An electric vehicle ring power supply system

Abstract

The application provides an electric vehicle annular power supply system. The system comprises a plurality of high-voltage units and a range extender connected into an annular architecture by high-voltage interconnection lines, wherein the high-voltage unit comprises a comprehensive controller and a high-voltage power module composed of a power battery; the range extender is connected with the comprehensive controller of each high-voltage unit to provide high voltage for the comprehensive controller; the comprehensive controller is used for power distribution control, state monitoring and overcurrent protection of vehicle high-voltage equipment; the high-voltage power modules of the plurality of high-voltage units are connected in parallel through a high-voltage distribution box, when a part of the high-voltage power modules fails, the normal high-voltage power modules supply power to the comprehensive controllers of other high-voltage units and provide high-voltage power supply for the vehicle high-voltage equipment. The application can realize redundant power supply for the vehicle high-voltage equipment, reduce the risk of vehicle high-voltage power failure and improve the reliability of the whole vehicle high-voltage power supply.

Description

Technical Field

[0001] This invention belongs to the field of high-voltage power distribution technology for electric vehicles, and specifically relates to a ring power supply system for electric vehicles. Background Technology

[0002] The electrification of heavy-duty special vehicles is an important direction for future equipment development. The silent operation of pure electric mode and the high mobility and reliability of distributed drive are advantages that chassis electrification cannot replace. To achieve these characteristics, special vehicles will adopt a high-power, multi-energy high-voltage power supply and distribution architecture to meet the needs of the vehicle's power and superstructure. Currently, due to the large amount of equipment installed on the vehicle, the high-voltage power grid becomes extremely complex, and the severe electromagnetic environment brought about by high voltage also poses a serious challenge to the reliability of the vehicle's high-voltage power supply.

[0003] In view of this, the present invention proposes a ring power supply system for electric vehicles, which adopts a modular, distributed ring power supply and distribution architecture. By interconnecting high-voltage DC buses, a high-voltage redundant power supply mode for the vehicle is formed, which can significantly reduce the risk of high-voltage power failure in electric vehicles and maximize the reliability of the high-voltage power supply of the whole vehicle. Summary of the Invention

[0004] To address the aforementioned problems in the prior art, the present invention provides a ring power supply system for electric vehicles.

[0005] To achieve the above objectives, the present invention adopts the following technical solution.

[0006] An electric vehicle ring power supply system includes multiple high-voltage units and a range extender connected in a ring structure by high-voltage interconnecting lines. Each high-voltage unit includes an integrated controller and a high-voltage power module composed of a power battery. The range extender is connected to the integrated controller of each high-voltage unit and provides high voltage to the integrated controller. The integrated controller is used for power distribution control, status monitoring, and overcurrent protection of the vehicle's high-voltage equipment. The high-voltage power modules of multiple high-voltage units are connected in parallel through a high-voltage distribution box. When some high-voltage power modules fail, the normal high-voltage power modules supply power to the integrated controllers of other high-voltage units and provide high-voltage power to the vehicle's high-voltage equipment.

[0007] Furthermore, a single high-voltage unit can supply power to the high-voltage equipment on both axles of the vehicle.

[0008] Furthermore, the range extender includes an engine, a generator, a generator controller, and related accessories; the generator controller receives instructions from the host vehicle controller via a CAN bus and controls the output of high-voltage DC power according to the instructions.

[0009] Furthermore, the integrated controller includes a high-voltage power distribution controller and connected to it an oil pump motor controller, an air pump motor controller, a Hall sensor, a high-voltage contactor, as well as a high-voltage fuse, a pre-charge resistor, and high and low voltage connectors.

[0010] Furthermore, the high-voltage power distribution controller of the integrated controller communicates with the host vehicle controller via the CAN bus, receives instructions from the vehicle controller, or uploads bus voltage, current and status information collected by Hall sensors to the vehicle controller.

[0011] Furthermore, the high-voltage power distribution controller of the integrated controller achieves high-voltage power-on by controlling the contactor of the pre-charge circuit to close, and achieves high-voltage power-off by controlling the contactor of the main power supply circuit to open.

[0012] Furthermore, when some high-voltage power modules fail, the integrated controller reports a fault alarm to the vehicle controller; upon receiving the fault alarm, the vehicle controller issues a fault handling command.

