A new energy modular upgrading and reconstruction method for internal combustion locomotives

Abstract

The invention relates to the technical field of locomotives, and aims to solve the problem that there is a lack of a method for upgrading and remanufacturing a diesel locomotive with new energy in the prior art, and provides a method for upgrading and remanufacturing a diesel locomotive with new energy in a modular manner, comprising the following steps: S1: dividing a locomotive into multiple modules; S2: removing a power system of the diesel locomotive, and disassembling an upper body steel structure of the diesel locomotive; S3: transforming a frame of the diesel locomotive to form a frame module, so that the frame module serves as a carrier of other modules and provides an installation position for other modules; S4: installing a required new energy power module on the frame module according to the reconstruction requirements; retaining a bogie of the diesel locomotive, using it as a bogie module after overhaul, and installing a traction motor drive module on the frame module to connect with the bogie module; the invention modularly upgrades and remanufactures a diesel locomotive into a new energy locomotive according to the reconstruction requirements, thereby reducing carbon emissions and costs.

Description

Technical Field

[0001] The present invention relates to the technical field of locomotives, and in particular to a method for modular upgrading and rebuilding of new energy vehicles for diesel locomotives. Background Art

[0002] Diesel locomotives are large-scale industrial products with multiple system integration and high complexity. They are of high value but have a certain service life and lifespan. Diesel locomotives use internal combustion engines as power to provide traction power and auxiliary power requirements for locomotives. They have been widely used in various railway transportation scenarios and have made great contributions to the national economy. With the development of science and technology and the development needs of the new era, green environmental protection, high efficiency and energy saving, low carbon and intelligence have become the development themes of rail transit equipment. Traditional diesel locomotives are facing great pressure for upgrading and technological innovation.

[0003] At present, there is no systematic method for upgrading and rebuilding diesel locomotives with new energy modularization on the market. If a diesel locomotive is directly replaced with a new energy locomotive, the value of the original locomotive will be wasted. At the same time, the production cost of new energy locomotives is high, and the production material cost and manufacturing energy consumption are high. Summary of the invention

[0004] The present invention aims to provide a method for modular upgrading and rebuilding of a diesel locomotive with new energy, so as to solve the problem that there is a lack of a method for modular upgrading and rebuilding of a diesel locomotive with new energy in the prior art.

[0005] The present invention is achieved by adopting the following technical solutions:

[0006] The present invention provides a method for upgrading and remanufacturing a new energy modular diesel locomotive, comprising the following steps:

[0007] S1: According to the functions and structural characteristics of diesel locomotives and new energy locomotives, the locomotives are divided into modules and divided into multiple modules;

[0008] S2: dismantle the power system of the diesel locomotive and dismantle the upper body steel structure of the diesel locomotive;

[0009] S3: The frame of the diesel locomotive is modified to form a frame module, so that the frame module serves as a carrier of other modules and provides installation positions for other modules;

[0010] S4: Newly set up the required new energy power module on the frame module according to the reconstruction requirements;

[0011] The bogie of the diesel locomotive is retained and used as a bogie module after overhaul, and a new traction motor drive module is installed on the frame module to connect with the bogie module.

[0012] The present invention divides the locomotive into multiple modules according to the functions and structural characteristics of diesel locomotives and new energy locomotives. Each equipment room above the locomotive frame forms a module respectively. The modules are combined and integrated into a new energy locomotive according to the reconstruction needs by dismantling, retaining, renovating and newly setting up. The method provides a new energy modular upgrading and reconstruction method for diesel locomotives.

[0013] The present invention is based on the existing diesel locomotive. The diesel locomotive is upgraded and rebuilt through the above method, some original vehicle parts are reasonably utilized, and some new parts are added, so that the diesel locomotive is transformed into a new energy locomotive, which can reduce carbon emissions and reduce damage to the environment. At the same time, the residual value of the original locomotive is maximized, the production material consumption cost and manufacturing energy consumption are reduced, and social resources are saved.

[0014] As the preferred technical solution:

[0015] The steel structure of the driver's cab of the diesel locomotive is not disassembled, but modified to form a driver's cab module.

[0016] As the preferred technical solution:

[0017] The air brake equipment of the diesel locomotive is retained and repaired, and a new car body steel structure is built to form the rear engine room module and the front engine room module;

[0018] A new converter cabinet module is installed on the frame module.

[0019] As the preferred technical solution:

[0020] The modules divided in step S1 include a power battery module, a diesel generator module, a hydrogen fuel cell module, a converter module, a driver's cab module, a rear engine room module, a front engine room module, a frame module, a bogie module, and a traction motor drive module.

[0021] As the preferred technical solution:

[0022] The new energy power module in step S2 includes a diesel generator module, a power battery module, a hydrogen fuel cell module, and a combination of at least two modules.

