Hybrid excavator thermal management system, control method and device

Abstract

The application discloses a hybrid excavator thermal management system, a control method and a device in the technical field of hybrid excavator thermal management, and aims to solve the problem that in the prior art, a hydraulic motor fan, a low-voltage electronic fan or an air-cooled high-voltage electronic fan is usually used, energy consumption is high, design is difficult, and in a high-temperature environment, a fan speed reduction protection mechanism is triggered, leading to a decrease in the heat dissipation efficiency of a radiator. The application comprises a VCU module and a plurality of thermal management modules, the plurality of thermal management modules comprising an engine thermal management module, an ISG motor electric control thermal management module, a slewing motor electric control thermal management module, a fan thermal management module and a hydraulic system thermal management module; the application adopts a liquid-cooled high-voltage fan, which can not only reduce the fuel consumption of an engine, but also can more effectively utilize the energy recovered by an ISG motor and a slewing motor, and since the high-voltage electronic fan adopts a liquid-cooled heat dissipation mode, the fan will not reduce the speed due to high temperature in a high-temperature environment, and the reliability of the thermal management system is improved.

Description

Technical Field

[0001] This invention relates to a thermal management system, control method, and device for a hybrid excavator, belonging to the field of thermal management technology for hybrid excavators. Background Technology

[0002] Excavators are multi-purpose construction machinery. Hybrid excavators add an ISG motor and a power battery to the traditional excavator, or replace the hydraulic swing motor with a swing motor. The ISG motor is connected in series with the engine flywheel to dynamically adjust the engine's output torque, provide power for starting the engine, and supply electrical energy to the swing motor and power battery. Compared to traditional excavators, hybrid excavators require additional cooling systems for the motor and power battery.

[0003] Existing technologies typically employ hydraulic motors to drive fans for forced air cooling of the radiator core. This approach requires a cooling pump to deliver high-pressure hydraulic oil to the hydraulic motor to drive the fan, resulting in low energy conversion efficiency, high energy consumption, and complex hydraulic piping. The second approach uses low-voltage electric fans for forced air cooling of the radiator core. This method uses an ISG motor to generate high-voltage electricity to a multi-function controller, which then distributes it to a DC-DC converter, which in turn powers the low-voltage fans. To meet the overall cooling requirements, this approach usually requires a large number of low-voltage electric fans, which not only complicates the electrical system... The first approach is difficult to design and has drawbacks such as excessive fan starting current and high energy consumption. The second approach uses a high-pressure air-cooled fan to force air cooling of the radiator core. In this approach, the ISG motor sends high-voltage electricity to the multi-function controller, which then provides power to the fan. Since the exhaust temperature of the engine water radiator and intercooler is high, usually exceeding 75°C, it becomes difficult for the fan to dissipate heat. When the high-pressure fan is in a high-temperature environment for a long time, it will trigger the fan speed reduction protection mechanism, which will lead to a decrease in radiator cooling efficiency, an increase in the ambient temperature of the fan, and a vicious cycle of further fan speed reduction.

[0004] As can be seen from the above, the thermal management of existing hybrid excavators typically uses hydraulic motor fans, low-pressure electric fans, or air-cooled high-pressure electric fans. These methods have high energy consumption, are difficult to design, and in high-temperature environments, they can trigger the fan speed reduction protection mechanism, resulting in a decrease in the heat dissipation efficiency of the radiator and affecting the stability of the thermal management of the hybrid excavator. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a thermal management system, control method and device for a hybrid excavator. It adopts a liquid-cooled high-pressure fan. Compared with the hydraulic motor fan, low-pressure electric fan and air-cooled high-pressure electric fan of the prior art, the use of a liquid-cooled high-pressure electric fan can not only reduce the engine's fuel consumption, but also make more effective use of the energy recovered by the ISG motor and the slewing motor. Since the high-pressure electric fan adopts a liquid cooling method, the fan will not reduce its speed due to high temperature in high-temperature environments, thereby improving the reliability of the thermal management system and reducing the overall machine failure rate.

[0006] To solve the above-mentioned technical problems, the present invention is implemented using the following technical solution:

[0007] In a first aspect, the present invention provides a thermal management system for a hybrid excavator, including a VCU module and multiple thermal management modules, wherein the multiple thermal management modules include an engine thermal management module, an ISG motor electronic control thermal management module, a swing motor electronic control thermal management module, a fan thermal management module and a hydraulic system thermal management module;

[0008] The engine thermal management module, the ISG motor electronic control thermal management module, the rotary motor electronic control thermal management module, the fan thermal management module, and the hydraulic system thermal management module all include liquid-cooled high-pressure fans, and multiple liquid-cooled high-pressure fans are electrically connected to the VCU module;

[0009] The fan thermal management module also includes a high-pressure fan radiator, a water pump, and a flow distributor. One end of each of the multiple liquid-cooled high-pressure fans is connected to the flow distributor, and the other end of each of the multiple liquid-cooled high-pressure fans is connected to the high-pressure fan radiator. The high-pressure fan radiator is connected to the flow distributor through the water pump, and both the flow distributor and the water pump are electrically connected to the VCU module.

