Energy recovery controller

Abstract

The present invention relates to an energy recovery controller, including a main control MCU, a current sampling circuit, a PWM step-up / step-down control circuit, a first battery group switching control circuit, a second battery group switching control circuit, a first battery group and a second battery group; the voltage of the first battery group and the second battery group is collected by the main control MCU to determine which group of batteries is suitable as a rechargeable battery, and when the electric vehicle is running, the main control MCU collects a brake signal to select a charging time for the motor charging circuit; when charging, the main control MCU first collects the power generation voltage of the motor, and then adjusts the charging voltage through a PWM signal, thereby providing a stable voltage for the charged battery group. The energy recovery controller of the present invention recovers the kinetic energy of the electric vehicle during braking or downhill, and charges it, thereby increasing the cruising range of the electric vehicle and improving the energy application efficiency.

Description

Technical Field

[0001] The invention relates to the field of new energy technology, in particular to an energy recovery controller. Background Art

[0002] With the rise of the express delivery and food delivery industries, there is a great demand for electric bicycles; however, the range of electric bicycles is generally low. The range of most brands of electric bicycles does not exceed 100 kilometers. A few brands of electric bicycles can exceed 100 kilometers, but it is only a little more than 100 kilometers. For the express delivery and food delivery industries, most employees ride more than the total range of electric vehicles in a day; however, during work, they need to find charging stations to charge temporarily, which wastes the precious time of employees. Therefore, the most urgent task to improve the current problem is to increase the range as much as possible. Fully charging at night can meet the daily mileage needs of as many express delivery and food delivery employees as possible. Summary of the invention

[0003] In view of this, the purpose of the present invention is to provide an energy recovery controller that can recover as much energy as possible wasted during braking, downhill and coasting of the electric vehicle during riding, thereby increasing the cruising range.

[0004] The energy recovery controller of the present invention comprises a main control MCU, a current sampling circuit, a PWM buck-boost control circuit, a first battery pack switching control circuit, a second battery pack switching control circuit, a first battery pack and a second battery pack;

[0005] The PWM step-up and step-down control circuit includes a motor generating circuit and a PWM voltage regulating driving circuit. The motor generating circuit is connected to the motor of the electric vehicle, and converts the AC power generated by the motor into a DC signal for output. The PWM voltage regulating driving circuit is connected to the main control MCU. The PWM signal generated by the main control MCU is amplified by the PWM voltage regulating driving circuit and then voltage-regulated with the DC signal.

[0006] The first battery pack switching circuit includes two switch circuits, one of which receives a control signal from the main control MCU and is used to control the on / off of the output end of the first battery pack and the motor power generation circuit, and the other switch circuit receives a control signal from the main control MCU and is used to control the on / off between the first battery pack and the motor;

[0007] The second battery pack switching circuit also includes two switch circuits, one of which receives a control signal from the main control MCU and is used to control the on / off of the output end of the second battery pack and the motor generating circuit, and the other switch circuit receives a control signal from the main control MCU and is used to control the on / off between the second battery pack and the motor;

[0008] The current sampling circuit includes three circuits, namely, a battery discharge current sampling circuit, a battery charging current sampling circuit and a motor power generation current sampling circuit. The input end of the battery discharge current sampling circuit is connected to the interface of the first battery pack or the second battery pack, and the output end is connected to the main control MCU; the input end of the motor power generation current sampling circuit is connected to the motor power generation circuit, and the output end is connected to the main control MCU; the input end of the battery charging current sampling circuit is connected to the interface of the second battery pack or the first battery pack, and the output end is connected to the main control MCU;

[0009] The main control MCU is connected to the interfaces of the first battery pack, the second battery pack and the motor at the same time, and is used to collect the discharge voltages of the first battery pack, the second battery pack and the motor.

[0010] Furthermore, the PWM step-up / step-down control circuit also includes a switch circuit, which is used to receive a control signal from the main control MCU and to control the on / off of the output end of the motor generating circuit.

[0011] Furthermore, the switching circuit includes a half-bridge driver and a switching tube, the input end of the half-bridge driver is connected to the pin of the main control MCU that can generate a PWM signal, the output end of the half-bridge driver is connected to and drives the switching tube, and the switching tube serves as a switching device that performs the switching function.

[0012] Furthermore, the battery discharge current sampling circuit, the battery charging current sampling circuit and the motor generation current sampling circuit all include a two-stage operational amplifier consisting of two operational amplifiers, the input end of the two-stage operational amplifier inputs the current sampling signal, and each stage output of the two-stage operational amplifier is output to the main control MCU.