[0023] As the preferred technical solution:

[0024] When a diesel generator module and a power battery module are newly provided in step S4, the hydraulic transmission diesel locomotive is modularly upgraded and rebuilt into a new energy hybrid locomotive;

[0025] When a new power battery module is provided in step S4, the hydraulic transmission internal combustion locomotive is modularly upgraded and rebuilt into a new energy pure electric locomotive;

[0026] When a power battery module and a hydrogen fuel cell module are newly provided in step S4, the hydraulic transmission diesel locomotive is modularly upgraded and rebuilt into a hydrogen fuel cell locomotive.

[0027] As the preferred technical solution:

[0028] The power battery module includes the power battery room steel structure, power battery pack, power battery high-voltage box, power battery management system, power battery water cooling unit, power battery fire extinguishing device and various pipelines. The external interface includes the power battery module bottom mounting seat, power battery external power output cable and communication cable;

[0029] The power battery room steel structure serves as the external frame. The power battery pack, power battery high-voltage box, power battery management system, power battery water cooling unit, power battery fire extinguishing device and various pipelines are arranged inside the power battery room steel structure. The power battery module bottom mounting seat is arranged at the bottom of the power battery module. The power battery module bottom mounting seat serves as an interface for connecting with the frame module.

[0030] The hydrogen fuel cell module includes a hydrogen fuel cell module steel structure, a hydrogen fuel cell, a hydrogen fuel cell cooling device, a hydrogen storage device and pipelines, and the external interface includes a hydrogen fuel cell module bottom mounting seat and a hydrogen fuel cell external power output cable and a communication cable;

[0031] The hydrogen fuel cell module steel structure serves as an external frame, and the hydrogen fuel cell, hydrogen fuel cell cooling device, hydrogen storage device and pipelines are arranged inside the hydrogen fuel cell module steel structure. The hydrogen fuel cell module bottom mounting seat is arranged at the bottom of the hydrogen fuel cell module, and the hydrogen fuel cell module bottom mounting seat serves as an interface for connecting with the frame module;

[0032] The diesel generator module includes a diesel generator module steel structure and a diesel generator set, and the external interface includes a diesel generator module bottom mounting base, a diesel generator power output cable and a communication cable;

[0033] The diesel generator set is arranged inside the diesel generator set module steel structure, the diesel generator set module bottom mounting seat is arranged at the bottom of the diesel generator set module, and the diesel generator set module bottom mounting seat is used as an interface for connecting with the frame module.

[0034] As the preferred technical solution:

[0035] The converter cabinet module includes a converter cabinet module steel structure and a main-auxiliary integrated converter cabinet, and the external interface includes a converter cabinet module bottom mounting seat, converter cabinet input and output cables, and communication cables;

[0036] The main and auxiliary integrated converter cabinet is arranged inside the converter cabinet module steel structure, the converter cabinet module bottom mounting seat is arranged at the bottom of the converter cabinet module, and the converter cabinet module bottom mounting seat is used as an interface for connecting with the frame module;

[0037] The driver's cab module includes the driver's cab steel structure, operating console, electrical cabinet, driver's seat, and driver's cab air conditioner. The external interface includes the driver's cab module bottom mounting seat, electrical cabinet external communication cables, and air brake control pipelines.

[0038] The rear engine room module includes the rear engine room module steel structure, air brake valve frame, driver's room air conditioning external unit and other equipment. Among them, the air brake valve frame uses the original vehicle equipment for maintenance, and the external interface includes the rear engine room module bottom mounting seat and air brake control pipeline;

[0039] The air brake valve frame and the driver's cab air conditioner outdoor unit are arranged inside the steel structure of the rear engine room module. The rear engine room module bottom mounting seat is set at the bottom of the rear engine room module. The rear engine room module bottom mounting seat serves as an interface for connection with the frame module.

[0040] Among them, the air brake valve frame is a frame or bracket installed on the locomotive, which is used to fix and support various valve components in the air brake system, such as brake valves, pressure reducing valves, emergency valves, etc.

[0041] As the preferred technical solution:

[0042] The traction motor drive module includes a traction motor, an elastic connection device, an intermediate gearbox, a universal joint, and an intermediate gearbox mounting seat. The universal joint uses the original vehicle equipment and is repaired. The traction motor is connected to both sides of the intermediate gearbox, and the intermediate gearbox is connected to the universal joint shaft, which is used to connect to the bogie. The external interface includes an intermediate gearbox mounting seat, an output universal joint shaft flange drive interface, and a traction motor cable connection interface.

