Design Challenge

MONTGOMERY DESIGN INTERNATIONAL

Working with a large US construction equipment manufacturer, Montgomery Design International USA (MDI) has developed a concept for a hybrid driven, autonomously operated wheeled loader that may also be the answer for the near-term replacement of hydraulic systems in this type of vehicle. Traditional hydraulic problems such as overheating, leakage, noise and environmental concerns could all but be eliminated by replacing these systems with electric hub motors. A 100% electric vehicle is still a way off, but incremental improvements to primary and secondary drive systems are being worked on by research groups at many manufacturers. Within the next 5-10 years it is expected that these companies will be able to offer such replacement technology at a marketable price. For the time being, cost, component availability and specific application remain the major deterrents to electric drive systems.

The MDI concept features an independent all-wheel-drive system that uses DC-AC powered through four individual wheel hub motors rated at 85bhp. These are driven by a diesel-powered generator putting out 300kW. The electric drivetrain removes the need for a traditional mechanical transmission, thereby reducing the overall vehicle part count by nearly 50%. The infinitely variable hub motors function as a continuously variable transmission for the primary drive system and for the secondary drive systems, allowing more precise control of buckets and other work tools. Another great benefit is that what used to be engine-powered accessories, such as the alternator, water pump and HVAC, can now operate independently and save as much as 50bhp, which can go back into the main drive and secondary drive electric systems. The engine also operates at a fairly constant speed, and can be tuned to run at the most efficient rpm range, thereby improving fuel consumption by 25% or so, and moving up to 30% more material for a given engine output. The loader arm pancake motors are rated at 55bhp.

Similar to hybrid-electric automobiles, the hybrid wheeled loader features regenerative capabilities. Braking energy from the slowing vehicle is captured and sent back to a lithium-polymer storage battery, which can then run accessories, power the loader arms and implements, and even run whole systems for limited periods. The hybrid-electric wheeled loader concept is shown as an autonomously operated vehicle, which is a completely separate issue, but it can also be fitted with a conventional cab for manual operation.

BIOGRAPHY

Montgomery Design International is a full service product design and development firm located in suburban Chicago, Illinois / USA. Founded in 1983, MDI has arguably become the most prolific consulting firm in the world with regard to the industrial design and styling of agricultural and construction equipment.

The MDI studio has worked for the IH and CaseIH companies since its inception, and for Caterpillar and AGCO for over 10 years. Key product lines credited to MDI include the complete line of MAGNUM tractors (two of which won prestigious international design awards), the entire NewHolland line of “cats eye” tractors, the Challenger 9000 4WD tractor (another design award winner) and numerous products and concepts for other large international firms such as Caterpillar, McCormick, Yanmar and JOY Mining.

In addition to the industrial vehicle work, MDI services many diverse industries including medical devices, gaming, household appliances, toys, lighting and the communications industry.