Range-extending charging system control method and device based on domain controller

Abstract

The invention discloses a range extending charging system control method and device based on a domain controller, and relates to the technical field of hybrid power mechanical engineering, and the method specifically comprises the steps: obtaining a starting request, calculating the electric power of a load in real time, judging the type of the request, and executing a corresponding control load power supply or battery charging mode. The device comprises a range extender, a cooling system and range-extending charging control equipment, wherein the range extender is used for integrating functions of complete machine control, buck-boost DCDC control, DC charging connection control and motor control. Through hardware integration and function optimization, the problems of complex wiring harness, high cost, large power consumption and the like caused by scattered arrangement of multiple controllers in the prior art are solved, the system reliability, the space utilization rate and the energy efficiency ratio are remarkably improved, it is guaranteed that the range extending charging system can normally start and operate, and the weight, the size, the hardware cost and the installation cost of the device are reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of hybrid mechanical engineering, and specifically to a control method and device for a range-extended charging system based on a domain controller. Background Art

[0002] Traditional diesel-powered equipment has high operating costs in scenarios of oil price fluctuations and long-term operations. The range-extended technology can reduce fuel consumption through "oil-electricity collaboration". Range-extended equipment can meet requirements such as low noise and low emissions. However, in engineering applications, range-extended equipment mostly adopts a control method with distributed controllers, which is controlled by the vehicle control unit (VCU) of the whole machine. The effects are achieved by controlling components such as the buck DCDC, BMS, PDU, and range extender controller (ECU and ISG). Since each controller forms an independent system and all need to have functions such as power supply, diagnosis, and heat dissipation, it results in multiple high-voltage and low-voltage wire harnesses, pipelines, and electrical components (relays, fuses, etc.), causing burdens in terms of cost, weight, space, and size. In addition, due to the relatively scattered locations, it is necessary to arrange each controller separately, and the controllers communicate through CAN signals, thereby generating network loads and resulting in relatively high low-voltage power consumption of the system, reducing the reliability of the electronic and electrical components of the entire system.

[0003] Based on this, there is now provided a control method and device for a range-extended charging system based on a domain controller, which can eliminate the drawbacks existing in the prior art solutions. Summary of the Invention

[0004] The purpose of the present invention is to provide a control method and device for a range-extended charging system based on a domain controller, so as to solve the problems of various burdens caused by each controller forming an independent system, increased network load and power consumption due to the scattered arrangement of each controller in the background art.

[0005] To achieve the above purpose, the present invention provides the following technical solutions: A control method for a range-extended charging system based on a domain controller, and the specific use steps are as follows: S1. Obtain a start request for the range-extended charging system; S2. Calculate the current load electric power in real time through working parameters; S3. Determine whether the operation request is a load start request: if it is a load start request, execute step S4, if it is a DC charging request, execute step S5; S4. Determine whether the load is normally connected and working. If the load is normally connected and working, control the range extender energy system to enter the load start mode, the domain controller starts to work, and the range extender supplies power to the DC load; S5. Control the range extender energy system to enter the DC charging mode, the domain controller starts to work, and the range extender supplies power to the battery pack.

[0006] Preferably, the startup request in step S1 is judged through the low-voltage signal line of the high-voltage socket of the DC output power supply of the DC load and the DC charging connection device. The low-voltage signal line includes 6 low-voltage charging signal lines for DC fast charging pile connection interaction, which are denoted as A+, A-, CC, CP, S+ and S-.

[0007] Preferably, the calculation steps of the load electric power in step S2 are as follows: S21. If the startup request is a load startup request, based on the real-time voltage and current data of the motor electronic control DC high-voltage bus obtained, the domain controller calculates the current load power; S22. If the startup request is a DC charging request, based on the allowed charging power or the maximum allowed charging voltage and current data of the battery pack obtained by the DC charging connection device, the domain controller calculates the current load power.

