Range-extending type hybrid power system of single-steel-wheel road roller and control method of range-extending type hybrid power system

Abstract

The invention discloses a single-steel-wheel road roller extended-range hybrid power system and a control method thereof.The system comprises a VCU complete machine controller, a battery pack, and a PDU distribution box, an ECU controller, a battery high-voltage box, a DC converter, an execution device and a range extender which are in signal connection with the VCU complete machine controller. The transmission efficiency of whole vehicle operation is low, and the cruising ability is poor in a pure electric mode.

Description

Technical Field

[0001] The present application relates to a single-wheeled road roller extended-range hybrid power system and a control method thereof, and belongs to the technical field of engineering machinery. Background Art

[0002] The non-road mobile mechanical equipment single steel wheel roller in roadbed construction vehicles is mainly used for the construction of new highway foundations. It is mostly used in the wilderness and does not work in fixed places. Conventionally, diesel engines are used as the power source, especially heavy-duty large-tonnage single steel wheel rollers. The power source is a high-power diesel engine, which has high fuel consumption and is accompanied by a large amount of exhaust emissions, causing great pollution to the environment. In addition, the operation mode of single steel wheel rollers is mostly hydraulic transmission, and there are technical problems such as low transmission efficiency and slow response.

[0003] As the penetration rate of new energy equipment continues to increase, the use of pure electric mode can play a certain role in solving the problem of environmental pollution. However, for heavy-duty single-wheel rollers, they are currently restricted by the imperfections of charging equipment and the lack of unified power battery standards, which causes great trouble to the charging and endurance of the entire machine and brings great inconvenience to users. Summary of the invention

[0004] The purpose of this application is to provide a single steel wheel roller extended-range hybrid power system and a control method thereof to solve the current problems of diesel engine environmental pollution, low vehicle operation transmission efficiency, and poor pure electric mode endurance.

[0005] To achieve the above objectives, the technical solutions adopted in this application are: In a first aspect, the present application provides an extended-range hybrid system, including a VCU whole machine controller, a battery pack, and a PDU distribution box, an ECU controller, a battery high-voltage box, a DC converter, an actuator, and a range extender, each of which is signal-connected to the VCU whole machine controller; The PDU distribution box is electrically connected to the DC converter, the battery high-voltage box and the actuator, and the battery pack is electrically connected to the battery high-voltage box; The range extender includes an engine connected to the ECU controller, a FISG motor mechanically connected to the engine, an RCU controller connected to the VCU whole machine controller, and a GCU controller electrically connected to the PDU distribution box. The FISG motor is electrically connected to the GCU controller, and the RCU controller is signal-connected to the GCU controller.

[0006] In combination with the first aspect, further, the execution device includes a front drive motor, a rear drive motor and a vibration motor respectively connected to the PDU distribution box through the MCU controller; and a reducer and a vibration wheel mechanically connected to the front drive motor in sequence, a drive axle mechanically connected to the rear drive motor, and a vibration wheel mechanically connected to the vibration motor.

[0007] Furthermore, the battery high voltage box includes a BDU battery high voltage control box and a BMS battery low voltage controller.

[0008] Furthermore, the battery pack is provided with a battery thermal management unit, and the battery thermal management unit is connected to the BMS battery low voltage controller.

[0009] Furthermore, the system also includes a vehicle charger, which is connected to the PDU distribution box.

[0010] Furthermore, the system is also provided with an engine radiator for the engine, and a motor electronic control radiator for the mechanical device, the FISG motor and the GCU controller.

[0011] Furthermore, the engine is a four-cylinder engine.

[0012] In a second aspect, the present application provides a road roller provided with any of the above-mentioned extended-range hybrid power systems.

[0013] In a third aspect, the present application further provides a control method for an extended-range hybrid power system, wherein the control method adopts the above-mentioned extended-range hybrid power system and comprises: a whole-machine driving operation mode and a whole-machine vibration operation mode, In the whole machine driving operation mode, the front drive motor and the rear drive motor receive commands from the VCU whole machine controller through the MCU controller to directly drive the vibration wheel and the drive axle respectively; In the whole machine vibration operation mode, the vibration motor receives the VCU whole machine controller command through the MCU controller and directly drives the vibration wheel.

[0014] Compared with the prior art, the present invention has the following beneficial effects: The present application provides an extended-range hybrid power single steel wheel roller, which uses a low-power four-cylinder engine to reduce displacement, reduce exhaust emissions, and reduce environmental pollution.

[0015] The FISG motor in the range extender is rigidly connected to the engine body, replacing the engine impeller housing, making the space more compact.

