travel can be easily unfolded and locked into place by a single operator.
Most solar panels have spaces between the panels that allow the wind to pass freely through them while exerting little pressure on the panel. For EV ARC, we didn’t have the luxury of dedicating the bay surface component to spaces; We had to maximize every square inch while we were convinced that it would face maximum winds.
Tightening, a strategy commonly used to mount modules on solar panels, uses pliers in 4 locations, however, this creates a single load and can minimize the structural integrity of the matrix. EV ARC pliers cover the full duration of each module, creating a beam. The patented application, called Envisimount, provides a full lifetime and increases the structural integrity of the matrix. The network has been officially cleaned and independently evaluated to cope with winds of up to 120 mph. We also know that it weathered category five hurricane force winds of 18 five km/h in the Caribbean.
It is no secret that, whether electrical or not, great deviation requires abundant power to resist with hatred. Typical diesel engine devices burn four to 16 gallons of fuel depending on the time, depending on the type of device and how it is used.
The new generation of electrical appliances is relatively small and consumes only 10 to 12 kWh, which is consistent with an inconsistent operating time. This presents some problems, one of which is the intermittent nature of the sun as an energy source. Obviously, it does not shine, which means that sunlight is rarely much needed to recharge the device.
This presents the need for a way to force the device when the sun is not outside. For us, the intermediary is the battery garage that we have in all our solar products. The solar-force garage allows us to take advantage of each of the photons that reach the grid.
EnvisionTrac moves the array to that it faces the sun during most of the day.Envision Solar
It’s rare for a piece of heavy construction machinery to operate at full capacity for an entire eight-hour day. The duty cycle is usually intermittent. According to industry standard numbers, these machines typically operate at some fraction of full capacity for three to four hours, including idle time., There are outliers, of course, but understanding typical use is vital for developing charging equipment that will work for most real-world scenarios. Trying to supply energy for eight hours of maximum capacity would result in a significant over investment in the charging equipment needed for an all-electric fleet.
One benefit of electrical machinery is that no fuel is burned during idling. Conventional equipment machinery consumes as much as 70% of its gas idling, which only creates heat, noise and noxious fumes. However, electrical machinery only consumes battery power when it is operating.
A typical small electric charger has a garage battery capacity of approximately 40 kWh (kilowatt hours); An excavator of comparable length has about 20 kWh of garage. An ARC EV, which sells for about $60,000, can buy and generate enough electrical power to hold a charger a lot of structure work, as the appliance recharges at the end of each shift and resumes in its entirety. In fact, structure teams don’t have to wait until the end of the shift. They can recharge it when not in use.
A loader or excavator, as described, that plugs in when not in use during the shift, may be in a position to paint on or near a full charge. Three CRAs can force two excavators and two loaders. If more capacity is needed, more EV CRAs would be deployed.
Envision Solar is now running on a wireless charging device that eliminates the need to plug it into the charger.
Jacob Fields is CEO of Envision Solar.
By submitting this form and your non-public information, you perceive and agree that the information provided herein will be processed, stored and used to provide you with the requested in accordance with Endeavor Business Media’s terms of use and privacy policy.
From our services, you agree to obtain magazines, electronic newsletters and other communications about the related offers of Endeavor Business Media, its brands, affiliates and/or third parties in accordance with Endeavour’s privacy policy. Contact us at [email protected] or by email at Endeavor Business Media, LLC, 331 54th Avenue N., Nashville, TN 37209.
You may opt out of receiving our communications at any time by sending an email to [email protected].
A vice president of Moog sees an effective and connected long term for the industry.
According to McKinsey and Company, peak primary structure projects exceed the budget and take 20% longer than expected. And the National Center for Construction Education and Research (NCCER) says more than 600,000 heavy appliance operators are needed across the United States through December 2022. In other words, the structure can be a difficult and not easy task for your machines.
For example, the maximum structure device works all day, even when an operator waits between tasks. This results in higher emissions and fuel consumption because, even when idle, a diesel engine runs on a torque converter and pump. The advent of the zero-emissions structure apparatus can be a solution to some of the industry’s challenges. Countries such as Norway and corporations such as CASE Construction Equipment and Bobcat Company are among those targeting zero-emissions sites.
Last year, Oslo News promoted the first structure assignment where the entire battery apparatus reigned on the site. In Las Vegas last March, CASE unveiled its backhoe, the first in the industry. And Bobcat, with its compact T76e track loader, has introduced the world’s first fully compact track loader.
Electric-powered vehicles like these stop the moment an operator completes a function, so there’s no energy lost. There’s also a reduction in noise. That means better communication between workers and a remarkable improvement in the audible environment for work sites adjacent to communities.