[0043] As the preferred technical solution:

[0044] The upper plane of the frame module is provided with a module mounting seat for installing each module, and the lower plane of the frame module is connected to the bogie through a side bearing and a traction device, so as to transfer the weight of each upper module and the traction and braking requirements to the bogie.

[0045] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0046] 1. The present invention fully reuses the components and systems of the old diesel locomotive such as the body steel structure, running gear and air system that can still be maintained and modularly reconstructs them. By adding some parts and systems and forming a modular solution, the transformation of diesel locomotives to new energy locomotives is realized, and the surplus value of the original locomotive is maximized, which has the effect of reducing production material consumption costs and manufacturing energy consumption and saving social resources.

[0047] 2. The present invention divides the locomotive into functional parts and modularly designs the rear engine room module, driver's room module, converter module, new energy power module (power battery module, hydrogen fuel cell module and diesel generator module), front engine room module, frame module, bogie module and traction motor drive module. The main newly added functional modules are the converter module, new energy power module and traction motor drive module. The modified modules are the driver's room module and frame module. The air brake equipment is retained. The module retained depending on the situation is the bogie module. The platform solution of the rebuilt locomotive is realized through modularization. It can be designed and manufactured in advance, saving the production cycle. The existing diesel locomotive can be upgraded and rebuilt clearly, simply and quickly, and the diesel locomotive can be converted into a new energy locomotive.

[0048] 3. The present invention reconstructs the traditional internal combustion locomotive with one or more new energy sources such as power batteries, hydrogen fuel cells, and high-performance diesel generator sets as the main power, completing the transformation of internal combustion locomotives into new energy locomotives. The locomotive operation mainly uses green and environmentally friendly power batteries or hydrogen fuel cells, and there is no need for the diesel engine to idle during waiting time, which has the effect of significantly saving fuel, reducing noise, and reducing emissions.

[0049] 4. The new energy modular upgrading and rebuilding method of the present invention can be applied to the rebuilding of various existing internal combustion locomotives. By combining the rebuilding requirements and the original vehicle status, the available original vehicle component systems are determined, and the newly manufactured modular functional components replace part of the original vehicle system, which can quickly and efficiently transform old vehicles into new ones. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Figure 1 This is a flow chart of the new energy modular upgrading and reconstruction method for a diesel locomotive according to the present invention.

[0051] Figure 2 This is a front view of the power battery module described in the present invention.

[0052] Figure 3 This is a top view of the power battery module described in the present invention.

[0053] Figure 4 This is a front view of the hydrogen fuel cell module described in the present invention.

[0054] Figure 5 It is a top view of the hydrogen fuel cell module described in the present invention.

[0055] Figure 6 This is a front view of the diesel generator module described in the present invention.

[0056] Figure 7 This is a top view of the diesel generator module described in the present invention.

[0057] Figure 8 This is a front view of the front machine room module described in the present invention.

[0058] Fig. 9 This is a top view of the front machine room module described in the present invention.

[0059] Fig.10 This is a front view of the converter cabinet module described in the present invention.

[0060] Fig.11 It is a top view of the converter cabinet module described in the present invention.

[0061] Fig.12 It is the front view of the driver's cab module described in the present invention.

[0062] Fig.13 This is a top view of the driver's cab module described in the present invention.

[0063] Fig.14 This is a front view of the rear engine room module described in the present invention.

[0064] Fig.15 This is a top view of the rear engine room module described in the present invention.

[0065] Fig.16 This is a front view of the bogie module described in the present invention.

[0066] Fig.17 It is a top view of the bogie module described in the present invention.

[0067] Fig.18 This is a front view of the traction motor drive module described in the present invention.

[0068] Fig.19 This is a top view of the traction motor drive module described in the present invention.

[0069] Fig. 20 It is a front view of the frame module of the present invention.

[0070] Fig.21 It is a top view of the frame module of the present invention.

[0071] Fig. 22 This is a front view of the new energy hybrid locomotive described in the present invention.

[0072] Fig.23This is a top view of the new energy hybrid locomotive described in the present invention.

[0073] Fig.24 This is a front view of the new energy pure electric locomotive described in the present invention.

[0074] Fig.25 It is a top view of the new energy pure electric locomotive described in the present invention.

[0075] Fig.26 This is a front view of the hydrogen fuel cell locomotive described in the present invention.

[0076] Fig. 27 This is a top view of the hydrogen fuel cell locomotive described in the present invention.

[0077] Fig.28 This is a block diagram of the working principle of the new energy modular upgrading and reconstruction of the internal combustion locomotive described in the present invention.