[0008] Preferably, the working process of the domain controller in step S4 is as follows: The domain controller enables the boost DCDC, raises the motor electronic control voltage to the rated voltage, and then the whole-machine control device inside the domain controller interacts with the engine to control the ignition start of the range extender. After the range extender starts successfully, the boost DCDC is switched to the buck DCDC by the buck-boost DCDC control device to charge the storage battery, and according to the load power calculated in the current mode, the range extender is controlled to generate electricity to supply power to the DC load.

[0009] Preferably, step S4 further includes: when the operation request is a load startup request and the load is not normally connected and working, controlling the range extender energy system to enter the self-start idle mode, the domain controller starts to work, and after the system initial startup completes self-check or the range extender self-starts to supply power to the storage battery, the system initial startup completes self-check, which can be executed when the system has not yet connected the load and the customer requests to start self-check, used to check whether there is a fault in the system start-stop function and report it in time, and preheat in advance to charge the storage battery.

[0010] Preferably, step S5 specifically includes: when the operation request is a non-load startup request, that is, a DC charging request, the DC charging connection device in the domain controller starts to work. When it is judged that the DC charging gun is correctly connected, the range extender energy system is controlled to enter the DC charging mode, the domain controller starts to work, and according to the load power calculated in the current mode, the range extender is controlled to generate electricity to supply power to the battery pack; The steps for the domain controller to charge the battery pack with DC through the DC charging gun are as follows: S51. The DC charging gun is inserted into the vehicle charging port, and the mechanical locking device is locked; S52. The DC charging connection device detects the gun plugging signal through the CC1 / CC2 contact status; S53. After detecting that the DC charging gun is correctly connected, the DC charging connection device supplies power to the vehicle BMS through the low-voltage auxiliary power supply to wake up the charging vehicle communication link; S54. The status detection and diagnosis module in the DC charging connection device is started to detect the insulation resistance between the system and the vehicle and receive the insulation status feedback from the BMS. After detecting an abnormality, charging is prohibited and an insulation fault warning is sent to the control panel; S55. The DC charging connection device determines the maximum output current and voltage according to the BMS requirements. If the DC fast charging pile terminal cannot meet the BMS requirements, power reduction or charging termination is triggered and reported to the control panel; S56. The domain controller monitors the parameter data and working status of the charging battery and the range extender in real time and updates and displays the above data on the control panel in real time. The parameter data includes but is not limited to the voltage, current, and temperature of the charging battery, the voltage and current actually output by the range extender, and the working status includes but is not limited to the system charging status, the state of charge of the charging battery, and the fault status; S57. Control the range extender energy system to enter the DC charging mode; S58. The domain controller adjusts the voltage and current output of the disc motor according to the above BMS feedback result and responds in a timely manner to the BMS request to reduce the current function requirement; S59. The normal termination conditions of the battery pack are: the state of charge reaches the set value, the battery voltage reaches the upper limit, and the user manually stops the charging request through the control panel or the charging emergency stop switch. When any of the above termination conditions is met, the BMS sends a charging end request; S510. The domain controller controls the power generation current of the range extender to gradually decrease to 0 and disconnects the contact. After confirming that there is no current on both the DC charging gun and the vehicle, the charging gun is unlocked and the machine is stopped to complete the charging process.

[0011] A range-extended charging system device based on a domain controller, including a range extender and a cooling system. The range extender is used to start, operate and generate electricity, and stop under the control instruction sent by the domain controller. The cooling system is used to dissipate heat from the range extender. The range extender includes an engine, a disc motor, a fuel tank, a cooling fan, a storage battery, a domain controller, a DC output power high-voltage socket, and a muffler cover; The engine is used to provide power output and drive the disc motor to generate electricity; The disc motor is used to convert mechanical energy into electrical energy to supply power to DC loads and battery packs; The fuel tank is used to store fuel and supply fuel at a constant pressure through the engine's self-priming oil pump and pressure-holding filter; The cooling fan is used for auxiliary heat dissipation and adjusts its rotation speed according to the thermal management instructions of the domain controller; The storage battery is used to supply power to the boost DCDC when the system starts and replenish power through the buck DCDC during operation; The domain controller is used to integrate the functions of overall machine control, buck-boost DCDC control, DC charging connection control, and motor control; The high-voltage socket of the DC output power supply is used to connect DC loads and charging devices; The silent cover is used to reduce the noise during the operation of the range extender.