[0013] Furthermore, the motor power generation circuit includes a rectifier and a filter which are arranged in sequence, and the alternating current generated by the motor becomes direct current after being rectified and filtered by the rectifier and the filter.

[0014] Furthermore, the PWM voltage regulation driving circuit includes a multi-stage amplifying transistor, and the PWM signal generated by the main control MCU is amplified by the multi-stage amplifying transistor and then used to adjust the DC voltage generated by the motor generating circuit and output it.

[0015] One of the first battery pack and the second battery pack is discharged for normal operation of the electric product, and the other battery pack is used for charging to recover the electrical energy or other natural energy wasted during the normal process of the product. If it is a rear-wheel drive vehicle, a generator is installed on the front wheel. During driving, the controller can control the front wheel to generate electricity at a certain stage, and charge the rechargeable battery pack through power generation; thereby achieving the purpose of energy recovery.

[0016] The voltage of the first battery group and the second battery group is collected by the main control MCU to determine which group of batteries is suitable as a rechargeable battery. When the electric vehicle is driving, the main control MCU collects the brake signal to select the charging time for the motor charging circuit; when charging, the main control MCU first collects the power generation voltage of the motor, and then adjusts the charging voltage through the PWM signal to provide a stable voltage for the charged battery pack.

[0017] The beneficial effects of the present invention are as follows: the energy recovery controller of the present invention recovers the kinetic energy of the electric vehicle during braking or downhill driving and charges it, thereby increasing the cruising range of the electric vehicle and improving the energy application efficiency. It also complies with the energy-saving and environmental protection concept advocated by the country. This technology has broad market application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present application and should not be regarded as limiting the scope. For those of ordinary skill in the art, other related drawings can be obtained based on these drawings without creative work:

[0019] FIG1 is a circuit diagram of a main control MCU of the present invention;

[0020] FIG2 is a circuit diagram of a PWM buck-boost control circuit of the present invention;

[0021] FIG3 is a circuit diagram of a first battery pack switching circuit of the present invention;

[0022] FIG4 is a circuit diagram of a second battery pack switching circuit of the present invention;

[0023] FIG5 is a circuit diagram of a motor generating current sampling circuit according to the present invention;

[0024] FIG6 is a circuit diagram of a battery discharge current sampling circuit according to the present invention;

[0025] FIG. 7 is a circuit diagram of a battery charging current sampling circuit according to the present invention. DETAILED DESCRIPTION

[0026] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. The components of the embodiments of the present application described and shown in the drawings here can be arranged and designed in various different configurations.

[0027] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application for which protection is sought, but merely represents selected embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in the field without creative work are within the scope of protection of the present application.

[0028] It should be noted that similar reference numerals and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings. At the same time, in the description of this application, the terms "first", "second", etc. are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0029] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0030] As shown in Figure 1- Figure 7 As shown: The energy recovery controller of this embodiment includes a main control MCU, a current sampling circuit, a PWM buck-boost control circuit, a first battery pack switching control circuit, a second battery pack switching control circuit, a first battery pack and a second battery pack. The main control MCU adopts the 32-bit Cortex-M0+ automotive-grade MCU chip AC7811.

[0031] The PWM step-up / step-down control circuit includes a motor generating circuit and a PWM voltage regulating driving circuit. The motor generating circuit is connected to the interface of the electric motor. The motor is a generator motor installed on the non-driving wheel of the electric vehicle. The motor drives the generator to generate electricity when the electric vehicle is braking or sliding. The motor generating circuit includes a rectifier and a filter arranged in sequence. The alternating current generated by the motor is rectified and filtered by the rectifier and the filter to become direct current. The rectifier is a SKBPC3516 three-phase rectifier bridge. The three output terminals ACIN1, ACIN2 and ACIN3 of the motor are connected to the three-phase rectifier bridge. After the three-phase rectifier bridge rectifies, the capacitors EC1, EC2, EC3 and C13 filter the alternating current generated by the motor, thereby converting the alternating current generated by the motor into a direct current signal for output.

[0032] The DC output is controlled by a switch open circuit. The switch circuit includes a half-bridge driver U8 and a MOS switch tube Q1. The model of the half-bridge driver is IR2103S. The logic high-end input HIN of the half-bridge driver is connected to the pin (DCDC-BUCK-PWM) of the main control MCU. The high-end output HO of the half-bridge driver is connected to the gate of the MOS switch tube Q1, and the source and drain of the switch tube Q1 are connected in series to the DC output line. The pin of the main control MCU controls the half-bridge driver and the MOS switch tube Q1 through high and low level signals.