[0078] Icons: 1-power battery module, 101-power battery room steel structure, 102-power battery pack, 103-power battery high-voltage box, 104-power battery water cooling unit, 105-power battery fire extinguishing device, 106-power battery module bottom mounting seat, 2-hydrogen fuel cell module, 201-hydrogen fuel cell module steel structure, 202-hydrogen fuel cell, 203-hydrogen fuel cell cooling device, 204-hydrogen storage device, 205-hydrogen fuel cell module bottom mounting seat, 3-diesel generator module, 301-diesel generator module steel structure, 302-diesel generator, 303-diesel generator module bottom mounting seat, 4-front engine room module, 401-front engine room steel structure, 402-air compressor unit, 403-air dryer, 404-front engine room module bottom mounting seat, 5-converter cabinet module, 501-converter cabinet module steel structure, 502-main and auxiliary integrated converter cabinet, 503-converter cabinet module bottom mounting seat, 6-driver's cab module, 601-driver's cab steel structure, 602-operating console, 603-electrical cabinet, 604-driver's seat, 605-driver's cab air conditioner, 606-driver's cab module bottom mounting seat, 7-rear engine room module, 701-rear engine room module steel structure, 702-air brake valve frame, 703-driver's cab air conditioner outdoor unit, 704-rear engine room module bottom mounting seat, 8-bogie module, 801-side bearing, 802-traction center pin, 803-axle gearbox drive device, 804-BB bogie, 9-traction motor drive module, 901-traction motor, 902-intermediate gearbox, 903-universal shaft, 904-intermediate gearbox mounting seat, 10-frame module, 1001-frame upper plane, 1002-frame lower plane, 1003-coupler. DETAILED DESCRIPTION

[0079] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0080] Example 1

[0081] This embodiment proposes a new energy modular upgrading and reconstruction method for a diesel locomotive. According to the functions and structural characteristics of the locomotive, the locomotive can be mainly divided into a power system, a converter system, an air brake system, a drive system, a driver operation and control system, and a running gear.

[0082] Among them, the power system is used to provide traction and auxiliary power for the locomotive, such as energy storage unit system, diesel generator system or hydrogen fuel system; the converter system is used to supply the electric energy generated by the power system to various electrical equipment of the locomotive after power conversion, and various electrical equipment include traction motors, auxiliary equipment motors, control electricity and lighting; the air brake system is used to provide control and power for the locomotive air brake, including air source system, brake valves, pipeline system, etc.; the drive system mainly refers to the traction motor and its transmission device. The speed and torque output by the traction motor are converted into the traction speed and traction force of the locomotive through the transmission device. In addition, the wheel speed can also be converted into braking force through the drive system to provide electric braking force for the locomotive; the driver operation and control system mainly provides the locomotive driver with various functions for operating the locomotive, mainly including equipment such as the control panel and electrical cabinet; the running gear carries the upper car body and all equipment, contacts with the track, and acts as the actuator of the drive system to provide traction and braking force for the locomotive. The bogie is the running gear of the rail vehicle.

[0083] Diesel locomotives need to be technically upgraded and rebuilt into new energy locomotives. The idea of ​​upgrading and rebuilding is: first dismantle the unused component systems, and then replace them with new functional modules. The main systems to be replaced are the power system; the newly added ones are the converter system, the front engine room module and the rear engine room module, and the traction motor drive module; the frames, air brake systems, drive systems, driver operation and control systems are modified as appropriate; the steel structure of the driver's cab, running gear, etc. are retained.

[0084] like Figure 1 As shown, the internal combustion locomotive new energy modular upgrading and reconstruction method comprises the following steps:

[0085] S1: According to the functions and structural characteristics of diesel locomotives and new energy locomotives, the locomotive is divided into modules, including a power battery module 1, a diesel generator module 3, a hydrogen fuel cell module 2, a converter module 5, a driver's cab module 6, a rear engine room module 7, a front engine room module 4, a frame module 10, a bogie module 8, and a traction motor drive module 9;

[0086] S2: Dismantle the hydraulic transmission box and its piping system of the diesel locomotive, dismantle the diesel engine and its oil, water and gas systems, dismantle the cooling system and related equipment of the diesel locomotive; dismantle the upper body steel structure of the diesel locomotive, and do not dismantle the driver's cab steel structure 601;

[0087] S3: The frame of the diesel locomotive is modified to form a frame module 10, so that the frame module 10 serves as a carrier of other modules and provides an installation position for other modules;

[0088] S4: Reconstructing the steel structure 601 of the driver's cab of the diesel locomotive to form a driver's cab module 6;

[0089] The main air brake equipment of the diesel locomotive is retained for overhaul and transformation, and a new car body steel structure is built to form the front engine room module 4 and the rear engine room module 7;

[0090] The diesel locomotive bogie is retained for overhaul as bogie module 8;

[0091] A new energy power module is newly installed on the frame module 10 according to the remanufacturing requirements, wherein the new energy power module includes a diesel generator module 3, a power battery module 1, a hydrogen fuel cell module 2 and a combination of at least two modules;

[0092] A converter module 5 and a traction motor drive module 9 are newly installed on the frame module 10, and the traction motor drive module 9 is connected to the bogie module 8;

[0093] Each module is mechanically installed on the frame module 10 through a module mounting seat that matches the frame module 10, and then connected to external power, communication, air pipeline and other interfaces. The whole is located on the bogie module 8 and connected to the drive interface of the cardan shaft 903 and the axle gearbox, completing the new energy modular reconstruction of the entire vehicle.