[0012] Preferably, the domain controller includes an overall machine control device, a buck-boost DCDC control device, a DC charging connection device, and a motor control device: The overall machine control device is used to provide one or more functions in any combination, and the functions include but are not limited to human-machine interaction, power-on and power-off control, energy management, fault diagnosis and handling, system status monitoring and thermal management, charging management, communication and network management; The buck-boost DCDC control device includes a power stage module, a control module, a drive module, and a protection module, and is used to achieve voltage conversion, power regulation, and circuit protection effects; The DC charging connection device includes a battery communication management module, a power supply control module, a status detection and diagnosis module, and a safety monitoring and protection module, and is used to manage the DC charging process and monitor the charging status; The motor control device is used to control the motor torque and speed parameters and can perform active discharging and energy recovery operations.

[0013] Preferably, the cooling system includes a main radiator, a secondary radiator, a main water tank, a secondary water tank, a main water pump, a secondary water pump, and a pressure maintaining filter: The main radiator is wound around the outside of the disc motor and is connected to the inlet and outlet of the range extender, and is used as the radiator for the coolant of the range extender; The secondary radiator is connected to the inlet and outlet of the domain controller and is used as the radiator for the coolant of the domain controller; The main water tank is used as the filling port for the coolant of the range extender; The secondary water tank is used as the filling port for the coolant of the domain controller; The main water pump is arranged inside the engine and is used to transport the coolant in the engine and the disc motor to the main radiator when the range extender starts; The secondary water pump is arranged inside the domain controller and is used to transport the coolant in the domain controller to the secondary radiator when the domain controller works; The pressure-holding filter is used to ensure that the oil in the fuel tank can be delivered to the engine at a constant pressure.

[0014] Preferably, the range-extending charging control device includes a storage module, a processing module, and a collection module. The storage module is used to store the program for implementing the range-extending charging system control method. The processing module is used to execute the program for implementing the charging system control method to realize the steps of the charging system control method. The collection module is used to collect the real-time values of the range-extending charging system based on the domain controller.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: In the range-extending charging system device based on the domain controller, the domain controller integrates the traditional whole-machine control device, the buck-boost DCDC control device, the DC charging connection device, the motor control device, and the ECU controller into one, avoiding increasing network load and power consumption, and fully avoiding the components that need to be connected by deploying an interactive wire harness inside the vehicle's domain controller in the prior art solution. Thus, the design is simplified, the hardware and labor costs can be reduced, the space occupied by electronic and electrical appliances, controllers, water pipes, and wire harnesses can be reduced. In addition, functions such as whole-machine fault diagnosis, thermal management, and internal bus communication can be realized, ensuring that the range-extending system can start and operate normally by itself, and at the same time greatly improving the efficiency and reliability of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic structural diagram of the steps of the control method of the present invention.

[0017] Figure 2 It is a schematic diagram of the steps of step S2 of the present invention.

[0018] Figure 3 It is a schematic diagram of the steps of step S5 of the present invention.

[0019] Figure 4 It is a schematic structural diagram of the range-extending charging system device of the present invention.

[0020] Figure 5 It is a schematic structural diagram of the range extender, the cooling system, and the range-extending charging control device of the present invention.

[0021] Figure 6 It is a schematic structural diagram of the domain controller of the present invention.

[0022] Figure 7 It is a front view of the muffler of the present invention.

[0023] Figure 8 It is a left view of the muffler of the present invention.

