An integrated hybrid power take-off system and crane

Abstract

The present invention discloses an integrated hybrid power take-off system and crane. The power take-off system includes a power battery, a battery management system (BMS), a high-voltage power distribution unit (HDU), an external power supply (OBC), an MCU, a power take-off (PTO), a hydraulic oil pump, and a coupler for stepless speed regulation. The coupler internally includes an input shaft, an output shaft, and a motor for adjusting the coupler's torque and torque. The power battery is connected to the HDU via the BMS, which in turn is connected to the motor via the MCU to provide power to the motor. The external power supply is connected to the HDU via the OBC to provide power to the motor and charge the power battery. The coupler input shaft is connected to the PTO, and the output shaft is connected to the hydraulic oil pump. The present invention solves the problems of the prior art, such as a narrow output speed range, loud engine adjustment noise, and high energy loss.

Description

Technical Field

[0001] The invention relates to an integrated hybrid power take-off system and a crane, belonging to the technical field of engineering machinery. Background Art

[0002] With the continuous advancement of science and technology, global attention is being focused on environmental governance and energy shortages. The country is also placing increasing emphasis on energy consumption in the construction machinery industry, leading the industry to move towards energy conservation and emission reduction. Currently, traditional truck cranes rely on engines to power the chassis and loading operations. Since the chassis' power for driving is much higher than for loading operations, the engine is tailored to the needs of the chassis' driving. During loading operations, the high engine power often prevents the engine from operating within its efficient range, resulting in high fuel consumption and the emission of significant amounts of harmful gases, making it less economical. To address this issue, hybrid loading systems have emerged. These systems feature a coaxial engine and electric motor, capable of driving the loading operation independently or in combination. However, due to the lack of a dedicated coupling mechanism, the motor regulates torque rather than speed during operation, leading to jerking and vibration during operation and difficulty maintaining the engine's optimal efficiency. Furthermore, due to the fixed speed ratio of the power take-off (PTO), loading operation speed depends on engine speed. High-speed operation results in high engine speed, high noise, and high fuel consumption. At low speeds, the engine speed cannot be reduced below idle, making micro-maneuverability difficult.

[0003] The working principle of the existing hybrid power take-off system is as follows: Figure 1 As shown, this system has two operating modes. One is that when the engine is working, the power is transmitted to the upper vehicle through the engine, clutch, gearbox, power take-off, motor and hydraulic oil pump for operation, and the motor is idling at this time; in the other mode, the motor directly drives the hydraulic pump, and drives the upper vehicle through the hydraulic system to operate. At this time, the drive shaft at the motor input end and the gearbox power take-off are idling under the action of the motor.

[0004] The existing crane operation process has the following shortcomings: the motor and power take-off are coaxially connected, and the number of motors is the same as the number of power take-offs. If the vehicle hydraulic system requires multiple power take-offs in the gearbox, multiple motors are required, which significantly increases system costs and requires a large amount of space, making it difficult to arrange the motors on the vehicle. When the crane uses a motor for vehicle loading, the motor also drives the power take-off, increasing the additional moment of inertia and power consumption. When the crane uses an engine for vehicle loading, the engine also drives the motor rotor, increasing the additional moment of inertia and fuel consumption. Neither method is the most economical. The power take-off uses a fixed speed ratio, and the vehicle loading speed depends entirely on the power source speed, making it difficult for the power source to operate in the optimal economic range. Summary of the Invention

[0005] In order to address the deficiencies of the prior art, the purpose of the present invention is to provide an integrated hybrid power take-off system and crane, which solves the problems in the prior art of unadjustable power take-off speed ratio, high noise and high fuel consumption caused by high-speed engine output, while also avoiding the sense of frustration caused by the motor when adjusting the engine output torque.

[0006] In order to achieve the above objectives, the present invention adopts the following technical solutions:

[0007] An integrated hybrid power take-off system, including a power battery, a BMS, a high-voltage power distribution unit, an OBC, an external power supply, an MCU, a power take-off, a hydraulic oil pump, and a coupler for stepless speed regulation;

[0008] The coupler includes an input shaft, an output shaft, and a motor that adjusts the coupler's speed and torque;

[0009] The power battery is connected to the high-voltage distribution unit through the BMS;

[0010] The high-voltage power distribution unit is connected to the motor through the MCU to provide power to the motor;

[0011] The external power supply is connected to the high-voltage distribution unit through the OBC to provide power to the motor and charge the power battery;

[0012] The coupler input shaft is connected to the power take-off, and the output shaft is connected to the hydraulic oil pump.