[0010] Furthermore, the engine thermal management module also includes a high-temperature radiator, an engine, and an intercooler radiator. The engine includes a mechanical water pump and a turbocharger. The mechanical water pump is used to drive the coolant in the engine to flow through the high-temperature radiator, and the turbocharger is used to drive the high-temperature air in the engine to flow through the intercooler radiator. The liquid-cooled high-pressure fan in the engine thermal management module is used to provide forced air cooling for the high-temperature radiator and the intercooler radiator.

[0011] Furthermore, both the ISG motor electronic control thermal management module and the rotary motor electronic control thermal management module include water pumps, and multiple water pumps are electrically connected to the VCU module.

[0012] The ISG motor electronic control thermal management module also includes an ISG motor, an ISG motor electronic control heat sink, and an ISG motor controller. The water pump in the ISG motor electronic control thermal management module is used to drive the coolant to transfer the heat of the ISG motor and the ISG motor controller to the ISG motor electronic control heat sink. The liquid-cooled high-pressure fan in the ISG motor electronic control thermal management module is used to provide forced air cooling for the ISG motor electronic control heat sink.

[0013] The rotary motor electronic control thermal management module also includes a rotary motor electronic control heat sink, a rotary motor, and a rotary motor controller. The water pump in the rotary motor electronic control thermal management module is used to drive the coolant to transfer the heat of the rotary motor and the rotary motor controller to the rotary motor electronic control heat sink. The liquid-cooled high-pressure fan in the rotary motor electronic control thermal management module is used to provide forced air cooling for the rotary motor electronic control heat sink.

[0014] The hydraulic system thermal management module also includes a hydraulic oil radiator, and the liquid-cooled high-pressure fan in the hydraulic system thermal management module is used to provide forced air cooling for the hydraulic oil radiator.

[0015] The liquid-cooled high-pressure fan includes a fan module and a control module. The control module is electrically connected to the VCU module and is used to monitor the fan coil temperature and the IGBT module temperature.

[0016] In a second aspect, the present invention provides a control method for a hybrid excavator thermal management system, based on the hybrid excavator thermal management system described in the first aspect, including liquid-cooled high-pressure fan speed control.

[0017] The liquid-cooled high-pressure fan speed control includes the ISG motor electronic control thermal management module and the liquid-cooled high-pressure fan speed control of the high-temperature heat sink.

[0018] The ISG motor electronic control thermal management module and the liquid-cooled high-pressure fan speed control of the high-temperature heat sink specifically include:

[0019] The VCU module acquires the engine coolant temperature, ISG motor inlet water temperature, and ISG motor controller inlet water temperature. Based on the engine coolant temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_EW. Based on the ISG motor inlet water temperature and ISG motor controller inlet water temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_ISG1. The larger of Duty_EW and Duty_ISG1 is used to obtain F_DutyDes_A. The first algorithm limits F_DutyDes_A to between 0 and 100.

[0020] The control module collects the fan coil temperature and IGBT module temperature, queries the corresponding thermal deceleration MAP to obtain the upper limit value of the fan duty cycle F_DutyDes_B, and limits F_DutyDes_B to between 0 and 100 through the first algorithm.

[0021] F_DutyDes_A and F_DutyDes_B are reduced to obtain F_Duty1Des, which is used as the duty cycle control signal for the liquid-cooled high-pressure fan to control the speed of the liquid-cooled high-pressure fan of the ISG motor electronic control thermal management module and the high-temperature heat sink.

[0022] Furthermore, the liquid-cooled high-pressure fan speed control also includes the liquid-cooled high-pressure fan speed control of the rotary motor electronic control radiator and the intercooler radiator;

[0023] The speed control of the liquid-cooled high-pressure fan in the rotary motor's electronically controlled radiator and the intercooler specifically includes:

[0024] The VCU module acquires the engine intake air temperature, rotary motor inlet water temperature, and rotary motor controller inlet water temperature. Based on the engine intake air temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_EC. Based on the rotary motor inlet water temperature and the rotary motor controller inlet water temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_Slew1. The maximum value of Duty_EC and Duty_Slew1 is taken to obtain F_DutyDes_C. The first algorithm limits F_DutyDes_C to between 0 and 100.

[0025] The control module collects the fan coil temperature and IGBT module temperature, queries the corresponding thermal deceleration MAP to obtain the upper limit value of the fan duty cycle F_DutyDes_D, and limits F_DutyDes_D to between 0 and 100 through the first algorithm.

[0026] Finally, F_DutyDes_C and F_DutyDes_D are reduced to obtain F_Duty2Des, which is used as the duty cycle control signal for the liquid-cooled high-pressure fan to control the speed of the liquid-cooled high-pressure fan of the rotary motor electronic control radiator and the intercooler radiator.

[0027] Furthermore, the liquid-cooled high-pressure fan speed control also includes liquid-cooled high-pressure fan speed control by the fan thermal management module and the hydraulic system thermal management module;

[0028] The liquid-cooled high-pressure fan speed control of the fan thermal management module and the hydraulic system thermal management module specifically includes:

[0029] The VCU module obtains the inlet temperature of the hydraulic oil cooler, queries the corresponding MAP to obtain the required fan duty cycle signal F_DutyDes_E, and limits F_DutyDes_E to between 0 and 100 through the first algorithm.