[0024] Figure 9Schematic diagram of the integrated structure of the range extender and the cooling system of the present invention.

[0025] Annotation of reference numerals in the drawings: Range extender 100, engine 110, disc motor 120, fuel tank 130, cooling fan 140, storage battery 150, domain controller 160, overall machine control device 161, buck-boost DCDC control device 162, DC charging connection device 163, motor control device 164, high-voltage socket for DC output power supply 170, silent cover 180, cooling system 200, main radiator 210, auxiliary radiator 220, main water kettle 230, auxiliary water kettle 240, main water pump 250, auxiliary water pump 260, pressure maintaining filter 270, range extender charging control device 300, storage module 310, processing module 320, acquisition module 330. Detailed implementation manners

[0026] In order to make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below with reference to the drawings and embodiments.

[0027] In this embodiment, as Figures 1-9 shown, a control method for a range extender charging system based on a domain controller specifically has the following usage steps: S1. Obtain a start request of the range extender charging system; S2. Calculate the current load electric power in real time through working parameters to facilitate adjusting the speed and power generation amount of the engine 110; S3. Determine whether the operation request is a load start request: If it is a load start request, execute step S4; if it is a DC charging request, execute step S5; S4. Determine whether the load is normally connected and working, such as whether the voltage matches and whether there is a short circuit situation. If the load is normally connected and working, control the range extender energy system to enter the load start mode, the domain controller 160 starts to work, and the range extender 100 supplies power to the DC load. If the load is abnormally connected and working, enter the self-start idle mode and trigger the protection mechanism; S5. Control the range extender energy system to enter the DC charging mode, the domain controller 160 starts to work, and the range extender 100 supplies power to the battery pack.

[0028] Among them, as Figure 2As shown, the start request in step S1 is judged through the low-voltage signal line of the high-voltage connection socket 170 of the DC output power supply of the DC load and the DC charging connection device 163. The start request types include load start and DC charging. The low-voltage signal line includes 6 low-voltage charging signal lines for DC fast charging pile connection interaction, and the low-voltage charging signal lines are denoted as A+, A-, CC, CP, S+, S-. If it is detected that the CC signal line is activated and the voltage of A+ is 12V, it is determined as a DC charging request. If the A+ and A- signals are activated and there are messages for requesting start and generating power agreed with the customer on the communication line of the S+ and S- signals, it is a load start request.

[0029] Among them, as Figure 2 and Figure 3 shown, the calculation steps of the load electric power in step S2 are as follows: S21. If the start request is a load start request, based on the real-time voltage and current data of the motor electronic control DC high-voltage bus obtained, the domain controller 160 calculates the current load power, and uses the formula power = voltage × current to calculate the value, which is convenient for dynamically adjusting the output of the range extender 100; S22. If the start request is a DC charging request, based on the allowed charging power or the maximum allowed charging voltage and current data of the battery pack obtained by the DC charging connection device 163, the domain controller 160 calculates the current load power, which is convenient for optimizing the charging power in real time and avoiding overload.

[0030] Among them, as Figure 2 and Figure 3 shown, the working process of the domain controller 160 in step S4 is as follows: The domain controller 160 enables the boost DCDC, raises the motor electronic control voltage to the rated voltage, and then the whole machine control device 161 inside the domain controller 160 interacts with the engine 110 (the ECU controller inside it) to control the range extender 100 to ignite and start, realizing rapid ignition. After the range extender 100 starts successfully, the boost DCDC is switched to the buck DCDC through the buck-boost DCDC control device 162 to charge the storage battery, maintaining the low-voltage power supply of the system, and controlling the range extender 100 to generate electricity to supply power to the DC load according to the load power calculated in the current mode, which is convenient for dynamically adjusting the power generation amount according to the load power.