[0094] Among them, the diesel locomotive refers to a hydraulic transmission diesel locomotive. The present invention uses the existing hydraulic transmission diesel locomotive as a carrier to carry out new energy modular upgrading and reconstruction.

[0095] The present invention rationally utilizes the frame, driver's cab steel structure 601, bogie and brake equipment of the original diesel locomotive, and repairs and regenerates them to form a frame module 10, a driver's cab module 6, a bogie module 8 and a front engine room module 4, and a rear engine room module 7; a converter cabinet module 5, a power battery module 1, a hydrogen fuel cell module 2, a diesel generator module 3, and a traction motor drive module 9 are newly installed; through the combination of different modules, a hybrid electric locomotive, a pure electric locomotive and a hydrogen fuel cell 202 locomotive can be regenerated respectively, realizing the upgrade and reconstruction from a diesel locomotive to a new energy locomotive.

[0096] like Figure 2 and Figure 3 As shown, the power battery module 1 includes a power battery room steel structure 101, a power battery pack 102, a power battery high-voltage box 103, a power battery management system, a power battery water cooling unit 104, a power battery fire extinguishing device 105 and various pipelines, and the external interface includes a power battery module bottom mounting seat 106, a power battery external power output cable and a communication cable.

[0097] The power battery room steel structure 101 serves as an external frame, and other equipment is arranged inside the power battery room steel structure 101 . The power battery module bottom mounting seat 106 is set at the bottom of the power battery module 1 , and the power battery module bottom mounting seat 106 serves as an interface for connecting with the frame module 10 .

[0098] like Figure 4 and Figure 5 As shown, the hydrogen fuel cell module 2 includes a hydrogen fuel cell module 2 steel structure, a hydrogen fuel cell 202, a hydrogen fuel cell 202 cooling device, a hydrogen storage device 204 and pipelines, and the external interface includes a hydrogen fuel cell module bottom mounting seat 205 and a hydrogen fuel cell 202 external power output cable and a communication cable.

[0099] The hydrogen fuel cell module 2 steel structure serves as an external frame, and other equipment is arranged inside the hydrogen fuel cell module 2 steel structure. The hydrogen fuel cell module bottom mounting seat 205 is set at the bottom of the hydrogen fuel cell module 2, and the hydrogen fuel cell module bottom mounting seat 205 serves as an interface for connecting with the frame module 10.

[0100] like Figure 6 and Figure 7 As shown, the diesel generator module 3 includes a diesel generator module 3 steel structure and a diesel generator 302, and the external interface includes a diesel generator module bottom mounting seat 303, a diesel generator 302 power output cable and a communication cable.

[0101] The diesel generator set 302 is arranged inside the steel structure of the diesel generator set module 3. The bottom mounting seat 303 of the diesel generator set module is set at the bottom of the diesel generator set module 3. The bottom mounting seat 303 of the diesel generator set module serves as an interface for connecting with the frame module 10.

[0102] like Figure 8 and Fig. 9 As shown, the front machine room module 4 includes a module steel structure, an air compressor unit 402, an air dryer 403, etc., wherein the air compressor unit 402 and the air dryer 403 are repaired and adaptively modified using the original vehicle equipment, and the external interfaces include the front machine room module bottom mounting seat 404, the air source output air pipeline, and the air compressor unit 402 and the air dryer 403 cables.

[0103] The air compressor unit 402 and the air dryer 403 are arranged inside the steel structure of the front engine room module 4. The front engine room module bottom mounting seat 404 is set at the bottom of the front engine room module 4. The front engine room module bottom mounting seat 404 is used as an interface for connecting with the frame module 10.

[0104] like Fig.10 and Fig.11 As shown, the converter cabinet module 5 includes a converter cabinet module 5 steel structure and a main-auxiliary integrated converter cabinet 502, and the external interface includes a converter cabinet module bottom mounting seat 503, converter cabinet input and output cables and communication cables.

[0105] The main and auxiliary integrated converter cabinet 502 is arranged inside the steel structure of the converter cabinet module 5, and the converter cabinet module bottom mounting seat 503 is set at the bottom of the converter cabinet module 5. The converter cabinet module bottom mounting seat 503 is used as an interface for connecting with the frame module 10.