[0013] Furthermore, the vehicle controller issues fault handling commands including:

[0014] The vehicle controller sends fault information to the instrument panel in the driver's cab, and the instrument panel in the driver's cab displays the fault information.

[0015] The vehicle controller sends a command to the integrated controller to disconnect the main contactor of the faulty high-voltage power module. The high-voltage power distribution controller of the integrated controller outputs a control signal to disconnect the corresponding contactor according to the command.

[0016] Based on the number of high-voltage power module failures, the vehicle controller sends a vehicle deceleration and power reduction operation command to the integrated controller. The integrated controller outputs a control signal according to the command to reduce the motor power and stop some components from working.

[0017] Based on the number of high-voltage power module failures, the vehicle controller sends an increase output power command to the range extender, and the range extender increases the output high-voltage power according to the command.

[0018] Furthermore, the integrated controller includes an emergency switch connected to the high-voltage contactor, pressing the emergency switch disconnects the high-voltage contactor.

[0019] Furthermore, the integrated controller includes an emergency switch connected to the high-voltage power distribution controller. When the emergency switch is pressed, the high-voltage power distribution controller outputs a control signal to disconnect the high-voltage contactor.

[0020] Compared with the prior art, the present invention has the following beneficial effects.

[0021] This invention establishes multiple high-voltage units and range extenders connected in a ring structure by high-voltage interconnecting lines. Each high-voltage unit includes an integrated controller and a high-voltage power supply module composed of a power battery. The range extender is connected to the integrated controller of each high-voltage unit to provide high voltage to the integrated controller. The integrated controller is used for power distribution control, status monitoring, and overcurrent protection of the vehicle's high-voltage equipment. The high-voltage power supply modules of multiple high-voltage units are connected in parallel through a high-voltage distribution box. When some high-voltage power supply modules fail, the normal high-voltage power supply modules supply power to the integrated controllers of other high-voltage units, enabling redundant power supply to the vehicle's high-voltage equipment, reducing the risk of high-voltage power failure, and improving the reliability of the vehicle's high-voltage power supply. Attached Figure Description

[0022] Figure 1 This is a block diagram of a ring power supply system for an electric vehicle according to an embodiment of the present invention. In the figure, 1-high voltage unit, 11-integrated controller, 12-high voltage power supply module, 2-range extender, 3-high voltage distribution box.

[0023] Figure 2 This is a schematic diagram of another embodiment of the present invention.

[0024] Figure 3 This is a schematic diagram of an scalable modular structure according to another embodiment of the present invention. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer and more understandable, the invention will be further described below in conjunction with the accompanying drawings and specific embodiments. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0026] Figure 1 This is a block diagram of a ring power supply system for an electric vehicle according to an embodiment of the present invention. It includes multiple high-voltage units 1 connected in a ring structure by high-voltage interconnecting lines and a range extender 2. Each high-voltage unit 1 includes a comprehensive controller 11 and a high-voltage power module 12 composed of a power battery. The range extender 2 provides high-voltage DC power to the comprehensive controller 11 and the high-voltage power module 12. The comprehensive controller 11 performs power distribution control, status monitoring, and overcurrent protection for the vehicle's high-voltage equipment. The high-voltage power modules 12 of the multiple high-voltage units 1 are connected in parallel through a high-voltage distribution box 3. When some high-voltage power modules 12 fail, the normal high-voltage power modules 12 supply power to the comprehensive controller 11 of the other high-voltage units 1 and provide high-voltage power to the vehicle's high-voltage equipment.