[0030] The control module collects the fan coil temperature and IGBT module temperature, queries the corresponding thermal deceleration MAP to obtain the upper limit values ​​of the fan duty cycle, Duty_FMW3 and Duty_IGBT3, and obtains F_DutyDes_F by taking the smaller value of Duty_FMW3 and Duty_IGBT3. The first algorithm limits F_DutyDes_F to between 0 and 100.

[0031] Finally, F_DutyDes_E and F_DutyDes_F are reduced to obtain F_Duty3Des, which is used as the duty cycle control signal for the liquid-cooled high-pressure fan to control the speed of the liquid-cooled high-pressure fan in the fan thermal management module and the hydraulic system thermal management module.

[0032] Furthermore, it also includes pump speed control and flow distributor flow control. Specifically, the pump speed control includes pump speed control by the ISG motor electrical control thermal management module and pump speed control by the rotary motor electrical control thermal management module.

[0033] The pump speed control of the ISG motor electronic control thermal management module includes: the VCU module acquires the inlet water temperature of the ISG motor and the inlet water temperature of the ISG motor controller, queries the corresponding MAP diagram to obtain the required pump duty cycle signals Duty_ISG2 and Duty_ISG_MCU, takes the largest value of Duty_ISG2 and Duty_ISG_MCU to obtain P_Duty1Des, limits P_Duty1Des to between 0 and 100 through the first algorithm, and the limited P_Duty1Des is the pump speed duty cycle control signal of the ISG motor electronic control thermal management module to control the pump speed of the ISG motor electronic control thermal management module;

[0034] The water pump speed control of the rotary motor electronic control thermal management module includes: the VCU module acquires the inlet water temperature of the rotary motor and the inlet water temperature of the rotary motor controller, queries the corresponding MAP diagram to obtain the required water pump duty cycle signals Duty_Slew2 and Duty_Slew_MCU, takes the larger value of Duty_Slew2 and Duty_Slew_MCU to obtain P_Duty2Des, limits P_Duty2Des to between 0 and 100 through the first algorithm, and the limited P_Duty2Des is the water pump speed duty cycle control signal of the rotary motor electronic control thermal management module, thereby controlling the water pump speed of the rotary motor electronic control thermal management module.

[0035] Furthermore, the water pump speed control also includes water pump speed control via the fan thermal management module:

[0036] The pump speed control of the fan thermal management module includes: the control module simultaneously collects the coil temperature and IGBT module temperature of each fan, queries the corresponding MAP map based on the coil temperature and IGBT module temperature to obtain the required flow rate Flow_Fan, obtains the Mass Flow by summing the required flow rate of each fan, queries the corresponding MAP map based on the Mass Flow to obtain the required pump duty cycle signal P_Duty3Des, limits P_Duty3Des to between 0 and 100 through a first algorithm, and the limited P_Duty3Des is the pump speed duty cycle control signal of the high-voltage fan thermal management module, thereby controlling the pump speed of the fan thermal management module.

[0037] Furthermore, the flow control of the flow distributor specifically includes:

[0038] The control module simultaneously collects the coil temperature and IGBT module temperature of each fan. Based on the coil temperature and IGBT module temperature, it queries the corresponding MAP to obtain the required flow rate Flow_Fan. The required flow rate of each fan is sent to the VCU module, which calculates the current value of each solenoid valve at the outlet of the flow distributor using a second algorithm, and controls the flow rate of the flow distributor.

[0039] Thirdly, the present invention provides a thermal management device for a hybrid excavator, comprising a housing, wherein a high-temperature radiator, an intercooler radiator, a hydraulic oil radiator, an ISG motor control radiator, a rotary motor control radiator, and a high-pressure fan radiator are disposed within the housing. The high-temperature radiator, the intercooler radiator, and the hydraulic oil radiator are installed in parallel. The ISG motor control radiator is located in front of the high-temperature radiator, the rotary motor control radiator is located in front of the intercooler radiator, and the high-pressure fan radiator is located in front of the hydraulic oil radiator.

[0040] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0041] 1. Due to the large heat dissipation of the engine and the harsh heat dissipation environment of the hybrid excavator, the present invention adopts a liquid-cooled high-pressure fan. Compared with the existing hydraulic motor fan, low-pressure electronic fan and air-cooled high-pressure electronic fan, the use of liquid-cooled high-pressure electronic fan can not only reduce the engine's fuel consumption, but also make more effective use of the energy recovered by the ISG motor and the slewing motor. Since the high-pressure electronic fan adopts a liquid-cooled heat dissipation method, the fan will not reduce its speed due to high temperature in high-temperature environments, thereby improving the reliability of the thermal management system and reducing the overall machine failure rate.

