A fault diagnosis system and method for a thermal management system

Abstract

This invention discloses a fault diagnosis system and method for a thermal management system. The system is equipped with pressure and flow sensors to monitor pressure and flow data at the pump outlet, motor inlet / outlet, and electrical control inlet / outlet of the thermal management system. The method collects the operating flow and pressure data of the medium in the thermal management system and diagnoses faults based on the acquired monitoring data. If an anomaly is detected, it is transmitted to a remote service platform via the overall controller for alerting. When a high-temperature alarm is triggered, the fault point can be quickly identified. Specifically, the diagnostic method of this invention involves: comparing the flow sensor monitoring data with the minimum flow requirement to determine a medium flow fault; determining a connecting pipeline fault based on the pressure difference between the pump outlet and motor inlet; and determining a residual air fault in the motor based on the flow sensor monitoring data, motor outlet, and electrical control inlet pressure data. This invention can quickly identify high-temperature fault points in the thermal management system.

Description

Technical Field

[0001] This invention relates to the field of motor and electronic control thermal management technology, and in particular to a thermal management system fault diagnosis system and method. Background Technology

[0002] Electric excavators frequently experience high-temperature alarms during operation. Whether it's a motor overheating alarm or an electronic control system overheating alarm, it will cause the motor to limit torque and speed, affecting the user experience. The thermal management system of an electric excavator's motor and electronic control system is complex, involving multiple connecting water pipes, water pumps, motors, electronic control systems, radiators, or chargers. The cooling medium removes heat from the motor and electronic control system, and the motor or electronic control system has strict requirements on the entire thermal management system, such as flow rate and water temperature. Other causes include residual air in the motor and electronic control system that hasn't been expelled, making it difficult to quickly troubleshoot these issues.

[0003] Currently, troubleshooting high-temperature faults in electric excavators is similar to that in traditional excavators, involving checking each possible fault point one by one. However, since the entire thermal management system is more complex than the traditional cooling system, the troubleshooting process is also more complicated, wasting manpower, resources, and time.

[0004] Existing electric excavator heat treatment systems can provide high-temperature alarms for components, such as motor high-temperature alarms or motor controller high-temperature alarms. However, the causes of high-temperature faults in electric excavator heat management systems are more complex, making it difficult to quickly determine the cause of high-temperature faults and affecting customer experience. Summary of the Invention

[0005] The purpose of this invention is to provide a fault diagnosis system and method for a thermal management system. By collecting the flow rate and pressure of the medium in the thermal management system, the system can determine whether the connecting pipelines and motors are normal, thereby enabling rapid identification of high-temperature fault points in the thermal management system.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] On one hand, the present invention provides a fault diagnosis system for a thermal management system, comprising:

[0008] The data acquisition module includes pressure sensors installed at the pump outlet, motor inlet / outlet, and electrical control inlet / outlet in the thermal management system to monitor pressure data at the installation locations; and flow sensors installed in the thermal management system to monitor the flow rate of the thermal management system.

[0009] The data processing module is used to acquire monitoring data from the pressure sensor and the flow sensor, and to diagnose faults in the thermal management system based on the acquired monitoring data. The diagnostic methods are as follows: comparing the flow sensor monitoring data with the minimum flow requirement to determine the medium flow fault; determining the connection pipeline fault based on the pressure difference between the water pump outlet and the motor inlet; and determining the motor residual air fault based on the flow sensor monitoring data, the motor outlet and the electrical control inlet pressure data.

[0010] Preferably, the pressure sensor includes:

[0011] The first pressure sensor is used to monitor the pressure at the water pump outlet.

[0012] The second pressure sensor is used to monitor the pressure at the motor inlet.

[0013] The third pressure sensor is used to monitor the pressure at the motor outlet.

[0014] The fourth pressure sensor is used to monitor the pressure at the electronic control inlet.

[0015] The fifth pressure sensor is used to monitor the pressure at the electronic control outlet.