[0106] like Fig.12 and Fig.13 As shown, the driver's cab module 6 includes all necessary driver and passenger equipment such as the driver's cab steel structure 601, the control panel 602, the electrical cabinet 603, the driver's seat 604, the driver's cab air conditioner 605, etc., among which the driver's cab steel structure 601 and the control panel 602 are adaptively modified using the original vehicle structure, and the external interfaces include the driver's cab module bottom mounting seat 606, the electrical cabinet 603 external communication cables, air brake control pipelines, etc.

[0107] like Fig.14 and Fig.15 As shown, the rear engine room module 7 includes the rear engine room module 7 steel structure, the air brake valve frame 702, the driver's room air conditioner 605 external unit and other equipment. Among them, the air brake valve frame 702 uses the original vehicle equipment for maintenance, and the external interface consists of the rear engine room module bottom mounting seat 704, the air brake control pipeline and other components.

[0108] The air brake valve frame 702 is a frame or bracket installed on the locomotive, which is used to fix and support various valve components in the air brake system, such as brake valves, pressure reducing valves, emergency valves, etc.

[0109] The air brake valve frame 702 and the driver's room air conditioner 605 are arranged inside the steel structure of the rear engine room module 7. The rear engine room module bottom mounting seat 704 is set at the bottom of the rear engine room module 7. The rear engine room module bottom mounting seat 704 is used as an interface for connecting with the frame module 10.

[0110] like Fig.16 and Fig.17 As shown, the bogie module 8 includes a BB bogie 804. The BB bogie is mainly used in internal combustion hydraulic locomotives. The power device composed of a diesel engine and a hydraulic transmission box outputs power to drive the axle gear to drive the wheelset to operate. If used in an electric locomotive, the traction motor 901 needs to output power to drive the axle gear to drive the wheelset to operate. The BB bogie 804 mainly includes an axle gearbox, a frame, a side bearing 801, a traction center pin 802 and other common parts of the bogie. When upgrading and remanufacturing, the BB bogie 804 is completely retained and repaired. The external interface is the side bearing 801, the traction center pin 802 and the axle gearbox drive connection flange interface.

[0111] Fig.17 In the figure, reference numeral 803 is an axle gearbox drive device. For a hydraulic transmission diesel locomotive, the axle gearbox drive device 803 is a diesel engine and a hydraulic transmission box. After upgrading and reconstruction, the axle gearbox drive device 803 is a traction motor drive module 9.

[0112] The traction motor drive module 9 is a newly designed drive module specifically for driving the BB bogie 804 . It is installed at the lower middle part of the frame by body suspension and drives the BB bogie 804 through the universal joint shaft 903 .

[0113] like Fig.18 and Fig.19 As shown, the traction motor drive module 9 includes a traction motor 901, an elastic coupling (elastic connection device), an intermediate gear box 902, a universal shaft 903, and an intermediate gear box mounting seat 904, wherein the universal shaft 903 uses the original vehicle equipment and is overhauled; the traction motors 901 are connected to both sides of the intermediate gear box 902, and the intermediate gear box 902 is connected to the universal shaft 903, and the universal shaft 903 is used to connect to the BB bogie 804.

[0114] The external interfaces are the intermediate gearbox mounting seat 904, the output universal shaft 903 flange drive interface, and the traction motor 901 cable connection interface.

[0115] like Fig. 20 and Fig.21 As shown, the frame module 10 is used as a carrier for the modules on the vehicle. A module mounting seat is arranged on the upper plane of the frame module 10 for mounting the modules. The lower plane of the frame module 10 is connected to the bogie through a side bearing 801 and a traction device, and the weight of the upper modules and the traction and braking requirements are transferred to the bogie. A coupler 1003 is arranged at the end of the frame. The frame module 10 is obtained by adaptively modifying the original frame of a hydraulic transmission diesel locomotive.

[0116] According to the above method, the modular upgrading and reconstruction scheme of new energy for diesel locomotives includes:

[0117] Solution 1: Modular upgrading of hydraulic transmission diesel locomotives into new energy hybrid locomotives, such as Fig. 22 and Fig.23 shown.

[0118] The diesel locomotive driver's cab steel structure 601 is modified to form a driver's cab steel module, the diesel locomotive frame is adaptively modified based on the original vehicle to form a frame module 10, a rear engine room module 7, a converter module 5, a power battery module 1, a diesel generator set module 3, and a front engine room module 4 are newly installed, a traction motor drive module 9 is installed in the middle of the frame module 10, and the lower BB bogie 804 of the diesel locomotive is retained.