[0042] 2. This invention provides a control method for the thermal management system of a hybrid excavator. The fan speed is controlled based on the coolant temperature of each thermal management module. Simultaneously, an upper limit for the fan speed is set based on the fan coil temperature and the IGBT temperature of the fan controller, preventing damage due to high internal fan temperatures and ensuring the stability of the liquid-cooled high-pressure fan during operation. The electronic water pump flow rate of the ISG motor and rotary motor thermal management modules is controlled based on temperature, allowing for temperature regulation of each thermal management module. The electronic water pump flow rate required for heat dissipation of each liquid-cooled high-pressure electronic fan is determined based on the fan coil temperature and the IGBT module temperature of the fan controller. A flow distributor controls the flow rate based on the fan temperature, improving flow distribution accuracy and enhancing fan operational stability. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of a thermal management system for a hybrid excavator according to an embodiment of the present invention;

[0044] Figure 2 This is a three-dimensional structural schematic diagram of a liquid-cooled high-pressure fan provided according to an embodiment of the present invention;

[0045] Figure 3 This is a three-dimensional structural schematic diagram of the thermal management device for a hybrid excavator provided according to an embodiment of the present invention;

[0046] Figure 4 This is a cross-sectional schematic diagram of a thermal management device for a hybrid excavator provided according to an embodiment of the present invention;

[0047] Figure 5 This is a schematic diagram of the liquid-cooled high-pressure fan speed control of the ISG motor electronic control thermal management module and high-temperature heat sink provided according to an embodiment of the present invention;

[0048] Figure 6 This is a schematic diagram of the liquid-cooled high-pressure fan speed control of the rotary motor electronic control radiator and the intercooler radiator according to an embodiment of the present invention;

[0049] Figure 7 This is a schematic diagram of the liquid-cooled high-pressure fan speed control of the fan thermal management module and the hydraulic system thermal management module provided in the embodiments of the present invention;

[0050] Figure 8 This is a schematic diagram of the water pump speed control of the ISG motor electronic control thermal management module according to an embodiment of the present invention;

[0051] Figure 9 This is a schematic diagram of water pump speed control of the rotary motor electronic control thermal management module according to an embodiment of the present invention;

[0052] Figure 10This is a schematic diagram of water pump speed control for a fan thermal management module according to an embodiment of the present invention;

[0053] Figure 11 This is a schematic diagram of flow control for a flow distributor according to an embodiment of the present invention. Detailed Implementation

[0054] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0055] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are used only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0056] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances. Example 1:

[0057] like Figure 1As shown, this invention provides a thermal management system for a hybrid excavator, including a VCU module and multiple thermal management modules. The multiple thermal management modules include an engine thermal management module, an ISG motor electronic control thermal management module, a swing motor electronic control thermal management module, a fan thermal management module, and a hydraulic system thermal management module. Each of the engine thermal management module, the ISG motor electronic control thermal management module, the swing motor electronic control thermal management module, the fan thermal management module, and the hydraulic system thermal management module includes a liquid-cooled high-pressure fan, and all of the multiple liquid-cooled high-pressure fans are electrically connected to the VCU module. The fan thermal management module further includes a high-pressure fan radiator, a water pump, and a flow distributor. One end of each of the multiple liquid-cooled high-pressure fans is connected to the flow distributor, and the other end of each of the multiple liquid-cooled high-pressure fans is connected to the high-pressure fan radiator. The high-pressure fan radiator is connected to the flow distributor via the water pump, and both the flow distributor and the water pump are electrically connected to the VCU module.

[0058] Specifically, the electric water pump drives the coolant flow, and the flow distributor regulates the coolant flow of the high-pressure electric fans in each thermal management module, thereby precisely controlling the temperature of the fan module and control module of each liquid-cooled high-pressure fan. This avoids thermal imbalance caused by the high-pressure fan speed reduction due to high temperature. The VCU module collects the coolant temperature of each thermal management module through the CAN bus to adjust the speed of the liquid-cooled high-pressure fan and the electric water pump, as well as the opening of the flow distributor, thereby controlling the coolant temperature of each thermal management module. At the same time, it can also send fault information of each module to the instrument.

[0059] Because hybrid excavators have large engine heat dissipation and harsh heat dissipation environments, this invention uses a liquid-cooled high-pressure fan. Compared with existing technologies such as hydraulic motor fans, low-pressure electronic fans, and air-cooled high-pressure electronic fans, using a liquid-cooled high-pressure electronic fan can not only reduce engine fuel consumption, but also more effectively utilize the energy recovered by the ISG motor and slewing motor. Since the high-pressure electronic fan uses liquid cooling, the fan will not reduce its speed due to high temperature in high-temperature environments, improving the reliability of the thermal management system and reducing the overall machine failure rate.

[0060] In one embodiment, the engine thermal management module further includes a high-temperature radiator, an engine, and an intercooler radiator. The engine includes a mechanical water pump and a turbocharger. The mechanical water pump is used to drive the coolant in the engine to flow through the high-temperature radiator, and the turbocharger is used to drive the high-temperature air in the engine to flow through the intercooler radiator. The liquid-cooled high-pressure fan in the engine thermal management module is used to provide forced air cooling for the high-temperature radiator and the intercooler radiator.

[0061] Specifically, the high-temperature coolant inside the engine is driven by a mechanical water pump to flow through the high-temperature radiator, and then the temperature is regulated by a liquid-cooled high-pressure electric fan. The high-temperature air after being boosted by the turbocharger flows through the intercooler radiator, and is then cooled by a liquid-cooled high-pressure electric fan.