Electric construction equipment also spells lower operating costs. CASE, for example, says its 580 EV backhoe will save an owner as much as 90% in annual vehicle, fuel and maintenance costs. By comparison, Equipment World magazine estimates a John Deere Model 310SJ backhoe-loader owned for four years and run approximately 900 hours per year would rack up preventative maintenance costs of $1,655 per year and $6.30 of diesel fuel per hour.
A driver behind the development and adoption of electric construction machines is battery technology. According to BloombergNEF, an increase in lithium-ion battery production over the last 10 years has helped prices plunge 85%, which has made electric vehicles commercially viable. Lithium-ion batteries enable longer operational time (up to eight hours) for electric construction vehicles and the ability to fully recharge some of these vehicles in eight hours.
Our contribution toward developing electric and zero-emission construction vehicles began two years ago by partnering with companies like Bobcat, CASE and Green Machine to provide the actuation, machine controls and electric drive train solution called WhisperDrive. By providing software, electronics to drive and control motors, cabling, gearboxes and machine controls, we helped Green Machine—which develops pack systems to replace lead-acid batteries and fossil fuel—and Bobcat produce its T550 compact track loader demonstrator and later its T76e prototype. Next, we began working on the CASE 580 EV backhoe. And we’re now working on a variety of small excavators.
The Bobcat T550 track loader we helped develop is fully electric, so there are no hydraulic hoses or oils to maintain. With zero emissions, the T550 also opens the possibility for construction workers to bring the machine inside a building. For the 580 EV, we teamed up with CASE to develop a pump drive unit and traction system along with sensors and controllers that electronically control the backhoe’s traction; the movements for the loader and excavation are hydraulic.
Despite the emphasis on electrical innovation, hydraulic motion devices also offer the ability to integrate intelligent designs. In the future, with the right combination of sensors, controllers, valves, actuators and interfaces, a device designer can simply equip a structure vehicle that is helping its operator automatically detect unexcavated spaces, preventing a backhoe from digging with a safe or adjusting intensity. The backhoe controls to a default slope.
With all that is possible, it is remarkable how bewildered classic device operators continue to be constrained and functionalityd by their vehicles. We know of device brands and homeowners who have spent years adjusting and adjusting their appliances to achieve which operators are the best touch. As with adjusting a classic car by adjusting with engine controls and perhaps camshaft conversion, mechanics adjust the hydraulic valves of a structure vehicle or replace portions on the joystick in the cab.
In our factory, we have demonstrated how the right combination of orders and electronics for classic homeowners digitally adjusts their appliances, achieving in a matter of days what some homeowners invest for years to achieve through mechanical adjustments.
The merit of digitally adjusting a vehicle structure is that owners can create operator-specific configurations for each user who manages the equipment. Using haptics is a way to make it less difficult for an operator to upgrade or operate equipment, as machine controls exchange data between the vehicle and the operator, offering a more accurate feel. The haptic, which comes from the Greek word “haptikos”, means a sense of touch. If you press an app on your cellular device, the vibration or sensation you feel is a type of haptic.
This sentiment might not be so vital for a veteran device operator. But as noted above, the structure industry has a growing number of roles to play as heavy appliance operators. Making the device less difficult to use provides a conceivable way to fill those jobs with young personnel who gravitate around new technologies and games.
The fabric industry can gain great benefits from connectivity and virtual machines. Think about how 4G and 5G modems can structure controllers. By creating systems for structure machines that come with devices with a variety of sensors to monitor temperature, torque, existing ones and speed, operators are more efficient. By collecting this knowledge and downloading it to the cloud, owners of the structure devices can analyze the output and replace the parameters through which their appliance reproduces the paints in on-site tasks.
Imagine an internet-connected, electric excavator that detects its battery will be empty in two hours. The machine then analyzes a weather forecast for rain the following workday. The machine alerts its operator and construction manager, and they adjust its energy consumption to squeeze out an extra hour of work albeit at slightly less power to capitalize on a few more hours of clear sky.
Connectivity is not new, but connecting devices, systems and appliances the right way (with built-in sensors) through new electric cars will make the task more efficient, safer and easier. In turn, what some might have idea becomes possible.
Ari Almqvist is the Group’s Vice President of Growth and Innovation at Moog Inc. Contact him at [email protected].
By submitting this form and your non-public information, you perceive and agree that the information provided herein will be processed, stored and used to provide you with the requested in accordance with Endeavor Business Media’s terms of use and privacy policy.
As part of our services, you agree to receive magazines, e-newsletters and other communication about related offerings from Endeavor Business Media, its brands, affiliates and/or third-party partners consistent with Endeavor’s Privacy Policy. Contact us at [email protected] or by mail to Endeavor Business Media, LLC, 331 54th Avenue N., Nashville, TN 37209.
You may opt out of receiving our communications at any time by sending an email to [email protected].