[0013] Furthermore, the aforementioned coupler includes a first speed ratio adjustment gear set, a planetary carrier, a second adjustment gear set, a sun gear, an outer ring gear, a first motor, and a second motor;

[0014] The first speed ratio adjustment gear set includes a first speed ratio adjustment gear and a second speed ratio adjustment gear, the second speed ratio adjustment gear set includes a third speed ratio adjustment gear and a fourth speed ratio adjustment gear, and the input shaft includes a first input shaft and a second input shaft;

[0015] The first input shaft is coaxially connected to the first speed ratio adjustment gear, the first input shaft is externally connected to the power take-off, and the second speed ratio adjustment gear is connected to the planet carrier;

[0016] The planet carrier is connected to the outer ring gear through the planet gear and the sun gear inside;

[0017] The second input shaft is connected to the second motor rotor, the second input shaft is coaxially connected to the third speed ratio adjustment gear, and the fourth speed ratio adjustment gear is coaxially connected to the sun gear;

[0018] The output shaft is connected to the outer ring gear, and the outer ring gear is coaxially connected to the rotor of the first motor.

[0019] Furthermore, the aforementioned also includes a braking element;

[0020] The first speed ratio adjustment gear is connected to the coupler housing through a brake element;

[0021] The third speed ratio adjustment gear is connected to the coupling housing via a brake element.

[0022] Furthermore, the aforementioned braking element is a clutch or a brake.

[0023] Furthermore, the first motor housing is connected to the inner housing of the coupler, and the second motor housing is connected to the inner housing of the coupler.

[0024] Furthermore, the aforementioned also includes a clutch, which is connected to the input end of the first input shaft.

[0025] A crane comprises any one of the aforementioned integrated hybrid power take-off systems.

[0026] The beneficial effects achieved by the present invention are:

[0027] 1. The speed ratio of the coupler is steplessly adjustable, which reduces the operating range of the engine speed, reduces product noise, and increases the output speed range;

[0028] 2. Realize the separate or mixed input of the three power sources of engine and motor, which improves the crane's adaptability to working conditions;

[0029] 3. The second motor adjusts the coupler output speed, and the first motor adjusts the coupler output torque, so that the engine torque and speed always operate in the optimal economic range, improving engine efficiency and reducing fuel consumption;

[0030] 4. The dual motors adjust the speed and torque through the coupler, the output torque does not fluctuate, and the vehicle operation is stable;

[0031] 5. During the speed regulation process of the second motor, when the torque of the second motor is in the opposite direction to the speed, the motor performs energy recovery, which can charge the battery and save energy;

[0032] 6. When one input shaft runs alone, the other input shaft is locked, which reduces the extra moment of inertia and reduces system consumption. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is an existing hybrid power take-off system;

[0034] Figure 2 This is the first embodiment of the integrated hybrid power take-off coupler of the present invention;

[0035] Figure 3 This is the second embodiment of the integrated hybrid power take-off coupler of the present invention;

[0036] Figure 4This is the third embodiment of the integrated hybrid power take-off coupler of the present invention;

[0037] Figure 5 The invention relates to an integrated hybrid power take-off system.

[0038] The meaning of the reference numerals in the figure are: 1-first speed ratio adjustment gear set; 2-planetary carrier; 3-second adjustment gear set; 4-sun gear; 5-outer ring gear; 6-brake element; 8-first motor; 9-second motor; 10-clutch; 1a-first speed ratio adjustment gear; 1b-second speed ratio adjustment gear; 3a-third speed ratio adjustment gear; 3b-fourth speed ratio adjustment gear. DETAILED DESCRIPTION

[0039] The present invention will be further described below in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention.

[0040] This embodiment discloses an integrated hybrid power take-off coupler, such as Figure 2 As shown, the coupler includes a differential gear system, the first input shaft is connected to the planetary carrier 2 through the first speed ratio adjustment gear set 1, the first speed ratio adjustment gear set 1 includes a first speed ratio adjustment gear 1a and a second speed ratio adjustment gear 1b, the first input shaft is coaxially connected to the first speed ratio adjustment gear 1a, the first speed ratio adjustment gear 1a is also connected to the coupler housing through a brake element 6 to achieve unlocking and locking of the first input end, the brake element is preferably a clutch or a brake, and the second speed ratio adjustment gear 1b is connected to the planetary carrier 2.