[0062] In one embodiment, both the ISG motor electronic control thermal management module and the rotary motor electronic control thermal management module include water pumps, and multiple water pumps are electrically connected to the VCU module. The ISG motor electronic control thermal management module also includes an ISG motor (integrated starter generator), an ISG motor electronic control radiator, and an ISG motor controller. The water pumps within the ISG motor electronic control thermal management module drive coolant to transfer heat from the ISG motor and the ISG motor controller to the ISG motor electronic control radiator. The liquid-cooled high-pressure fan within the ISG motor electronic control thermal management module provides forced air cooling to the ISG motor electronic control radiator. The rotary motor electronic control thermal management module also includes a rotary motor electronic control radiator, a rotary motor electronic control radiator, and a rotary motor controller. The system includes a rotary motor and a rotary motor controller. The water pump within the rotary motor thermal management module drives coolant to transfer heat from the rotary motor and the rotary motor controller to the rotary motor thermal management radiator. A liquid-cooled high-pressure fan within the rotary motor thermal management module provides forced air cooling to the rotary motor thermal management radiator. The hydraulic system thermal management module also includes a hydraulic oil radiator. A liquid-cooled high-pressure fan within the hydraulic system thermal management module provides forced air cooling to the hydraulic oil radiator. The liquid-cooled high-pressure fan includes a fan module and a control module. The control module is electrically connected to the VCU module and is used to monitor the fan coil temperature and the IGBT module (Insulated Gate Bipolar Transistor) temperature.

[0063] Specifically, the liquid-cooled high-pressure fan consists of a fan module and a control module. The control module is fixed to the fan module with bolts. The control module receives and sends messages to the VCU module via the CAN line. It can be used to monitor the temperature of the fan stator coil and IGBT module (insulated gate bipolar transistor), control the fan speed, and provide feedback on fan faults. The hydraulic system thermal management module includes a hydraulic oil radiator and a liquid-cooled high-pressure electric fan. The hydraulic system (i.e., the thermal management modules other than the hydraulic system thermal management module) transfers excess heat from the system to the hydraulic oil radiator through hydraulic oil, and then the liquid-cooled high-pressure electric fan cools the heat sink core. Example 2:

[0064] like Figures 5-11As shown, this invention discloses a control method for a hybrid excavator thermal management system. Based on the hybrid excavator thermal management system described in Embodiment 1, it includes liquid-cooled high-pressure fan speed control, water pump speed control, and flow distributor flow control. The liquid-cooled high-pressure fan speed control includes the liquid-cooled high-pressure fan speed control of the ISG motor electronic control thermal management module and the high-temperature radiator, the liquid-cooled high-pressure fan speed control of the rotary motor electronic control radiator and the intercooler radiator, and the liquid-cooled high-pressure fan speed control of the fan thermal management module and the hydraulic system thermal management module.

[0065] Optional, Figures 5-11 ALG1 is the first algorithm.

[0066] like Figure 5 As shown in one embodiment, the speed control of the ISG motor electronic control thermal management module and the liquid-cooled high-pressure fan of the high-temperature heat sink specifically includes:

[0067] The VCU module obtains the engine coolant temperature, ISG motor inlet water temperature, and ISG motor controller inlet water temperature via the CAN line. Based on the engine coolant temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_EW. Based on the ISG motor inlet water temperature and the ISG motor controller inlet water temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_ISG1. The larger of Duty_EW and Duty_ISG1 is obtained as F_DutyDes_A. The first algorithm limits F_DutyDes_A to between 0 and 100.

[0068] The control module collects the fan coil temperature and IGBT module temperature, queries the corresponding thermal deceleration MAP to obtain the upper limit value of the fan duty cycle F_DutyDes_B, and limits F_DutyDes_B to between 0 and 100 through the first algorithm.

[0069] F_DutyDes_A and F_DutyDes_B are reduced to obtain F_Duty1Des, which is used as the duty cycle control signal for the liquid-cooled high-pressure fan, i.e., the duty cycle control signal for the liquid-cooled high-pressure fan 1 and the liquid-cooled high-pressure fan 2, to control the speed of the liquid-cooled high-pressure fan of the ISG motor electronic control thermal management module and the high-temperature heat sink.

[0070] like Figure 6 As shown, in one embodiment, the speed control of the liquid-cooled high-pressure fan of the rotary motor electronically controlled radiator and the intercooler specifically includes:

[0071] The VCU module obtains the engine intake air temperature, rotary motor inlet water temperature, and rotary motor controller inlet water temperature via the CAN line. Based on the engine intake air temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_EC. Based on the rotary motor inlet water temperature and the rotary motor controller inlet water temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_Slew1. The maximum value of Duty_EC and Duty_Slew1 is taken to obtain F_DutyDes_C. The first algorithm limits F_DutyDes_C to between 0 and 100.

[0072] The control module collects the fan coil temperature and IGBT module temperature, queries the corresponding thermal deceleration MAP to obtain the upper limit value of the fan duty cycle F_DutyDes_D, and limits F_DutyDes_D to between 0 and 100 through the first algorithm.

[0073] Finally, F_DutyDes_C and F_DutyDes_D are reduced to obtain F_Duty2Des, which is used as the duty cycle control signal for the liquid-cooled high-pressure fan, that is, the duty cycle control signal for the liquid-cooled high-pressure fan 3 and the liquid-cooled high-pressure fan 4, to control the speed of the liquid-cooled high-pressure fan of the rotary motor electronic control heat sink and the intercooler heat sink.