[0027] In this embodiment, the system mainly consists of multiple high-voltage units 1 and range extenders 2. The multiple high-voltage units 1 are connected in a ring structure by high-voltage interconnecting lines, such as... Figure 1 , 2 As shown. High-voltage unit 1 includes an integrated controller 11 and a high-voltage power module 12. The high-voltage power module 12 is composed of a power battery, and its high-voltage output is connected to a high-voltage interconnect. The range extender 2 is connected to the integrated controller 11 of each high-voltage unit 1, and its purpose is to provide adjustable high-voltage DC power to the integrated controller 11 and the high-voltage power module 12. The high-voltage power modules 12 of multiple high-voltage units 1 are connected in parallel through a high-voltage distribution box 3, which can provide sufficient high-voltage power to multi-axle vehicles. The high-voltage distribution box 3 mainly consists of a battery management system (BMS), high-voltage contactors, fuses, pre-charge resistors and pre-charge contactors, a box housing, and related structural components. The power batteries of the high-voltage power modules 12 can be externally charged through the high-voltage distribution box 3 using a charging interface. The integrated controller 11 is the control center of the high-voltage unit 1, used for power distribution control, status monitoring, and overcurrent protection of the vehicle's high-voltage equipment.

[0028] This embodiment achieves redundant power supply to the vehicle's high-voltage equipment by connecting multiple high-voltage power supply modules 12 in parallel. For example, when some high-voltage power supply modules 12 fail, the normal high-voltage power supply modules 12 can supply power to the integrated controller 11 of other high-voltage units 1 via high-voltage interconnection lines, and also supply power to the vehicle's high-voltage equipment, reducing the risk of high-voltage power failure and improving the reliability of power supply to the vehicle's high-voltage equipment. This embodiment adopts a modular design, facilitating power capacity expansion, such as... Figure 3 As shown.

[0029] As an optional embodiment, a high-voltage unit 1 can supply power to the high-voltage equipment on both axles of the vehicle.

[0030] This implementation provides the power supply capability of a single high-voltage unit 1. In this embodiment, one high-voltage unit 1 can be used for power supply and distribution to at most two axles of the vehicle. As mentioned above, this embodiment employs a modular design, facilitating power expansion, and the number of high-voltage units 1 can be determined based on the number of axles in a multi-axle vehicle.

[0031] As an optional embodiment, the range extender 2 includes an engine, a generator, a generator controller, and related accessories; the generator controller receives instructions from the host vehicle controller via a CAN bus and controls the output of high-voltage DC power according to the instructions.

[0032] This embodiment provides a technical solution for range extender 2. Range extender 2 mainly consists of an engine, a generator, a generator controller, and related accessories, and is used to generate high-voltage direct current. Range extender 2 outputs high-voltage electricity with the required power according to the instructions issued by the vehicle controller. Specifically, this is achieved by the generator controller receiving instructions from the host vehicle controller via the CAN bus.

[0033] As an optional embodiment, the integrated controller 11 includes a high-voltage power distribution controller and connected to it an oil pump motor controller, an air pump motor controller, a Hall sensor, a high-voltage contactor, as well as a high-voltage fuse, a pre-charge resistor, and high and low voltage connectors.

[0034] This embodiment provides a technical solution for an integrated controller 11. The integrated controller 11 mainly consists of three controllers: a high-voltage power distribution controller, an oil pump motor controller, and an air pump motor controller. As their names suggest, the oil pump motor controller and the air pump motor controller are used to control the oil pump motor and the air pump motor, respectively, such as... Figure 2 As shown. The high-voltage power distribution controller is the central controller of the integrated controller 11, used to coordinate the work of other controllers and components, and to realize the high-voltage power distribution control of the vehicle. The integrated controller 11 also includes Hall sensors, high-voltage contactors, high-voltage fuses, pre-charge resistors, and high and low voltage connectors. The Hall sensor is a current sensor used to sample the high-voltage current and output it to the high-voltage power distribution controller to realize the measurement of the high-voltage current. The high-voltage contactors, high-voltage fuses, pre-charge resistors, etc., are used to realize high-voltage pre-charging and overcurrent protection, etc.

[0035] As an optional embodiment, the high-voltage power distribution controller of the integrated controller 11 communicates with the host vehicle controller via a CAN bus, receives instructions from the vehicle controller, or uploads bus voltage, current and status information collected by Hall sensors to the vehicle controller.

[0036] This embodiment presents a technical solution for data communication between the integrated controller 11 and the host vehicle controller. The host computer of the integrated controller 11 is the vehicle controller. The high-voltage power distribution controller of the integrated controller 11 receives instructions from the vehicle controller via the CAN bus and can also upload data to the vehicle controller via the CAN bus, such as bus voltage, current and status information collected by Hall sensors, etc.