[0031] Among them, as Figure 1As shown, step S4 further includes: when the operation request is a load start request and the load is not properly connected and working, controlling the range extender energy system to enter the self-start idle mode. When the load is not connected, the range extender 100 runs at a low speed to charge the battery and preheat the system, reducing cold start wear. The domain controller 160 starts to work. When the system is initially started, it completes self-check or the range extender 100 self-starts to supply power to the battery. The system can complete self-check when it has not yet connected to the load and the customer requests to start the self-check, which is used to check whether there are faults in the system start-stop function and report them in a timely manner, and preheat in advance to charge the battery. The detection includes but is not limited to real-time monitoring of the insulation resistance value and the difference in monomer voltage balance.

[0032] Among them, as Figure 1 shown, step S5 specifically includes: when the operation request is a non-load start request, i.e., a DC charging request, the DC charging connection device 163 in the domain controller 160 starts to work. When it is determined that the DC charging gun is correctly connected, the range extender energy system is controlled to enter the DC charging mode. The domain controller 160 starts to work and controls the range extender 100 to generate electricity to supply power to the battery pack according to the load power calculated in the current mode. After the charging gun is connected, insulation detection and the GB / T27930 protocol are used to ensure charging safety; The steps for the domain controller 160 to charge the battery pack through the DC charging gun are as follows: S51. The DC charging gun is inserted into the vehicle charging port, and the mechanical locking device locks; S52. The DC charging connection device 163 detects the gun head insertion signal through the CC1 / CC2 contact status; S53. When it is detected that the DC charging gun is correctly connected, the DC charging connection device 163 supplies power to the vehicle BMS through the low-voltage auxiliary power supply, wakes up the charging vehicle communication link, and the low-voltage auxiliary power supply can be set to a voltage of 12V or 24V; S54. The status detection and diagnosis module in the DC charging connection device 163 starts, detects the insulation resistance between the system and the vehicle and receives the insulation status feedback from the BMS. If an abnormality is detected, charging is prohibited and an insulation fault warning is sent to the control panel. According to the charging protocol (GB / T27930) requirements, the BMS sends battery key parameters to the DC charging connection device 163. The battery key parameters include but are not limited to the total battery voltage, the current SOC (state of charge), the maximum allowable charging current, the highest or lowest monomer voltage limit, the temperature range of the battery pack and monomer battery cells, the battery capacity, the health status, etc.; S55. The DC charging connection device 163 determines the maximum output current and voltage according to the BMS requirements. If the DC fast charging pile terminal cannot meet the BMS requirements, it triggers power reduction or termination of charging and reports to the control panel; S56. The domain controller 160 monitors the parameter data and working status of the charging battery and the range extender 100 in real time, and updates and displays the above data on the control panel in real time. The parameter data includes, but is not limited to, the voltage, current, and temperature of the charging battery, the voltage and current actually output by the range extender 100. The working status includes, but is not limited to, the system charging status, the state of charge of the charging battery, and the fault status. The fault status of the charging battery includes three states: overvoltage, overtemperature, and insulation failure. The system charging status includes five states: ready, charging, charging completed, fault, and emergency stop; S57. Control the range extender energy system to enter the DC charging mode; S58. The domain controller 160 adjusts the voltage and current output of the disc motor 120 according to the above BMS feedback result. For example, when the battery charging status switches from constant current CC to constant voltage CV mode, it responds to the voltage stabilization request of the BMS and timely responds to the functional requirement of the BMS to reduce the current, such as when the temperature rises or the monomer voltage is uneven; S59. The normal termination conditions of the battery pack are: the state of charge reaches the set value, the battery voltage reaches the upper limit, and the user manually stops the charging request through the control panel or the charging emergency stop switch. When any of the above termination conditions is met, the BMS sends a charging end request; S510. The domain controller 160 controls the generated current of the range extender to gradually decrease to 0 and disconnects the contact. After confirming that there is no current on both the DC charging gun and the vehicle, the charging gun is unlocked and the machine is stopped to complete the charging process.