[0119] Solution 2: Modular upgrading of hydraulic transmission diesel locomotives into new energy pure electric locomotives, such as Fig.24 and Fig.25 shown.

[0120] On the basis of Scheme 1, the diesel generator module 3 is cancelled and replaced with the power battery module 1, and the front engine room module 4 is deformed to form a pure electric reconstruction scheme.

[0121] Option 3: Modular upgrading of hydraulic transmission diesel locomotives into hydrogen fuel cell 202 locomotives, such as Fig.26 and Fig. 27 shown.

[0122] On the basis of Scheme 1, the diesel generator module 3 is cancelled and replaced with the hydrogen fuel cell module 2, thus forming a hydrogen fuel cell 202 reconstruction scheme.

[0123] New energy power modules are not limited to the above three types, and can be upgraded and rebuilt according to actual conditions.

[0124] The working principle of the modular upgrading and reconstruction of diesel locomotive new energy is as follows Fig.28 shown.

[0125] The present invention fully reuses the components and systems of the old diesel locomotive such as the body steel structure, running gear and air system that can still be maintained in use, and carries out modular reconstruction. By adding some parts and systems and forming a modular solution, the transformation of diesel locomotives to new energy locomotives is realized, and the surplus value of the original locomotive is maximized. It has the effect of reducing production material costs and manufacturing energy consumption, and saving social resources.

[0126] The present invention divides the locomotive into functional parts and modularly designs a driver's cab module 6, a converter module 5, a new energy power module (a power battery module 1, a hydrogen fuel cell module 2 and a diesel generator module 3), a rear engine room module 7, a front engine room module 4, a frame module 10, a bogie module and a traction motor drive module 9, wherein the main newly added functional modules are the converter module 5, the new energy power module and the traction motor drive module 9, the modified modules are the driver's cab module 6 and the frame module 10, the main air brake equipment is retained, and the module retained as appropriate is the bogie module. The platform solution of the rebuilt locomotive is realized through modularization, which can be designed and manufactured in advance, saving the production cycle, and can clearly, simply and quickly upgrade and rebuild the existing diesel locomotive to transform it into a new energy locomotive.

[0127] The present invention reconstructs the traditional internal combustion locomotive by using one or more new energy sources such as power batteries, hydrogen fuel cells 202, and high-performance diesel generator sets 302 as the main power, completing the transformation of the internal combustion locomotive into a new energy locomotive. The locomotive operation mainly uses green and environmentally friendly power batteries or hydrogen fuel cells 202, and there is no need for the diesel engine to idle during the waiting period, which has the effect of significantly saving fuel, reducing noise, and reducing emissions.

[0128] The new energy modular upgrading and rebuilding method of the present invention can be applied to the rebuilding of various existing internal combustion locomotives. By combining the rebuilding requirements and the original vehicle status, the available original vehicle component systems are determined, and the newly-made modular functional components replace part of the original vehicle system, which can quickly and efficiently realize the transformation of old vehicles into new ones.

[0129] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for modular upgrading and rebuilding of a diesel locomotive with new energy, characterized in that: The following steps are involved: S1: According to the functions and structural characteristics of diesel locomotives and new energy locomotives, the locomotives are divided into modules and divided into multiple modules; S2: dismantle the power system of the diesel locomotive and dismantle the upper body steel structure of the diesel locomotive; S3: The frame of the diesel locomotive is modified to form a frame module, so that the frame module serves as a carrier of other modules and provides installation positions for other modules; S4: Newly set up the required new energy power module on the frame module according to the reconstruction requirements; The bogie of the diesel locomotive is retained and used as a bogie module after overhaul, and a new traction motor drive module is installed on the frame module to connect with the bogie module.

2. The method for upgrading and rebuilding a diesel locomotive with new energy modularization according to claim 1 is characterized in that: The steel structure of the driver's cab of the diesel locomotive is not disassembled, but modified to form a driver's cab module.

3. The method for modular upgrading and rebuilding of diesel locomotives with new energy according to claim 1, characterized in that: The air brake equipment of the diesel locomotive is retained and repaired, and a new car body steel structure is built to form the front engine room module and the rear engine room module; A new converter cabinet module is installed on the frame module.

4. The method for modular upgrading and rebuilding of diesel locomotives with new energy according to claim 1, characterized in that: The modules divided in step S1 include a power battery module, a diesel generator module, a hydrogen fuel cell module, a converter module, a driver's cab module, a rear engine room module, a front engine room module, a frame module, a bogie module, and a traction motor drive module.

5. The method for modular upgrading and rebuilding of diesel locomotives with new energy according to claim 1, characterized in that: The new energy power module in step S2 includes a diesel generator module, a power battery module, a hydrogen fuel cell module, and a combination of at least two modules.