[0037] As an optional embodiment, the high-voltage power distribution controller of the integrated controller 11 achieves high-voltage power-on by controlling the closing of the contactor in the pre-charge circuit and achieves high-voltage power-off by controlling the opening of the contactor in the main power supply circuit.

[0038] This embodiment describes a method for controlling high-voltage power-on and power-off. High-voltage power-on and power-off are achieved by the high-voltage power distribution controller of the integrated controller 11 through controlling the on / off state of the high-voltage contactors. The high-voltage contactors include a pre-charge circuit contactor and a main power supply circuit contactor. When the high-voltage power distribution controller receives a power-on command from the vehicle controller via the CAN bus, it controls the pre-charge circuit contactor to close, connecting the charging voltage input from the range extender 2. Once the pre-charge voltage rises to 95% of the bus voltage, it controls the main circuit contactor to close, and after a delay, disconnects the pre-charge circuit contactor. When the high-voltage power distribution controller receives a power-off command, it controls the main circuit contactor to de-energize.

[0039] As an optional embodiment, when some high-voltage power modules 12 fail, the integrated controller 11 reports a fault alarm to the vehicle controller; after receiving the fault alarm, the vehicle controller issues a fault handling instruction.

[0040] This embodiment provides a fault handling solution. The fault in this embodiment refers to the failure of some (not all) of the high-voltage power supply modules 12. When such a fault occurs, the integrated controller 11 first reports a fault alarm message to the vehicle controller via the CAN bus. After receiving the fault alarm message, the vehicle controller issues a fault handling command to the integrated controller 11 based on the specific fault alarm information.

[0041] As an optional embodiment, the vehicle controller issues fault handling instructions including:

[0042] The vehicle controller sends fault information to the instrument panel in the driver's cab, and the instrument panel in the driver's cab displays the fault information.

[0043] The vehicle controller sends a command to the integrated controller 11 to disconnect the main contactor of the faulty high-voltage power module 12. The high-voltage power distribution controller of the integrated controller 11 outputs a control signal to disconnect the corresponding contactor according to the command.

[0044] Based on the number of faults in the high-voltage power module 12, the vehicle controller sends a vehicle deceleration and power reduction operation command to the integrated controller 11. The integrated controller 11 outputs a control signal according to the command to reduce the motor power and stop some components from working.

[0045] Based on the number of faults in the high-voltage power module 12, the vehicle controller sends an instruction to the range extender 2 to increase the output power. The range extender 2 then increases the output high-voltage power according to the instruction.

[0046] This embodiment provides a technical solution for handling fault handling commands issued by the vehicle controller. This embodiment presents processing methods for four different fault handling commands.

[0047] The first type of instruction is a fault information display instruction. The vehicle controller sends the fault information to the instrument panel in the driver's cab via the CAN bus, where the fault information is displayed to alert the driver.

[0048] The second type of instruction is a faulty high-voltage power module 12 main contactor disconnection instruction. The vehicle controller sends the instruction to the integrated controller 11. After receiving the instruction, the high-voltage power distribution controller of the integrated controller 11 outputs a control signal to disconnect the corresponding contactor according to the instruction.

[0049] The third type of instruction is a vehicle deceleration and power reduction operation instruction. Based on the number of faults in the high-voltage power module 12, the vehicle controller sends a vehicle deceleration and power reduction operation instruction to the integrated controller 11. The integrated controller 11 outputs a control signal according to the instruction, reducing the motor power and causing some components to stop working. Generally, the more faults in the high-voltage power module 12, the greater the reduction in motor power. The components that stop working are generally other assemblies installed outside the vehicle chassis, such as the tank body of a tank mixer truck or the cargo box of a box truck.

[0050] The fourth type of command is the power range extension command. Based on the number of faults in the high-voltage power module 12, the vehicle controller sends a power range extension command to the range extender 2. The range extender 2 then increases the output power of the high-voltage circuit according to the command. Generally, the more faults in the high-voltage power module 12, the greater the power increase required.

[0051] As an optional embodiment, the integrated controller 11 includes an emergency switch connected to a high-voltage contactor, pressing the emergency switch disconnects the high-voltage contactor.