[0041] The second input shaft is connected to the rotor of the second motor 9, the housing of the second motor 9 is connected to the coupler housing, and is connected to the sun gear 4 through the second speed ratio adjustment gear set 3. The second speed ratio adjustment gear set 3 includes a third speed ratio adjustment gear 3a and a fourth speed ratio adjustment gear 3b. The third speed ratio adjustment gear 3a is connected to the coupler housing through a brake element to achieve unlocking and locking of the second input shaft. The fourth speed ratio adjustment gear 3b is coaxially connected to the sun gear 4.

[0042] The shaft of the outer ring gear 5 is coaxially connected to the rotor of the first motor 8 , the housing of the first motor 8 is connected to the coupler housing, the motor output shaft is the coupler output shaft, the planet carrier 2 is externally connected to the outer ring gear 5 , and internally connected to the sun gear 4 .

[0043] The first speed ratio adjusting gear set 1 and the second speed ratio adjusting gear set 3 are used to adjust the speed ratio of the input shaft, and the brake element 6 is used to lock or unlock the input shaft, and both can be installed or cancelled according to actual use conditions.

[0044] According to the characteristics of the planetary gear differential system, the torques of the first and second input shafts can be coupled and transmitted to the outer ring gear 5 in a fixed ratio. That is, the torques of the two input shafts are distributed in a fixed ratio, and the combined force is output to the outer ring gear 5. The first motor 8 performs the final adjustment of the output torque of the outer ring gear 5 of the differential system, achieving the system's parallel-parallel operation. When the speed of the first input shaft remains unchanged, changes in the speed of the second input shaft will cause changes in the speed of the output shaft, thereby achieving stepless adjustment of the output shaft speed. When the speed of the second input shaft is in the same direction as the speed of the first output shaft, the higher the speed of the second input shaft, the lower the speed of the coupler output, reaching a minimum of zero speed, in which case the second motor 9 performs energy recovery. When the speed of the second input shaft is in the opposite direction to the speed of the first output shaft, the higher the speed of the second input shaft, the higher the speed of the coupler output, in which case the second motor 9 outputs power. When the brake element 6 on the first input shaft engages, the first input shaft, the first ratio adjustment gear set 1, the planetary carrier 2, and the coupler housing are locked. Only the second input shaft drives the output shaft through the sun gear 4, the outer ring gear 5, and the first motor 8. In this state, power to the first input shaft is cut off. When the brake element 6 on the second input shaft is engaged, the second input shaft, the second speed ratio adjustment gear set 3, the sun gear 4 and the coupler housing are locked, and only the first input shaft drives the output shaft to rotate through the planetary carrier 2, the outer ring gear 5 and the first motor 8. In this state, the power of the second input shaft is cut off.

[0045] When the first input shaft of the power coupler is in normal state, such as Figure 3 As shown, the power coupler input shaft can add a clutch 10 at the input end. When the power needs to be cut off, the clutch is disengaged. The working process of the coupler is similar to Figure 2 The coupler is the same, with only an additional clutch to cut off the input shaft power.

[0046] The first motor 8 and the second motor 9 can be integrated and installed inside the coupler, such as Figure 2 、 Figure 3 As shown, it can also be installed outside the coupler, such as Figure 4 shown.

[0047] The following mainly introduces the coupler in Figure 2 in detail:

[0048] Truck crane hybrid power take-off system Figure 5 As shown, the first input shaft is connected to the transmission power take-off (or engine power take-off), and the output shaft is connected to the hydraulic oil pump, which outputs high-pressure oil to provide power for the vehicle operation system.

[0049] The power battery is connected to the high-voltage power distribution unit via the BMS (battery management system). The motor controllers MCU1 and MCU2 provide power to the second motor 9 and the first motor 8. The motor controller MCU1 is connected to the second motor 9 of the coupler, and the motor controller MCU2 is connected to the first motor 8 of the coupler. An external power supply, through the OBC (onboard charger) and the high-voltage power distribution unit, provides power to the motors and simultaneously charges the power battery.