[0074] like Figure 7 As shown, in one embodiment, the liquid-cooled high-pressure fan speed control of the fan thermal management module and the hydraulic system thermal management module specifically includes:

[0075] The VCU module obtains the inlet temperature of the hydraulic oil cooler through the CAN line, queries the corresponding MAP to obtain the required fan duty cycle signal F_DutyDes_E, and limits F_DutyDes_E to between 0 and 100 through the first algorithm.

[0076] The control module collects the fan coil temperature and IGBT module temperature, queries the corresponding thermal deceleration MAP to obtain the upper limit values ​​of the fan duty cycle, Duty_FMW3 and Duty_IGBT3, and obtains F_DutyDes_F by taking the smaller value of Duty_FMW3 and Duty_IGBT3. The first algorithm limits F_DutyDes_F to between 0 and 100.

[0077] Finally, F_DutyDes_E and F_DutyDes_F are reduced to obtain F_Duty3Des, which is used as the duty cycle control signal for the liquid-cooled high-pressure fan, that is, the duty cycle control signal for the liquid-cooled high-pressure fan 5, liquid-cooled high-pressure fan 6, liquid-cooled high-pressure fan 7 and liquid-cooled high-pressure fan 8, to control the speed of the liquid-cooled high-pressure fan in the fan thermal management module and the hydraulic system thermal management module.

[0078] In one embodiment, the water pump speed control specifically includes:

[0079] like Figure 8 As shown, the water pump speed control of the ISG motor electronic control thermal management module includes: the VCU module obtains the ISG motor inlet water temperature and the ISG motor controller inlet water temperature through the CAN line, queries the corresponding MAP diagram to obtain the required water pump duty cycle signals Duty_ISG2 and Duty_ISG_MCU, takes the maximum value of Duty_ISG2 and Duty_ISG_MCU to obtain P_Duty1Des, limits P_Duty1Des to between 0 and 100 through the first algorithm, and the limited P_Duty1Des is the water pump speed duty cycle control signal of the ISG motor electronic control thermal management module, thereby controlling the water pump speed of the ISG motor electronic control thermal management module;

[0080] like Figure 9 As shown, the water pump speed control of the rotary motor electronic control thermal management module includes: the VCU module obtains the rotary motor inlet water temperature and the rotary motor controller inlet water temperature through the CAN line, queries the corresponding MAP diagram to obtain the required water pump duty cycle signals Duty_Slew2 and Duty_Slew_MCU, takes the larger value of Duty_Slew2 and Duty_Slew_MCU to obtain P_Duty2Des, limits P_Duty2Des to between 0 and 100 through the first algorithm, and the limited P_Duty2Des is the water pump speed duty cycle control signal of the rotary motor electronic control thermal management module, thereby controlling the water pump speed of the rotary motor electronic control thermal management module;

[0081] like Figure 10 As shown, the water pump speed control of the fan thermal management module includes: the control module simultaneously collects the coil temperature and IGBT module temperature of each fan, queries the corresponding MAP diagram based on the coil temperature and IGBT module temperature to obtain the required flow rate Flow_Fan, obtains the Mass Flow by summing the required flow rate of each fan, queries the corresponding MAP diagram based on the Mass Flow to obtain the required water pump duty cycle signal P_Duty3Des, limits P_Duty3Des to between 0 and 100 through a first algorithm, and the limited P_Duty3Des is the water pump speed duty cycle control signal of the high-voltage fan thermal management module, thereby controlling the water pump speed of the fan thermal management module.

[0082] like Figure 11 As shown, in one embodiment, the flow control of the flow distributor specifically includes:

[0083] The control module simultaneously collects the coil temperature and IGBT module temperature of each fan, queries the corresponding MAP diagram based on the coil temperature and IGBT module temperature to obtain the required flow rate Flow_Fan, and sends the required flow rate of each fan to the VCU module. The second algorithm calculates the current value of each solenoid valve at the outlet of the flow distributor and controls the flow rate of the flow distributor. Optionally, ALG2 in the attached figure is the first algorithm.

[0084] This invention controls fan speed based on the coolant temperature of each thermal management module, and sets an upper limit for fan speed based on the fan coil temperature and the IGBT temperature of the fan controller, preventing damage from high internal fan temperatures and ensuring the stability of the liquid-cooled high-pressure fan during operation. The electronic water pump flow rate of the ISG motor and rotary motor thermal management modules is controlled by a temperature-based method, allowing for temperature regulation of each thermal management module. The electronic water pump flow rate required for heat dissipation of each liquid-cooled high-pressure electronic fan is determined based on the fan coil temperature and the IGBT module temperature of the fan controller, and the flow distributor controls the flow rate based on the fan temperature, improving flow distribution accuracy and fan operational stability. Example 3:

[0085] like Figures 2-4 As shown, the present invention provides a thermal management device for a hybrid excavator, including a housing. The housing contains a high-temperature radiator, an intercooler radiator, a hydraulic oil radiator, an ISG motor control radiator, a swing motor control radiator, and a high-pressure fan radiator. The high-temperature radiator, the intercooler radiator, and the hydraulic oil radiator are installed in parallel. The ISG motor control radiator is located in front of the high-temperature radiator, the swing motor control radiator is located in front of the intercooler radiator, and the high-pressure fan radiator is located in front of the hydraulic oil radiator.