[0016] The engine in the range extender does not need to be equipped with an original starter motor, and can rely on the FISG motor to directly start the engine; when starting the engine, the FISG motor acts as a starter motor with large torque and quick start, effectively solving the problem of engine starting difficulties in low temperature and high altitude environments; and the engine is not affected by operating conditions and can remain in the lowest fuel consumption area for a long time, saving energy, reducing emissions, and reducing noise.

[0017] The engine in the extended-range mode can meet the charging needs of the power battery pack anytime and anywhere according to the battery pack capacity requirements, effectively solving the problems of charging difficulties and range anxiety.

[0018] This application sets up a front drive motor and a rear drive motor to directly drive the vibration wheel and the drive axle. The high-voltage electricity transmission efficiency is high and the response is fast. The peak power and torque characteristics of the motor itself are used to start quickly and have high instantaneous climbing ability. The high voltage electricity is transmitted to the vibration motor through the MCU controller, which has high transmission efficiency, fast response, energy saving and emission reduction. At the same time, it is not controlled by the engine speed, and the vibration frequency of the vibration wheel can be infinitely adjustable to meet the requirements of the respective road construction process. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is an architecture diagram of a range-extended hybrid power system provided in an embodiment of the present application; Figure 2 is a working principle diagram of the extended-range hybrid power system provided in an embodiment of the present application; Figure 3 It is a principle diagram of the driving operation mode provided in an embodiment of the present application; Figure 4 It is a principle diagram of the vibration operation mode provided in an embodiment of the present application. DETAILED DESCRIPTION

[0020] The present application is further described below in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present application, and cannot be used to limit the protection scope of the present application.

[0021] Embodiment 1: like Figure 1 As shown, it is an architecture diagram of the extended-range hybrid system provided in this embodiment, which includes a range extender, an ECU controller, a VCU whole machine controller, a PDU distribution box, a battery high-voltage box, a battery pack, an MCU1 controller, an MCU2 controller, an MCU3 controller, a front drive motor, a rear drive motor, a vibration motor, and a DC / DC converter.

[0022] The range extender includes an engine, a FISG motor, an RCU controller, a GCU controller, and an ECU controller.

[0023] The engine can meet the battery pack charging needs anytime and anywhere according to the power battery pack capacity requirements. Users do not need to worry about the inconvenience of battery charging, effectively solving the charging difficulties and range anxiety.

[0024] The engine of this application uses a low-power four-cylinder engine to replace the original high-power six-cylinder engine, with a reduced displacement, reduced exhaust emissions, and no urea added, saving users' expenses and reducing environmental pollution. Compared with the conventional diesel version of the same tonnage roller, fuel consumption can be reduced by about 30%, without urea addition, and based on the annual use cost, it can save users 40,000 yuan in fuel costs if used for 1,500 hours a year.

[0025] This application sets a FISG motor to replace the engine flywheel housing and integrate it into the engine. The FISG motor converts the mechanical energy output by the engine into electrical energy. The FISG motor is connected to the engine body through a torsional vibration damper, replacing the engine flywheel housing, and the space is more compact. The extended-range engine does not need to be equipped with the original starter motor, and can rely on the FISG motor to directly start the engine. When starting the engine, the FISG motor serves as a starter motor with large torque and rapid start, which effectively solves the problem of difficulty in starting the engine in low temperature and high altitude environments. In addition, the engine is not affected by the operating conditions and can be maintained in the lowest fuel consumption area for a long time, saving energy and reducing emissions and noise.

[0026] Specifically, when the engine needs to be started, the FISG motor is used as an electric motor. It receives power from the vehicle battery and generates torque to rotate the engine crankshaft, thereby starting the engine. When the engine is running normally, the FISG motor switches its role and becomes a generator. It uses the mechanical energy of the engine to drive the motor to rotate, thereby generating alternating current. In this process, mechanical energy is converted into electrical energy, which can be used by the vehicle's electrical system or stored in the battery pack.

[0027] The RCU controller is connected to the VCU machine controller through the CAN bus, receives the machine's required operation instructions, and gives corresponding commands to the GCU controller and ECU controller.

[0028] The GCU controller is connected to the FISG motor and receives commands from the VCU vehicle controller to control the speed and torque of the FISG motor. It collects and transmits parameters such as the temperature and speed inside the FISG motor. At the same time, it can protect the motor, including overcurrent, overvoltage, overtemperature, overspeed, etc., and rectify the three-phase AC power generated by the FISG motor into DC power to provide energy for the entire machine.

[0029] The ECU controller is connected to the VCU machine controller through the CAN bus, receives the machine's required operating intentions, and controls the engine operation.