[0050] The integrated hybrid power take-off operation system of the present invention has three operation paths: hybrid mode, pure oil mode, and pure electric mode.

[0051] When no external power source is available and the battery is fully charged, the driver can select the hybrid power mode. In this mode, the driver starts the engine and, after engaging the power take-off, the brake element 6 in the coupler automatically disengages. The engine and the second motor 9, connected in series with the first motor 8, work together to achieve power output through the differential gear system. The second motor 9 primarily regulates the output speed. The first motor 8 outputs torque based on the load, reducing the overall load on the differential gear system ring gear. By regulating the speed of the second motor 9 and the torque of the first motor 8, the engine always operates within the optimal speed and torque range, reducing engine fuel consumption.

[0052] When powered by an external power source, the driver can select pure electric mode. In this mode, the brake element 6 on the first input shaft engages, transforming the coupler into a fixed-ratio power take-off. When low torque output is required, the first motor 8 directly outputs power (alternatively, the second motor 9 can output power through the sun gear 4 and outer ring gear 5). When high torque output is required, the first and second motors 8 and 9 work together to output power. In this mode, the power take-off input is disconnected.

[0053] When there's no external power source or the battery is low, the driver can select oil-only mode. In this mode, brake element 6 on the second input shaft engages, transforming the coupler into a fixed-ratio power take-off. Engine torque and speed are adjusted based on the load and the throttle position. In this mode, input power to the first and second motors 8 and 9 is cut off (or the motors idle).

[0054] This embodiment also relates to a crane, which uses the aforementioned integrated hybrid power take-off system to solve the problems in the prior art of the non-adjustable speed ratio of the power take-off, high noise and high fuel consumption caused by high-speed engine output, while also avoiding the sense of frustration caused by the motor when adjusting the engine output torque.

[0055] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. An integrated hybrid power take-off system, characterized in that: Including power battery, BMS, high-voltage distribution unit, OBC, external power supply, MCU, power take-off, hydraulic oil pump and coupler for stepless speed regulation; The coupler includes an input shaft, an output shaft and a motor for adjusting the speed and torque of the coupler; The power battery is connected to the high-voltage power distribution unit through the BMS; The high-voltage power distribution unit is connected to the motor through the MCU to provide power to the motor; The external power supply is connected to the high-voltage power distribution unit through the OBC to provide power to the motor and charge the power battery; The coupler input shaft is connected to the power take-off, and the output shaft is connected to the hydraulic oil pump; The coupler comprises a first speed ratio adjustment gear set (1), a planetary carrier (2), a second speed ratio adjustment gear set (3), a sun gear (4), an outer ring gear (5), a first motor (8) and a second motor (9); The first speed ratio adjustment gear set (1) includes a first speed ratio adjustment gear (1a) and a second speed ratio adjustment gear (1b), the second speed ratio adjustment gear set (3) includes a third speed ratio adjustment gear (3a) and a fourth speed ratio adjustment gear (3b), and the input shaft includes a first input shaft and a second input shaft; The first input shaft is coaxially connected to the first speed ratio adjustment gear (1a), the first input shaft is externally connected to a power take-off, and the second speed ratio adjustment gear (1b) is connected to the planet carrier (2); The planet carrier (2) is externally connected to the outer ring gear (5) through the planetary gears and internally connected to the sun gear (4); The second input shaft is connected to the rotor of the second motor (9), the second input shaft is coaxially connected to the third speed ratio adjustment gear (3a), and the fourth speed ratio adjustment gear (3b) is coaxially connected to the sun gear (4); The output shaft is connected to the outer gear ring (5), and the outer gear ring (5) is coaxially connected to the rotor of the first motor (8); Also included is a brake element (6); The first speed ratio adjustment gear (1a) is connected to the coupling housing via a brake element (6); The third speed ratio adjustment gear (3a) is connected to the coupling housing via a brake element (6); The housing of the first motor (8) is connected to the inner housing of the coupler, and the housing of the second motor (9) is connected to the inner housing of the coupler.

2. The integrated hybrid power take-off system according to claim 1, characterized in that: The braking element (6) is a clutch or a brake.

3. The integrated hybrid power take-off system according to claim 2, characterized in that: It also includes a clutch (10), wherein the clutch (10) is connected to the input end of the first input shaft.

4. A crane, characterized in that: It comprises an integrated hybrid power take-off system as described in any one of claims 1-3.

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