[0086] Specifically, the high-temperature radiator, intercooler radiator, and hydraulic oil radiator are installed in parallel. The high-temperature radiator and intercooler radiator share a common air guide shroud, while the hydraulic oil radiator uses its own separate air guide shroud. The ISG motor electronic control radiator is connected in series in front of the high-temperature radiator, sharing liquid-cooled high-pressure electronic fans 1 and 2. The rotary motor electronic control radiator is connected in series in front of the intercooler radiator, sharing liquid-cooled high-pressure electronic fans 3 and 4. The high-pressure fan radiator is connected in series in front of the hydraulic oil radiator, sharing liquid-cooled high-pressure electronic fans 5, 6, 7, and 8. Optionally, the control module of the liquid-cooled high-pressure fan is bolted to the fan module.

[0087] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A control method for a thermal management system of a hybrid excavator, characterized in that, It includes liquid-cooled high-pressure fan speed control, as well as a VCU module and multiple thermal management modules, including an engine thermal management module, an ISG motor electronic control thermal management module, a rotary motor electronic control thermal management module, a fan thermal management module, and a hydraulic system thermal management module; The engine thermal management module, the ISG motor electronic control thermal management module, the rotary motor electronic control thermal management module, the fan thermal management module, and the hydraulic system thermal management module all include liquid-cooled high-pressure fans, and multiple liquid-cooled high-pressure fans are electrically connected to the VCU module; The fan thermal management module also includes a high-pressure fan radiator, a water pump, and a flow distributor. One end of each of the multiple liquid-cooled high-pressure fans is connected to the flow distributor, and the other end of each of the multiple liquid-cooled high-pressure fans is connected to the high-pressure fan radiator. The high-pressure fan radiator is connected to the flow distributor through the water pump, and both the flow distributor and the water pump are electrically connected to the VCU module. The engine thermal management module also includes a high-temperature radiator, an engine, and an intercooler radiator. The engine includes a mechanical water pump and a turbocharger. The mechanical water pump is used to drive the coolant in the engine to flow through the high-temperature radiator. The turbocharger is used to drive the high-temperature air in the engine to flow through the intercooler radiator. The liquid-cooled high-pressure fan in the engine thermal management module is used to provide forced air cooling for the high-temperature radiator and the intercooler radiator. Both the ISG motor electronic control thermal management module and the rotary motor electronic control thermal management module include water pumps, and multiple water pumps are electrically connected to the VCU module; The ISG motor electronic control thermal management module also includes an ISG motor, an ISG motor electronic control heat sink, and an ISG motor controller. The water pump in the ISG motor electronic control thermal management module is used to drive the coolant to transfer the heat of the ISG motor and the ISG motor controller to the ISG motor electronic control heat sink. The liquid-cooled high-pressure fan in the ISG motor electronic control thermal management module is used to provide forced air cooling for the ISG motor electronic control heat sink. The rotary motor electronic control thermal management module also includes a rotary motor electronic control heat sink, a rotary motor, and a rotary motor controller. The water pump in the rotary motor electronic control thermal management module is used to drive the coolant to transfer the heat of the rotary motor and the rotary motor controller to the rotary motor electronic control heat sink. The liquid-cooled high-pressure fan in the rotary motor electronic control thermal management module is used to provide forced air cooling for the rotary motor electronic control heat sink. The hydraulic system thermal management module also includes a hydraulic oil radiator, and the liquid-cooled high-pressure fan in the hydraulic system thermal management module is used to provide forced air cooling for the hydraulic oil radiator. The liquid-cooled high-pressure fan includes a fan module and a control module. The control module is electrically connected to the VCU module and is used to monitor the fan coil temperature and IGBT module temperature. The liquid-cooled high-pressure fan speed control includes the ISG motor electronic control thermal management module and the liquid-cooled high-pressure fan speed control of the high-temperature heat sink, specifically including: The VCU module acquires the engine coolant temperature, ISG motor inlet water temperature, and ISG motor controller inlet water temperature. Based on the engine coolant temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_EW. Based on the ISG motor inlet water temperature and ISG motor controller inlet water temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_ISG1. The larger of Duty_EW and Duty_ISG1 is used to obtain F_DutyDes_A. The first algorithm limits F_DutyDes_A to between 0 and 100. The control module collects the fan coil temperature and IGBT module temperature, queries the corresponding thermal deceleration MAP to obtain the upper limit value of the fan duty cycle F_DutyDes_B, and limits F_DutyDes_B to between 0 and 100 through the first algorithm. F_DutyDes_A and F_DutyDes_B are reduced to obtain F_Duty1Des, which is used as the duty cycle control signal for the liquid-cooled high-pressure fan to control the speed of the liquid-cooled high-pressure fan of the ISG motor electronic control thermal management module and the high-temperature heat sink.