[0033] The PWM voltage regulation drive circuit is connected to the control pin (DCDC-BOST-PWM) of the main control MCU, and uses the PWM signal generated by the main control MCU and the DC signal generated by the motor generating circuit for voltage regulation. However, the PWM signal generated by the main control MCU is relatively weak and cannot be used directly for regulation. Therefore, the PWM voltage regulation drive circuit includes multi-stage amplifying transistors, namely Q28, Q29 and Q31. The PWM signal generated by the main control MCU is amplified by the multi-stage amplifying transistors to drive the MOS switch tube Q4, and then the on-off of the MOS switch tube Q4 and the parallel capacitor C19 are used to adjust the voltage of the DC output. Finally, it is rectified and filtered by the Schottky diode D22 and the filter capacitors EC4, EC5, C14 and C15 again when it is output. A stable battery charging voltage (DC-60V is used in this embodiment, and it needs to be set according to the battery voltage value during actual implementation), the DC power generated by the motor generating circuit is regulated and output, and the PWM signal generated by the main control MCU is amplified by the PWM voltage regulation drive circuit and regulated together with the DC signal; the benefits brought by this are: many control systems currently have only a single buck charging function, that is, the speed of the energy recovery motor must reach a certain value, and its output voltage must be higher than a certain value before charging recovery can be performed; and this technology can automatically switch between boost and buck, even if the speed is very low and the voltage generated by the generator is very low, we can also increase the charging voltage to a certain value through the boost circuit, and charge the battery stably with constant current or constant voltage, thereby further improving the recovery rate.

[0034] The first battery pack switching circuit includes two switch circuits. The specific composition of the switch circuit is consistent with the switch circuit in the PWM buck-boost control circuit, and both include a half-bridge driver (U6 and U7) and a switch tube. The switch tube here adopts a pair of tubes composed of two symmetrical MOS switch tubes. The first battery pack (i.e., battery A) is respectively connected to the DC60V power supply and the motor (MOTO-VCC) processed by the motor power generation and PWM buck-boost control circuit, and is used for charging and discharging respectively; the half-bridge driver U6 in one of the switch circuits receives the PWM control signal (BAT-A-CHG-EN) of the main control MCU and is used to control the switching state of the pair of tubes (Q3 and Q5), thereby controlling the on-off of the first battery pack and the output end of the motor power generation circuit (charging voltage, DC-60V is used in this embodiment, and it needs to be set according to the battery voltage value in actual implementation). Similarly, the other switch circuit receives the control signal of the main control MCU and is used to control the on-off between the first battery pack and the motor (MOTO-VCC). The pair of tubes is used to prevent reverse connection.

[0035] The structure of the second battery pack switching circuit is basically the same as that of the first battery pack switching circuit, including two switch circuits, one of which receives a control signal from the main control MCU and is used to control the on-off of the output end of the second battery pack and the motor generating circuit, and the other switch circuit receives a control signal from the main control MCU and is used to control the on-off between the second battery pack and the motor. Please refer to the diagram, which will not be described in detail here;

[0036] The current sampling circuit includes three circuits, namely, a battery discharge current sampling circuit, a battery charge current sampling circuit and a motor generation current sampling circuit. In this embodiment, it is assumed that the first battery group (i.e., battery A) is in a discharge state and the second battery group (i.e., battery B) is in a charge state;

[0037] The battery discharge current sampling circuit, the battery charging current sampling circuit and the motor power generation current sampling circuit all include a two-stage operational amplifier consisting of two operational amplifiers, the input end of the two-stage operational amplifier inputs a current sampling signal, and each stage output of the two-stage operational amplifier is output to the main control MCU, so there are two output ends;

[0038] The input end (A-IAVE-SENS+ and A-IAVE-SENS-) of the battery discharge current sampling circuit is connected to the interface of the first battery pack, and the output end (A-IAVE and A-TRAP) is connected to the main control MCU; the input end (BAT-CHG-CURR+ and BAT-CHG-CURR-) of the motor power generation current sampling circuit is connected to the motor power generation circuit, and the output end (CHG-CURR-AD and CHG-CURR-IRQ) is connected to the main control MCU; the input end (B-IAVE-SENS+ and B-IAVE-SENS-) of the battery charging current sampling circuit is connected to the interface of the second battery pack or the first battery pack, and the output end (B-IAVE and B-TRAP) is connected to the main control MCU;

[0039] Two pins with analog-to-digital conversion function of the main control MCU are connected in series with current limiting resistors and then connected to the interfaces of the first battery pack, the second battery pack and the motor (A-BAT-VDET, B-BAT-VDET and MOTO-VCC respectively) for collecting the discharge voltage (or power generation voltage) of the first battery pack, the second battery pack and the motor.