6. The method for modular upgrading and rebuilding of diesel locomotives with new energy according to claim 5, characterized in that: When a diesel generator module and a power battery module are newly provided in step S4, the hydraulic transmission diesel locomotive is modularly upgraded and rebuilt into a new energy hybrid locomotive; When a new power battery module is provided in step S4, the hydraulic transmission internal combustion locomotive is modularly upgraded and rebuilt into a new energy pure electric locomotive; When a power battery module and a hydrogen fuel cell module are newly provided in step S4, the hydraulic transmission diesel locomotive is modularly upgraded and rebuilt into a hydrogen fuel cell locomotive.

7. The method for modular upgrading and rebuilding of diesel locomotives with new energy according to claim 5, characterized in that: The power battery module includes the power battery room steel structure, power battery pack, power battery high-voltage box, power battery management system, power battery water cooling unit, power battery fire extinguishing device and various pipelines. The external interface includes the power battery module bottom mounting seat, power battery external power output cable and communication cable; The power battery room steel structure serves as the external frame. The power battery pack, power battery high-voltage box, power battery management system, power battery water cooling unit, power battery fire extinguishing device and various pipelines are arranged inside the power battery room steel structure. The power battery module bottom mounting seat is arranged at the bottom of the power battery module. The power battery module bottom mounting seat serves as an interface for connecting with the frame module. The hydrogen fuel cell module includes a hydrogen fuel cell module steel structure, a hydrogen fuel cell, a hydrogen fuel cell cooling device, a hydrogen storage device and pipelines, and the external interface includes a hydrogen fuel cell module bottom mounting seat and a hydrogen fuel cell external power output cable and a communication cable; The hydrogen fuel cell module steel structure serves as an external frame, and the hydrogen fuel cell, hydrogen fuel cell cooling device, hydrogen storage device and pipelines are arranged inside the hydrogen fuel cell module steel structure. The hydrogen fuel cell module bottom mounting seat is arranged at the bottom of the hydrogen fuel cell module, and the hydrogen fuel cell module bottom mounting seat serves as an interface for connecting with the frame module; The diesel generator module includes a diesel generator module steel structure and a diesel generator set, and the external interface includes a diesel generator module bottom mounting base, a diesel generator power output cable and a communication cable; The diesel generator set is arranged inside the diesel generator set module steel structure, the diesel generator set module bottom mounting seat is arranged at the bottom of the diesel generator set module, and the diesel generator set module bottom mounting seat is used as an interface for connecting with the frame module.

8. The method for modular upgrading and rebuilding of diesel locomotives with new energy according to claim 4, characterized in that: The converter cabinet module includes a converter cabinet module steel structure and a main-auxiliary integrated converter cabinet, and the external interface includes a converter cabinet module bottom mounting seat, converter cabinet input and output cables, and communication cables; The main and auxiliary integrated converter cabinet is arranged inside the converter cabinet module steel structure, the converter cabinet module bottom mounting seat is arranged at the bottom of the converter cabinet module, and the converter cabinet module bottom mounting seat is used as an interface for connecting with the frame module; The driver's cab module includes the driver's cab steel structure, operating console, electrical cabinet, driver's seat, and driver's cab air conditioner. The external interface includes the driver's cab module bottom mounting seat, electrical cabinet external communication cables, and air brake control pipelines. The rear engine room module includes the rear engine room module steel structure, air brake valve frame, driver's room air conditioning external unit and other equipment. Among them, the air brake valve frame uses the original vehicle equipment for maintenance, and the external interface includes the rear engine room module bottom mounting seat and air brake control pipeline; The air brake valve frame and the driver's cab air conditioner outdoor unit are arranged inside the steel structure of the rear engine room module. The rear engine room module bottom mounting seat is set at the bottom of the rear engine room module. The rear engine room module bottom mounting seat serves as an interface for connection with the frame module.

9. The method for modular upgrading and rebuilding of diesel locomotives with new energy according to claim 4, characterized in that: The traction motor drive module includes a traction motor, an elastic connection device, an intermediate gearbox, a universal joint, and an intermediate gearbox mounting seat. The universal joint uses the original vehicle equipment and is repaired. The traction motor is connected to both sides of the intermediate gearbox, and the intermediate gearbox is connected to the universal joint shaft, which is used to connect to the bogie. The external interface includes an intermediate gearbox mounting seat, an output universal joint shaft flange drive interface, and a traction motor cable connection interface.

10. The method for modular upgrading and rebuilding of diesel locomotives with new energy according to claim 4, characterized in that: The upper plane of the frame module is provided with a module mounting seat for installing each module, and the lower plane of the frame module is connected to the bogie through a side bearing and a traction device, so as to transfer the weight of each upper module and the traction and braking requirements to the bogie.

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