[0016] Preferably, the data processing module is specifically used for,

[0017] Acquire pressure and flow data collected by the first pressure sensor, second pressure sensor, third pressure sensor, fourth pressure sensor, fifth pressure sensor and flow sensor;

[0018] The monitoring data from the flow sensor With minimum flow requirements Compare the results and make the following judgments:

[0019] like If so, it is determined that the system medium flow rate is low; if If so, it is determined that the system medium cannot circulate;

[0020] Calculate the difference between the pressure data monitored by the first pressure sensor and the second pressure sensor, and make the following judgment:

[0021] like If so, it is determined to be a fault in the connecting pipeline;

[0022] in, , The pressure data is monitored by the first pressure sensor. The pressure data is monitored by the second pressure sensor. for and The difference, The pipeline resistance is calculated theoretically. The set threshold;

[0023] Acquire monitoring data from flow sensors The pressure data monitored by the third and fourth pressure sensors are used to make the following judgments:

[0024] like ,but,

[0025] The estimated flow resistance of the medium flowing through the motor at this time is as follows:

[0026] ,

[0027] in, For the estimated flow resistance, The flow data is monitored by the flow sensor. and For motor flow rate, and For motor flow resistance;

[0028] The actual flow resistance of the motor is calculated as follows:

[0029] ,

[0030] in, This is the actual flow resistance of the motor. and These are the pressure data monitored by the third and fourth pressure sensors, respectively.

[0031] based on and Make a judgment.

[0032] like If so, it is determined to be a residual air fault in the motor.

[0033] in, To set a threshold.

[0034] Preferably, the system further includes:

[0035] The whole machine controller is connected to the data processing module. The whole machine controller is used to transmit the judgment result of the data processing module to the remote service platform for reminder.

[0036] A remote service platform is connected to the main controller. The remote service platform is used to obtain the fault diagnosis results transmitted by the main controller to remind service personnel and to investigate the fault points.

[0037] Secondly, the present invention provides a method for diagnosing faults in a thermal management system, implemented using the aforementioned thermal management system fault diagnosis system, the method comprising:

[0038] In the event of a high-temperature fault, the pressure and flow data collected by the pressure sensor and flow sensor are acquired.

[0039] The flow sensor monitoring data is compared with the minimum flow requirement to determine the medium flow fault;

[0040] Based on the pressure difference between the pump outlet and motor inlet, determine the fault in the connecting pipeline;

[0041] Based on flow sensor monitoring data and motor outlet and electronic control inlet pressure data, residual air faults in the motor are identified.

[0042] Preferably, comparing the flow sensor monitoring data with the minimum flow requirement to determine a medium flow fault includes:

[0043] The monitoring data from the flow sensor With minimum flow requirements Compare the results and make the following judgments:

[0044] like If so, it is determined that the system medium flow rate is low; if If so, it is determined that the system medium cannot circulate.

[0045] Preferably, the step of determining the connection pipeline fault based on the pressure difference between the pump outlet and the motor inlet includes:

[0046] Calculate the difference between the pump outlet pressure and the motor inlet pressure, and make the following judgments:

[0047] like If so, it is determined to be a fault in the connecting pipeline;

[0048] in, , The pressure data is monitored at the water pump outlet. This refers to the pressure data monitored at the motor inlet. for and The difference, The pipeline resistance is calculated theoretically. The threshold value is set.

[0049] Preferably, the step of determining residual air faults in the motor based on flow sensor monitoring data, motor outlet pressure data, and electronic control inlet pressure data includes:

[0050] Acquire monitoring data from flow sensors ,like ,but,

[0051] The estimated flow resistance of the medium flowing through the motor at this time is as follows:

[0052] ,

[0053] in, For the estimated flow resistance, The flow data is monitored by the flow sensor. and For motor flow rate, and For motor flow resistance;

[0054] The actual flow resistance of the motor is calculated as follows:

[0055] ,

[0056] in, This is the actual flow resistance of the motor. and These are the pressure data monitored at the motor outlet and the electronic control inlet, respectively.

[0057] based on and Make a judgment.

[0058] like If so, it is determined to be a residual air fault in the motor.

[0059] in, To set a threshold.

[0060] The beneficial effects of this invention are as follows:

[0061] This invention provides a fault diagnosis system and method for a thermal management system. The system is equipped with pressure and flow sensors to monitor pressure and flow data at the water pump outlet, motor inlet and outlet, and electrical control inlet and outlet of the thermal management system. When the motor or electrical control system alarms due to high temperature, the system collects the flow and pressure data of the medium in the thermal management system, diagnoses the fault of the thermal management system based on the acquired monitoring data, and transmits the diagnosis results to a remote service platform. The specific fault point can be quickly identified through the remote service platform, facilitating service personnel to repair the fault. Attached Figure Description

[0062] Figure 1 A schematic diagram of the structure of a thermal management system fault diagnosis system provided by the present invention;

[0063] Figure 2 The present invention provides a flowchart of a fault diagnosis method for a thermal management system. Detailed Implementation

[0064] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the embodiments and accompanying drawings. Here, the illustrative embodiments and descriptions of this invention are used to explain the invention, but are not intended to limit the invention.