[0030] The input end of the PDU distribution box is connected to the GCU controller and the battery high-voltage box, and the output end is connected to the MCU1 controller, MCU2 controller, and MCU3 controller. The PDU high-voltage distribution box distributes the high-voltage DC power transmitted by the FISG motor and battery pack to each back-end load, and can also transmit it to the DC / DC for low-voltage power consumption of the entire machine.

[0031] One end of the battery high-voltage box is connected to the PDU distribution box, and the other end is connected to the battery pack. The battery high-voltage box is the "brain" of the battery pack, responsible for managing, maintaining, and monitoring each battery module.

[0032] The battery pack is a power-type battery specially designed for use with extended-range engines. It has a small capacity and a large charge and discharge rate. As an energy supplement for the entire machine, it plays a role in "peak shaving and valley filling".

[0033] The MCU1 controller is connected to the PDU distribution box at one end and the front drive motor at the other end. It controls the speed and torque of the front drive motor, collects and transmits parameters such as the temperature and speed inside the motor, and protects the motor, including overcurrent, overvoltage, temperature, overspeed, etc. It inverts the DC power transmitted from the PDU distribution box into three-phase AC power and provides it to the front drive motor.

[0034] The MCU2 controller is connected to the PDU distribution box at one end and the rear drive motor at the other end. It controls the speed and torque of the rear drive motor, collects and transmits parameters such as the temperature and speed inside the motor, and protects the motor, including overcurrent, overvoltage, temperature, overspeed, etc. It inverts the DC power transmitted from the PDU distribution box into three-phase AC power and provides it to the rear drive motor.

[0035] The MCU3 controller is connected to the PDU distribution box at one end and the vibration motor at the other end. It controls the speed and torque of the vibration motor, collects and transmits parameters such as the temperature and speed inside the motor, and protects the motor, including overcurrent, overvoltage, temperature, overspeed, etc. It inverts the DC power transmitted from the PDU distribution box into three-phase AC power and provides it to the vibration motor.

[0036] The DC / DC converter is an on-board transformer that is connected to the PDU distribution box to convert the high-voltage DC power from the PDU distribution box into low-voltage 24V DC power to supply power to the low-voltage components on the entire machine.

[0037] The VCU whole machine controller is used to control the ECU controller, RCU controller, GCU controller, front drive motor controller MCU1, rear drive motor controller MCU2, vibration motor controller MCU3, battery pack battery high voltage box and transformer DC / DC converter, collect parameter information of each component, calculate and determine the parameters required for the whole machine operation.

[0038] Optionally, the battery pack is equipped with a battery thermal management unit, which is connected to the battery high-voltage box to perform thermal management such as heating and cooling of the power battery pack.

[0039] Optionally, the whole machine is equipped with an on-board charger, which is connected to the PDU distribution box. It is mainly used when the whole vehicle is left unused for a long time, resulting in the problem of power battery pack being depleted. The battery pack can be charged and supplemented through the on-board charger.

[0040] Optionally, the whole machine is equipped with an engine radiator and a motor electronic control radiator. The engine radiator is used for thermal management of the diesel engine. The motor electronic control radiator is used for thermal management of each motor, each corresponding controller, FISG motor and GCU controller.

[0041] Furthermore, the extended-range hybrid single-wheel roller also includes a key switch, which is connected to the VCU whole machine controller and is used to control the start of the engine.

[0042] Furthermore, the front drive motor, the vibration wheel reducer, and the vibration wheel are rigidly connected in sequence.

[0043] Furthermore, the rear-drive motor, drive axle, and tire are rigidly connected in sequence.

[0044] Furthermore, the vibration motor is rigidly connected to the vibration wheel.

[0045] Embodiment 2: like Figure 2 , which is a working principle diagram of the extended-range hybrid power system provided in an embodiment of the present application, The range extender provides the power source for the whole machine, and is equipped with a small-capacity power battery pack. When the whole vehicle is running normally and vibrating and compacting, the electric energy generated by the range extender assembly will be able to meet the needs of the whole machine.

[0046] When the power consumption is high at the moment of starting, accelerating, vibrating, and when the vehicle is climbing and vibrating, and the range extender cannot meet the needs of the whole machine, the battery pack will be involved to provide energy replenishment and play the role of "peak shaving and valley filling". The normal working range of the power battery SOC is 30% to 70%. The BMS battery low-voltage controller monitors the battery pack status in real time. According to the battery pack SOC capacity requirements, the range extender assembly can replenish energy to the power battery pack at any time.