[0033] As Figures 4-9 shown, a range extender charging system device based on a domain controller includes a range extender 100 and a cooling system 200, which are uniformly coordinated and controlled by the domain controller 160 to ensure that the range extender 100 efficiently and stably supplies power to DC loads or battery packs, and at the same time maintains temperature balance through the cooling system 200. The range extender 100 is used to start, operate and generate electricity, and stop under the control instructions sent by the domain controller 160. The cooling system 200 is used to dissipate heat from the range extender 100. The range extender 100 includes an engine 110, a disc motor 120, a fuel tank 130, a cooling fan 140, a storage battery 150, a domain controller 160, a DC output power high-voltage socket 170, and a silent cover 180; The engine 110 is used to provide power output to drive the disc motor 120 to generate electricity. The engine 110 is equipped with an ECU controller and interacts with the domain controller 160. At the same time, according to the thermal management function of the domain controller 160, it controls the start and stop, low-speed rotation or high-speed rotation of the cooling fan 140 to ensure normal system temperature; The disc motor 120 is used to convert mechanical energy into electrical energy to supply power to DC loads and battery packs; The fuel tank 130 is used to store fuel and supply fuel at a constant pressure through the self-priming oil pump of the engine 110 and the pressure-maintaining filter 270, without the need to use an electronic oil pump; The cooling fan 140 is used for auxiliary heat dissipation and adjusts the rotational speed according to the thermal management instructions of the domain controller 160; The battery 150 is used to supply power to the boost DCDC when the system starts and supplement power through the buck DCDC during operation, so that the domain controller 160 can be in a powered state; The domain controller 160 is used to integrate the functions of whole machine control, buck-boost DCDC control, DC charging connection control and motor control. When the range extender 100 supplies power to a DC load or a battery pack, the domain controller 160 monitors the power generation efficiency of the range extender 100 in real time and dynamically adjusts the output power of the range extender 100 according to the load demand to achieve the optimal fuel economy. By replacing the traditional distributed controller architecture with an integrated domain controller 160, efficient coordinated control of the range extender 100, charging system and load is achieved; The DC output power high-voltage connection socket 170 is used to connect DC loads and charging devices; The silent cover 180 is used to reduce the noise generated during the operation of the range extender 100. The silent cover 180 is made of multi-layer composite sound insulation materials, filled with sound-absorbing cotton inside and covered with a high-temperature resistant coating outside. It has a heat dissipation function while reducing the noise generated during the operation of the range extender 100, and can adjust parameters such as the material and style of the silent cover 180 according to the actual environment to meet the noise reduction index; Specifically, the above components achieve a three-level protection effect of "source suppression - path blocking - end absorption" through layout optimization, filtering and shielding, and software noise reduction. The high-voltage power layer (such as the buck-boost DCDC control device 162) is physically isolated from the low-voltage control layer (such as sensors), and a partitioned layout is adopted. The shell of the range extender 100 is grounded and a silent cover 180 is installed, and filtering and suppression modules and functions are added in software and circuits.