[0065] It should also be noted that, in order to avoid obscuring the invention with unnecessary details, only the structures and / or processing steps closely related to the solution according to the invention are shown in the accompanying drawings, while other details that are not closely related to the invention are omitted.

[0066] It should be emphasized that the term "including / comprises" as used herein refers to the presence of a feature, element, step, or component, but does not exclude the presence or addition of one or more other features, elements, steps, or components.

[0067] It should also be noted that, unless otherwise specified, the term "connection" in this article can refer not only to a direct connection, but also to an indirect connection involving an intermediary.

[0068] Secondly, the term "an embodiment" or "embodiment" as used in this invention refers to a specific feature, structure, or characteristic that can be included in at least one implementation of this invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that excludes other embodiments.

[0069] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0070] The first embodiment of the present invention provides a fault diagnosis system for a thermal management system, see [link to relevant documentation]. Figure 1 It includes: a data collection module 16, a data processing module 17, a whole machine controller 18, and a remote service platform 19. The data collection module includes: a fan 1, a radiator 2, a water pipe 1 3, a water pump 4, a first pressure sensor 5, a second water pipe 2 6, a second pressure sensor 7, a motor 8, a third pressure sensor 9, a fourth pressure sensor 10, a third water pipe 3 11, an electronic control 12, a fifth pressure sensor 13, a flow sensor 14, and a fourth water pipe 4 15.

[0071] Specifically, the first pressure sensor 5 is used to monitor the pressure at the outlet of the water pump 4, the second pressure sensor 7 is used to monitor the pressure at the inlet of the motor 8, water pipe 1 3 connects the outlet of the radiator and the inlet of the water pump 3, water pipe 2 6 connects the outlet of the water pump 4 and the inlet of the motor 8, the third pressure sensor 9 is used to measure the pressure at the outlet of the motor 8, the fourth pressure sensor 10 is used to measure the pressure at the inlet of the electronic control 12, water pipe 3 11 connects the outlet of the motor 8 and the inlet of the electronic control 12, the fifth pressure sensor 13 is used to measure the pressure at the outlet of the electronic control 12, water pipe 4 15 connects the outlet of the electronic control 12 and the inlet of the radiator 2, and the flow sensor 14 is used to monitor the flow rate in the system and is located at the outlet of the electronic control 12.

[0072] Data processing module 17 is connected to the first pressure sensor 5, the second pressure sensor 7, the third pressure sensor 9, the fourth pressure sensor 10, the fifth pressure sensor 13, and the flow sensor 14. Data processing module 17 is used for:

[0073] Acquire pressure and flow data collected by the first pressure sensor 5, the second pressure sensor 7, the third pressure sensor 9, the fourth pressure sensor 10, the fifth pressure sensor 13, and the flow sensor 14;

[0074] Data monitored by flow sensor 14 With minimum flow requirements Compare the results and make the following judgments:

[0075] like If so, it is determined that the system medium flow rate is low; if If so, it is determined that the system medium cannot circulate;

[0076] Calculate the difference between the pressure data monitored by the first pressure sensor 5 and the second pressure sensor 7, and make the following judgment:

[0077] like If so, it is determined to be a fault in the connecting pipeline;

[0078] in, , The pressure data is monitored by the first pressure sensor. The pressure data is monitored by the second pressure sensor. for and The difference, The pipeline resistance is calculated theoretically. The set threshold value can be changed according to design requirements.

[0079] Acquire monitoring data from flow sensors The pressure data monitored by the third and fourth pressure sensors are used to make the following judgments:

[0080] like ,but,

[0081] The estimated flow resistance of the medium flowing through the motor at this time is as follows:

[0082] ,

[0083] in, For the estimated flow resistance, The flow data is monitored by the flow sensor. and For motor flow rate, and This refers to the motor flow resistance; it should be noted that the correspondence between motor flow rate and motor flow resistance is pre-stored in the data processing module, and the motor flow rate is obtained from the test bench data of the motor supplier.

[0084] The actual flow resistance of the motor is calculated as follows:

[0085] ,

[0086] in, This is the actual flow resistance of the motor. and These are the pressure data monitored by the third and fourth pressure sensors, respectively.