[0052] This embodiment provides an emergency response plan. Emergency response is achieved by setting up an emergency switch connected to the high-voltage contactors. In an emergency, pressing the emergency switch can disconnect all high-voltage contactors.

[0053] As an optional embodiment, the integrated controller 11 includes an emergency switch connected to the high-voltage power distribution controller. When the emergency switch is pressed, the high-voltage power distribution controller outputs a control signal to disconnect the high-voltage contactor.

[0054] This embodiment provides another emergency response solution. Unlike the previous embodiment where the emergency switch was connected to the high-voltage contactor, in this embodiment, the emergency switch is connected to the high-voltage power distribution controller of the integrated controller 11. Instead of directly disconnecting the high-voltage contactor through the emergency switch, pressing the emergency switch sends a high / low level signal (trigger signal) to the high-voltage power distribution controller, which then outputs a control signal to disconnect all high-voltage contactors.

[0055] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A ring power supply system for electric vehicles, characterized in that, The system includes multiple high-voltage units and range extenders connected in a ring structure by high-voltage interconnecting lines. Each high-voltage unit includes an integrated controller and a high-voltage power module composed of a power battery. The range extender is connected to the integrated controller of each high-voltage unit to provide high voltage to the integrated controller. The integrated controller is used for power distribution control, status monitoring, and overcurrent protection of the vehicle's high-voltage equipment. The high-voltage power modules of multiple high-voltage units are connected in parallel through a high-voltage distribution box. When some high-voltage power modules fail, the normal high-voltage power modules supply power to the integrated controllers of other high-voltage units and provide high-voltage power to the vehicle's high-voltage equipment. in: When some high-voltage power modules fail, the integrated controller reports a fault alarm to the vehicle controller; after receiving the fault alarm, the vehicle controller issues a fault handling command. The fault handling instructions issued by the vehicle controller include: The vehicle controller sends fault information to the instrument panel in the driver's cab, and the instrument panel in the driver's cab displays the fault information. The vehicle controller sends a command to the integrated controller to disconnect the main contactor of the faulty high-voltage power module. The high-voltage power distribution controller of the integrated controller outputs a control signal to disconnect the corresponding contactor according to the command. Based on the number of high-voltage power module failures, the vehicle controller sends a vehicle deceleration and power reduction operation command to the integrated controller. The integrated controller outputs a control signal according to the command to reduce the motor power and stop some components from working. Based on the number of high-voltage power module failures, the vehicle controller sends an increase output power command to the range extender, and the range extender increases the output high-voltage power according to the command.

2. The electric vehicle ring power supply system according to claim 1, characterized in that, A single high-voltage unit can power the high-voltage equipment on both axles of a vehicle.

3. The electric vehicle ring power supply system according to claim 1, characterized in that, The range extender includes an engine, a generator, a generator controller, and related accessories; the generator controller receives instructions from the host vehicle controller via a CAN bus and controls the output of high-voltage DC power according to the instructions.

4. The electric vehicle ring power supply system according to claim 1, characterized in that, The integrated controller includes a high-voltage power distribution controller and connected to it an oil pump motor controller, an air pump motor controller, a Hall sensor, a high-voltage contactor, as well as a high-voltage fuse, a pre-charge resistor, and high and low voltage connectors.

5. The electric vehicle ring power supply system according to claim 4, characterized in that, The high-voltage power distribution controller of the integrated controller communicates with the host vehicle controller via the CAN bus, receives instructions from the vehicle controller, or uploads bus voltage, current and status information collected by Hall sensors to the vehicle controller.

6. The electric vehicle ring power supply system according to claim 4, characterized in that, The high-voltage power distribution controller of the integrated controller achieves high-voltage power-on by controlling the pre-charge circuit contactor to close and the high-voltage power-off by controlling the main power supply circuit contactor to open.

7. The electric vehicle ring power supply system according to claim 4, characterized in that, The integrated controller includes an emergency switch connected to a high-voltage contactor; pressing the emergency switch disconnects the high-voltage contactor.

8. The electric vehicle ring power supply system according to claim 4, characterized in that, The integrated controller includes an emergency switch connected to the high-voltage power distribution controller. When the emergency switch is pressed, the high-voltage power distribution controller outputs a control signal to disconnect the high-voltage contactor.

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