[0034] Among them, as Figure 6 shown, the domain controller 160 includes a whole machine control device 161, a buck-boost DCDC control device 162, a DC charging connection device 163 and a motor control device 164: The whole machine control device 161 is used to provide one or more functions in any combination, and the functions include but are not limited to human-machine interaction, power-on and power-off control, energy management, fault diagnosis and handling, system status monitoring and thermal management, charging management, communication and network management; The buck-boost DCDC control device 162 includes a power stage module, a control module, a drive module, and a protection module, which are used to achieve voltage conversion, power regulation, and circuit protection effects. The power stage module includes a switching element, an inductor, and a capacitor component. The control module includes a PWM controller and a feedback network component. The protection module is used to prevent overvoltage, overcurrent, too high or too low temperature, etc.; The DC charging connection device 163 includes a battery communication management module, a power supply control module, a status detection and diagnosis module, and a safety monitoring and protection module, which are used to manage the DC charging process and monitor the charging status; The motor control device 164 is used to control the motor torque and speed parameters, and can perform active discharging and energy recovery operations; Specifically, the domain controller 160 can, based on the analysis of the functions and application scenarios of each integrated device, divide and combine the functions of the range extender charging system device, and integrate the control parts of the whole machine control device 161, the buck-boost DCDC control device 162, and the DC charging connection device 163 into a VCU+DCDC+DC control board. The main control chip uses Infineon TC397, and the motor control device 164 uses a single ISG control board with the main control chip using Infineon TC275. The VCU+DCDC+DC control boards of the above devices communicate with each other through internal software. The VCU+DCDC+DC control board and the ISG control board communicate through the internal network CAN. The domain controller 160 communicates with the control panel screen or the ECU controller of the engine 110 through the output low-voltage CAN interface. Through the domain controller 160, the traditional and scattered whole machine control device 161, the buck-boost DCDC control device 162, the DC charging connection device 163, the motor control device 164 and other functional devices can be integrated into one, significantly reducing the use of high-voltage and low-voltage wiring harnesses and electrical components, reducing the complexity, weight and space occupancy of the system, and reducing the manufacturing cost and labor cost.

[0035] Among them, as Figures 4-8 shown, the cooling system 200 includes a main radiator 210, a secondary radiator 220, a main water tank 230, a secondary water tank 240, a main water pump 250, a secondary water pump 260, and a pressure maintaining filter 270: The main radiator 210 is wound around the outside of the disc motor 120 and is connected to the inlet and outlet of the range extender 100, and is used as the radiator for the coolant of the range extender 100. The secondary radiator 220 and the main radiator 210 can adopt an independent cooling circuit to avoid mixing the engine coolant; The secondary radiator 220 is connected to the inlet and outlet of the domain controller 160 and is used as the radiator for the coolant of the domain controller 160. The coolant forms a closed-loop flow driven by the secondary water pump 260; The main water tank 230 is used as the filling port for the coolant of the range extender 100; The auxiliary water bottle 240 is used as a filling port for the coolant of the domain controller 160; The main water pump 250 is disposed inside the engine 110. When the range extender 100 is started, it is used to transport the coolant in the engine 110 and the disc motor 120 to the main heat sink 210. During the operation of the range extender 100, the main water pump 250 of the engine 110 will make the coolant in the water pipe flow through the mechanical structure. The higher the speed, the greater the cooling water flow rate; The auxiliary water pump 260 is arranged inside the domain controller 160. When the domain controller 160 is working, it is used to transport the coolant in the domain controller 160 to the auxiliary heat sink 220. The auxiliary water pump 260 of the domain controller 160 is controlled by a PWM duty cycle (0% to 100%). The larger the PWM duty cycle, the higher the speed and the greater the cooling water flow rate. The PWM duty cycle can be adjusted according to the internal temperature sensor data to achieve dynamic heat dissipation. The pressure-maintaining filter 270 is used to ensure that the oil in the oil tank 130 can be delivered to the engine 110 at a constant pressure; Specifically, heat dissipation can be achieved through full heat exchange between the coolant and the liquid cooling plate made of high thermal conductivity silicone grease and a copper-aluminum composite substrate. The coolant flows through multiple controllers to achieve integrated heat dissipation. For some areas with limited space, heat pipes are embedded and connected to the cooling fins. At the same time, the integrated water pump speed is controlled to increase the water flow rate and take away the heat from the coolant, which directly enters the auxiliary heat sink, thereby achieving fast and sufficient heat dissipation effects.

[0036] Among them Figure 4 and Figure 5 As shown, it also includes an extended-range charging control device 300, which includes a storage module 310, a processing module 320 and a collection module 330. The storage module 310 is used to store a program for implementing the extended-range charging system control method, and the processing module 320 is used to execute the program for implementing the charging system control method to implement the steps of the charging system control method. The processing module 320 pushes the collected data (such as SOC, fault code) to the control panel, supports historical data query, and realizes energy efficiency analysis. The collection module 330 is used to collect real-time values ​​of the extended-range charging system based on the domain controller 160. The collection module 330 can monitor the system status in real time through high-precision sensors (such as voltage / current sampling sensors) to provide a data basis for dynamic control.