[0087] based on and Make a judgment.

[0088] like If so, it is determined to be a residual air fault in the motor.

[0089] in, The threshold is set according to the design requirements of the machine body.

[0090] The whole machine controller 18 is connected to the data processing module 17. The whole machine controller 18 is used to transmit the judgment result of the data processing module to the remote service platform for reminder.

[0091] The remote service platform 19 is connected to the whole machine controller 18. The remote service platform 19 is used to obtain the fault diagnosis results transmitted by the whole machine controller 18 and remind the service personnel to quickly troubleshoot the fault.

[0092] Based on the aforementioned thermal management system fault diagnosis system, a second embodiment of the present invention provides a thermal management system fault diagnosis method, see [link to documentation]. Figure 2 The method includes:

[0093] In the event of a high-temperature fault, pressure and flow data are acquired from the first pressure sensor, the second pressure sensor, the third pressure sensor, the fourth pressure sensor, the fifth pressure sensor, and the flow sensor.

[0094] Compare the flow sensor monitoring data with the minimum flow requirement to determine the medium flow fault;

[0095] Based on the pressure data difference monitored by the first and second pressure sensors, a fault in the connecting pipeline is determined.

[0096] Based on the monitoring data from the flow sensor and the pressure data monitored by the third and fourth pressure sensors, a residual air fault in the motor is determined.

[0097] In this embodiment, the flow sensor monitoring data is compared with the minimum flow requirement to determine the medium flow fault, as follows:

[0098] Flow sensor monitoring data With minimum flow requirements Compare the results and make the following judgments:

[0099] like If so, it is determined that the system medium flow rate is low; if If so, it is determined that the system medium cannot circulate.

[0100] In this embodiment, the fault in the connecting pipeline is determined based on the pressure data difference monitored by the first pressure sensor and the second pressure sensor, as follows:

[0101] Calculate the difference between the pressure data monitored by the first pressure sensor 5 and the second pressure sensor 7, and make the following judgment:

[0102] like If so, it is determined to be a fault in the connecting pipeline;

[0103] in, , The pressure data is monitored by the first pressure sensor. The pressure data is monitored by the second pressure sensor. for and The difference, The pipeline resistance is calculated theoretically. The threshold value is set.

[0104] In this embodiment, Set to 10%.

[0105] In this embodiment, based on the monitoring data from the flow sensor and the pressure data monitored by the third and fourth pressure sensors, a residual air fault in the motor is determined, as follows:

[0106] Acquire monitoring data from flow sensors The pressure data monitored by the third and fourth pressure sensors are used to make the following judgments:

[0107] like ,but,

[0108] The estimated flow resistance of the medium flowing through the motor at this time is as follows:

[0109] ,

[0110] in, For the estimated flow resistance, The flow data is monitored by the flow sensor. and For motor flow rate, and The motor flow resistance is shown in Table 1. It should be noted that the correspondence between motor flow rate and motor flow resistance is pre-stored in the data processing module.

[0111] The actual flow resistance of the motor is calculated as follows:

[0112] ,

[0113] in, This is the actual flow resistance of the motor. and These are the pressure data monitored by the third and fourth pressure sensors, respectively.

[0114] based on and Make a judgment.

[0115] like If so, it is determined to be a residual air fault in the motor.

[0116] in, To set a threshold.

[0117] In this embodiment, Set to 10%.

[0118] Table 1. Relationship between motor flow rate and flow resistance

[0119]

[0120] It should be noted that the calculation method for electronic control is the same as that described above, and will not be repeated here.

[0121] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solutions of the present invention, and these simple modifications all fall within the protection scope of the present invention. In addition, the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present invention will not describe the various possible combinations separately.