2. The control method for the thermal management system of a hybrid excavator according to claim 1, characterized in that, The liquid-cooled high-pressure fan speed control also includes the liquid-cooled high-pressure fan speed control of the rotary motor electronic control radiator and the intercooler radiator. The speed control of the liquid-cooled high-pressure fan in the rotary motor's electronically controlled radiator and the intercooler specifically includes: The VCU module acquires the engine intake air temperature, rotary motor inlet water temperature, and rotary motor controller inlet water temperature. Based on the engine intake air temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_EC. Based on the rotary motor inlet water temperature and the rotary motor controller inlet water temperature, it queries the corresponding MAP to obtain the required fan duty cycle signal Duty_Slew1. The maximum value of Duty_EC and Duty_Slew1 is taken to obtain F_DutyDes_C. The first algorithm limits F_DutyDes_C to between 0 and 100. The control module collects the fan coil temperature and IGBT module temperature, queries the corresponding thermal deceleration MAP to obtain the upper limit value of the fan duty cycle F_DutyDes_D, and limits F_DutyDes_D to between 0 and 100 through the first algorithm. Finally, F_DutyDes_C and F_DutyDes_D are reduced to obtain F_Duty2Des, which is used as the duty cycle control signal for the liquid-cooled high-pressure fan to control the speed of the liquid-cooled high-pressure fan of the rotary motor electronic control radiator and the intercooler radiator.

3. The control method for the thermal management system of a hybrid excavator according to claim 1, characterized in that, The liquid-cooled high-pressure fan speed control also includes the liquid-cooled high-pressure fan speed control of the fan thermal management module and the hydraulic system thermal management module; The liquid-cooled high-pressure fan speed control of the fan thermal management module and the hydraulic system thermal management module specifically includes: The VCU module obtains the inlet temperature of the hydraulic oil cooler, queries the corresponding MAP to obtain the required fan duty cycle signal F_DutyDes_E, and limits F_DutyDes_E to between 0 and 100 through the first algorithm. The control module collects the fan coil temperature and IGBT module temperature, queries the corresponding thermal deceleration MAP to obtain the upper limit values ​​of the fan duty cycle, Duty_FMW3 and Duty_IGBT3, and obtains F_DutyDes_F by taking the smaller value of Duty_FMW3 and Duty_IGBT3. The first algorithm limits F_DutyDes_F to between 0 and 100. Finally, F_DutyDes_E and F_DutyDes_F are reduced to obtain F_Duty3Des, which is used as the duty cycle control signal for the liquid-cooled high-pressure fan to control the speed of the liquid-cooled high-pressure fan in the fan thermal management module and the hydraulic system thermal management module.

4. The control method for the thermal management system of a hybrid excavator according to claim 1, characterized in that, It also includes pump speed control and flow distributor flow control. Specifically, the pump speed control includes pump speed control by the ISG motor electrical control thermal management module and pump speed control by the rotary motor electrical control thermal management module. The pump speed control of the ISG motor electronic control thermal management module includes: the VCU module acquires the inlet water temperature of the ISG motor and the inlet water temperature of the ISG motor controller, queries the corresponding MAP diagram to obtain the required pump duty cycle signals Duty_ISG2 and Duty_ISG_MCU, takes the largest value of Duty_ISG2 and Duty_ISG_MCU to obtain P_Duty1Des, limits P_Duty1Des to between 0 and 100 through the first algorithm, and the limited P_Duty1Des is the pump speed duty cycle control signal of the ISG motor electronic control thermal management module to control the pump speed of the ISG motor electronic control thermal management module; The water pump speed control of the rotary motor electronic control thermal management module includes: the VCU module acquires the inlet water temperature of the rotary motor and the inlet water temperature of the rotary motor controller, queries the corresponding MAP diagram to obtain the required water pump duty cycle signals Duty_Slew2 and Duty_Slew_MCU, takes the larger value of Duty_Slew2 and Duty_Slew_MCU to obtain P_Duty2Des, limits P_Duty2Des to between 0 and 100 through the first algorithm, and the limited P_Duty2Des is the water pump speed duty cycle control signal of the rotary motor electronic control thermal management module, thereby controlling the water pump speed of the rotary motor electronic control thermal management module.

5. The control method for the thermal management system of a hybrid excavator according to claim 4, characterized in that, The pump speed control also includes pump speed control via the fan thermal management module; The pump speed control of the fan thermal management module includes: the control module simultaneously collects the coil temperature and IGBT module temperature of each fan, queries the corresponding MAP map based on the coil temperature and IGBT module temperature to obtain the required flow rate Flow_Fan, obtains the Mass Flow by summing the required flow rate of each fan, queries the corresponding MAP map based on the Mass Flow to obtain the required pump duty cycle signal P_Duty3Des, limits P_Duty3Des to between 0 and 100 through a first algorithm, and the limited P_Duty3Des is the pump speed duty cycle control signal of the high-voltage fan thermal management module, thereby controlling the pump speed of the fan thermal management module.

6. The control method for the thermal management system of a hybrid excavator according to claim 5, characterized in that, The flow control of the flow distributor specifically includes: The control module simultaneously collects the coil temperature and IGBT module temperature of each fan. Based on the coil temperature and IGBT module temperature, it queries the corresponding MAP to obtain the required flow rate Flow_Fan. The required flow rate of each fan is sent to the VCU module, which calculates the current value of each solenoid valve at the outlet of the flow distributor using a second algorithm, and controls the flow rate of the flow distributor.

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