[0040] The specific implementation principle is as follows: one of the first battery pack and the second battery pack is discharged for normal operation of the electric product, and the other battery pack is used for charging to recover the electrical energy or other natural energy wasted during the normal process of the product; if it is a rear-wheel drive vehicle, a generator is installed on the front wheel. During driving, the controller can control the front wheel to generate electricity at a certain stage, and charge the rechargeable battery pack through power generation; thereby achieving the purpose of energy recovery.

[0041] The voltage of the first battery group and the second battery group is collected by the main control MCU to determine which battery group is suitable as a rechargeable battery. When the electric vehicle is driving, the main control MCU collects the brake signal to select the charging time for the motor charging circuit; when charging, the main control MCU first collects the power generation voltage of the motor, and then decides whether to boost or buck charge at this time through the main control MCU, thereby providing a stable voltage for the charged battery pack.

[0042] The charging current is controlled by this technology, and the corresponding charging current is selected according to the current speed and resistance, so that the normal driving of the electric vehicle will not be affected by the charging resistance when the electric vehicle is driving.

[0043] The energy recovery controller of the present invention recovers the kinetic energy of the electric vehicle during braking or downhill driving and charges it, thereby increasing the range of the electric vehicle and improving the energy application efficiency. It also complies with the concept of energy conservation and environmental protection advocated by the country. This technology has broad market application prospects.

[0044] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution of the present invention, which should be included in the scope of the claims of the present invention.

Claims

1. Energy recovery controller, characterized in that: It includes a main control MCU, a current sampling circuit, a PWM buck-boost control circuit, a first battery pack switching control circuit, a second battery pack switching control circuit, a first battery pack and a second battery pack; The PWM step-up and step-down control circuit includes a motor generating circuit and a PWM voltage regulating driving circuit. The motor generating circuit is connected to the motor of the electric vehicle, and converts the AC power generated by the motor into a DC signal for output. The PWM voltage regulating driving circuit is connected to the main control MCU. The PWM signal generated by the main control MCU is amplified by the PWM voltage regulating driving circuit and then voltage-regulated with the DC signal. The first battery pack switching circuit includes two switch circuits, one of which receives a control signal from the main control MCU and is used to control the on / off of the output end of the first battery pack and the motor power generation circuit, and the other switch circuit receives a control signal from the main control MCU and is used to control the on / off between the first battery pack and the motor; The second battery pack switching circuit also includes two switch circuits, one of which receives a control signal from the main control MCU and is used to control the on / off of the output end of the second battery pack and the motor generating circuit, and the other switch circuit receives a control signal from the main control MCU and is used to control the on / off between the second battery pack and the motor; The current sampling circuit includes three circuits, namely, a battery discharge current sampling circuit, a battery charging current sampling circuit and a motor power generation current sampling circuit. The input end of the battery discharge current sampling circuit is connected to the interface of the first battery pack or the second battery pack, and the output end is connected to the main control MCU; the input end of the motor power generation current sampling circuit is connected to the motor power generation circuit, and the output end is connected to the main control MCU; the input end of the battery charging current sampling circuit is connected to the interface of the second battery pack or the first battery pack, and the output end is connected to the main control MCU; The main control MCU is connected to the interfaces of the first battery pack, the second battery pack and the motor at the same time, and is used to collect the discharge voltages of the first battery pack, the second battery pack and the motor; The PWM step-up / step-down control circuit also includes a switch circuit, which is used to receive a control signal from the main control MCU and to control the on / off of the output end of the motor generating circuit; The switch circuit includes a half-bridge driver and a switch tube, the input end of the half-bridge driver is connected to a pin of the main control MCU that can generate a PWM signal, the output end of the half-bridge driver is connected to and drives the switch tube, and the switch tube serves as a switch device that performs a switching function; The battery discharge current sampling circuit, the battery charging current sampling circuit and the motor generation current sampling circuit all include a two-stage operational amplifier consisting of two operational amplifiers, the input end of the two-stage operational amplifier inputs a current sampling signal, and each stage output of the two-stage operational amplifier is output to the main control MCU.

2. The energy recovery controller according to claim 1, characterized in that: The motor power generation circuit includes a rectifier and a filter arranged in sequence, and the alternating current generated by the motor becomes direct current after being rectified and filtered by the rectifier and the filter.

3. The energy recovery controller according to claim 1, characterized in that: The PWM voltage regulation driving circuit includes a multi-stage amplifying transistor. The PWM signal generated by the main control MCU is amplified by the multi-stage amplifying transistor and is used to adjust the DC voltage generated by the motor generating circuit and output it.

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