[0047] like Figure 3As shown, it is a schematic diagram of the driving operation mode provided in this embodiment; the front and rear walking operation modes of the whole machine are directly driven by the front drive motor and the rear drive motor. The front drive motor is rigidly connected to the vibration wheel through a reducer, and the rear drive motor is rigidly connected to the drive axle. When the VCU whole machine controller receives the driver's walking signal, the VCU controller transmits the signal to the PDU distribution box, RCU controller, battery high-voltage box, MCU1 controller, and MCU2 controller. According to the vehicle speed required by the driver, each controller executes the corresponding command, reasonably allocates the torque, power, speed, etc. required by each motor, and transmits it to the FISG motor and the front and rear drive motors to complete the corresponding walking operation.

[0048] This application is transmitted to the front drive motor and the rear drive motor through the MCU1 controller and the MCU2 controller respectively. The front drive motor directly drives the vibration wheel to work, and the rear drive motor directly drives the drive axle to work. The high-voltage power transmission efficiency can reach 85% to 90%, with high transmission efficiency, fast response, energy saving and emission reduction. Using the peak power and torque characteristics of the motor itself, it starts quickly and has high instantaneous climbing ability.

[0049] like Figure 4 As shown, it is a schematic diagram of the vibration operation mode provided by this embodiment; the whole machine vibration wheel has large vibration and small vibration operation modes. The vibration motor is rigidly connected to the vibration wheel. According to the actual road compaction requirements, the VCU whole machine controller receives the driver's large vibration or small vibration compaction signal, and the VCU whole machine controller transmits the signal to the PDU distribution box, RCU controller, battery high voltage box, MCU3 controller, and the MCU3 controller reasonably allocates the required torque, speed, power and other information to the vibration motor. The vibration motor executes the driver's intention as needed to complete the corresponding vibration mode, wherein the battery high voltage box includes the BDU battery high voltage control box and the BMS battery low voltage controller.

[0050] This embodiment also provides a single steel wheel roller, which is provided with the extended-range hybrid power system described in the first embodiment.

[0051] This application is transmitted to the vibration motor through the MCU3 controller, and the high-voltage power transmission efficiency can reach 85% to 90%, with high transmission efficiency, fast response, energy saving and emission reduction. At the same time, it is not controlled by the engine speed, and the vibration frequency of the vibration wheel can be infinitely adjustable to meet the requirements of each road construction process.

[0052] The above is only a preferred implementation of the present application. 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 application. These improvements and modifications should also be regarded as the scope of protection of the present application.

Claims

1. An extended-range hybrid system, characterized in that: It includes a VCU whole machine controller, a battery pack, and a PDU distribution box, an ECU controller, a battery high-voltage box, a DC converter, an actuator, and a range extender that are respectively connected to the VCU whole machine controller signal; The PDU distribution box is electrically connected to the DC converter, the battery high-voltage box and the actuator, and the battery pack is electrically connected to the battery high-voltage box; The range extender includes an engine connected to the ECU controller, a FISG motor mechanically connected to the engine, an RCU controller connected to the VCU whole machine controller, and a GCU controller electrically connected to the PDU distribution box; the FISG motor is electrically connected to the GCU controller, and the RCU controller is signal-connected to the GCU controller.

2. The extended-range hybrid system according to claim 1, characterized in that: The execution device includes a front drive motor, a rear drive motor and a vibration motor respectively connected to the PDU distribution box through an MCU controller; a reducer and a vibration wheel mechanically connected to the front drive motor in sequence, a drive axle mechanically connected to the rear drive motor, and a vibration wheel mechanically connected to the vibration motor.

3. The extended-range hybrid system according to claim 1, characterized in that: The battery high voltage box includes a BDU battery high voltage control box and a BMS battery low voltage controller.

4. The extended-range hybrid system according to claim 3, characterized in that: The battery pack is provided with a battery thermal management unit, and the battery thermal management unit is connected to the BMS battery low voltage controller.

5. The extended-range hybrid system according to claim 1, characterized in that: The system also includes a vehicle charger, which is connected to the PDU distribution box.

6. The extended-range hybrid system according to claim 1, characterized in that: The system is also provided with an engine radiator for the engine, and a motor electronic control radiator for the mechanical device, the FISG motor and the GCU controller.

7. The extended-range hybrid system according to claim 1, characterized in that: The engine is a four-cylinder engine.

8. A single steel wheel roller, characterized in that: A range-extended hybrid power system as described in any one of claims 1 to 7 is provided.

9. A control method for a range-extended hybrid power system, characterized in that: The control method adopts the extended-range hybrid power system of claim 2, including: a whole-machine driving operation mode and a whole-machine vibration operation mode, In the whole machine driving operation mode, the front drive motor and the rear drive motor receive commands from the VCU whole machine controller through the MCU controller to directly drive the vibration wheel and the drive axle respectively; In the whole machine vibration operation mode, the vibration motor receives the VCU whole machine controller command through the MCU controller and directly drives the vibration wheel.

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