Claims

1. A fault diagnosis system for a thermal management system, characterized in that, include: The data acquisition module includes pressure sensors installed at the water pump outlet, motor inlet / outlet, and electrical control inlet / outlet in the thermal management system to monitor pressure data at the installation locations. In addition, flow sensors are installed in the thermal management system to monitor the flow rate of the thermal management system; The pressure sensors include: a first pressure sensor for monitoring the pressure at the water pump outlet, a second pressure sensor for monitoring the pressure at the motor inlet, a third pressure sensor for monitoring the pressure at the motor outlet, a fourth pressure sensor for monitoring the pressure at the electrical control inlet, and a fifth pressure sensor for monitoring the pressure at the electrical control outlet. The data processing module is used to acquire monitoring data from the pressure sensor and the flow sensor, and to diagnose faults in the thermal management system based on the acquired monitoring data. The diagnostic methods are as follows: comparing the flow sensor monitoring data with the minimum flow requirement to determine a medium flow fault; determining a connecting pipe fault based on the pressure difference between the pump outlet and the motor inlet; and determining a motor residual air fault based on the flow sensor monitoring data, the motor outlet pressure data, and the electrical control inlet pressure data. The data processing module diagnoses faults in the thermal management system, specifically including... Acquire pressure and flow data collected by the first pressure sensor, second pressure sensor, third pressure sensor, fourth pressure sensor, fifth pressure sensor and flow sensor; The monitoring data from the flow sensor With minimum flow requirements Compare the results and make the following judgments: like If so, it is determined that the system medium flow rate is low; if If so, it is determined that the system medium cannot circulate; Calculate the difference between the pressure data monitored by the first pressure sensor and the second pressure sensor, and make the following judgment: like If so, it is determined to be a fault in the connecting pipeline; in, , The pressure data is monitored by the first pressure sensor. The pressure data is monitored by the second pressure sensor. for and The difference, The pipeline resistance is calculated theoretically. The set threshold; Acquire monitoring data from flow sensors The pressure data monitored by the third and fourth pressure sensors are used to make the following judgments: like ,but, The estimated flow resistance of the medium flowing through the motor at this time is as follows: ， in, For the estimated flow resistance, The flow data is monitored by the flow sensor. and For motor flow rate, and For motor flow resistance; The actual flow resistance of the motor is calculated as follows: ， in, This is the actual flow resistance of the motor. and These are the pressure data monitored by the third and fourth pressure sensors, respectively. based on and Make a judgment. like If so, it is determined to be a residual air fault in the motor. in, To set a threshold.

2. The thermal management system fault diagnosis system according to claim 1, characterized in that, The system also includes: The whole machine controller is connected to the data processing module, and the whole machine controller is used to transmit the judgment result of the data processing module to the remote service platform for reminder; A remote service platform is connected to the main controller. The remote service platform is used to obtain the fault diagnosis results transmitted by the main controller to remind service personnel and to investigate the fault points.

3. A method for diagnosing faults in a thermal management system, characterized in that, The method is implemented using the thermal management system fault diagnosis system as described in claim 1 or 2, and includes: In the event of a high-temperature fault, the pressure and flow data collected by the pressure sensor and flow sensor are acquired. The flow sensor monitoring data is compared with the minimum flow requirement to determine the medium flow fault; Based on the pressure difference between the pump outlet and motor inlet, determine the fault in the connecting pipeline; Based on flow sensor monitoring data and motor outlet and electronic control inlet pressure data, residual air faults in the motor are identified.

4. The method for diagnosing faults in a thermal management system according to claim 3, characterized in that, The flow sensor monitoring data is compared with the minimum flow requirement to determine a medium flow fault, including: The monitoring data from the flow sensor With minimum flow requirements Compare the results and make the following judgments: like If so, it is determined that the system medium flow rate is low; if If so, it is determined that the system medium cannot circulate.

5. The method for fault diagnosis of a thermal management system according to claim 3, characterized in that, The method of determining connection pipeline faults based on the pressure difference between the pump outlet and the motor inlet includes: Calculate the difference between the pump outlet pressure and the motor inlet pressure, and make the following judgments: like If so, it is determined to be a fault in the connecting pipeline; in, , The pressure data is monitored at the water pump outlet. This refers to the pressure data monitored at the motor inlet. for and The difference, The pipeline resistance is calculated theoretically. The threshold value is set.

6. The method for fault diagnosis of a thermal management system according to claim 3, characterized in that, The method of determining residual air faults in the motor based on flow sensor monitoring data and motor outlet and electronic control inlet pressure data includes: Acquire monitoring data from flow sensors ,like ,but, The estimated flow resistance of the medium flowing through the motor at this time is as follows: ， in, For the estimated flow resistance, The flow data is monitored by the flow sensor. and For motor flow rate, and For motor flow resistance; The actual flow resistance of the motor is calculated as follows: ， in, This is the actual flow resistance of the motor. and These are the pressure data monitored at the motor outlet and the electronic control inlet, respectively. based on and Make a judgment. like If so, it is determined to be a residual air fault in the motor. in, To set a threshold.

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