[0037] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. A control method for an extended-range charging system based on a domain controller, characterized in that, The specific usage steps are as follows: S1. Obtain the start request of the range extender charging system; S2. Calculate the current load electric power in real time through operating parameters; S3. Determine whether the operation request is a load start request: if it is a load start request, execute step S4; if it is a DC charging request, execute step S5; S4. Determine whether the load is normally connected and working. If the load is normally connected and working, control the range extender energy system to enter the load start mode, the domain controller (160) starts to work, and the range extender (100) supplies power to the DC load; S5. Control the range extender energy system to enter the DC charging mode, the domain controller (160) starts to work, and the range extender (100) supplies power to the battery pack.

2. The control method of an extended-range charging system based on a domain controller according to claim 1, wherein, The start request in step S1 is judged through the low-voltage signal line of the high-voltage socket (170) of the DC output power supply of the DC load and the DC charging connection device (163). The low-voltage signal line includes 6 low-voltage charging signal lines for DC fast charging pile connection interaction, and the low-voltage charging signal lines are denoted as A+, A-, CC, CP, S+ and S-.

3. The control method of an extended-range charging system based on a domain controller according to claim 2, characterized in that, The calculation steps of the load electric power in step S2 are as follows: S21. If the start request is a load start request, calculate the current load power by using the domain controller (160) based on the real-time voltage and current data of the motor electronic control DC high-voltage bus obtained; S22. If the start request is a DC charging request, calculate the current load power by using the domain controller (160) based on the allowed charging power or the maximum allowed charging voltage and current data of the battery pack obtained by the DC charging connection device (163).

4. The control method of an extended-range charging system based on a domain controller according to claim 3, characterized in that, The working process of the domain controller (160) starting to work in step S4 is as follows: The domain controller (160) enables the boost DCDC, raises the motor electronic control voltage to the rated voltage, and then the whole machine control device (161) inside the domain controller (160) interacts with the engine (110) to control the range extender (100) to ignite and start. After the range extender (100) starts successfully, the boost DCDC is switched to the buck DCDC through the buck-boost DCDC control device (162) to charge the storage battery, and the range extender (100) is controlled to generate electricity to supply power to the DC load according to the load power calculated in the current mode.

5. A control method for an extended-range charging system based on a domain controller according to claim 4, characterized in that, Step S4 further includes: when the operation request is a load start request and the load is not normally connected and working, control the range extender energy system to enter the self-start idle mode, the domain controller (160) starts to work, the system completes self-checking during the initial start or the range extender (100) self-starts to supply power to the storage battery. The system completing self-checking during the initial start can be executed when the system has not been connected to the load and the customer requests to start the self-check, which is used to check whether there is a fault in the system start-stop function and report it in time, and preheat in advance to charge the storage battery.

6. The control method of an extended-range charging system based on a domain controller according to claim 5, characterized in that, The specific steps of step S5 are as follows: When the operation request is a non-load start request, i.e., a DC charging request, the DC charging connection device (163) in the domain controller (160) starts to work. When it is determined that the DC charging gun is correctly connected, the range extender energy system is controlled to enter the DC charging mode, the domain controller (160) starts to work, and according to the load power calculated in the current mode, the range extender (100) is controlled to generate electricity to supply power to the battery pack; The steps for the domain controller (160) to charge the battery pack directly through the DC charging gun are as follows: S51. The DC charging gun is inserted into the vehicle charging port, and the mechanical locking device locks; S52. The DC charging connection device (163) detects the gun head insertion signal through the CC1 / CC2 contact status; S53. When it is detected that the DC charging gun is correctly connected, the DC charging connection device (163) supplies power to the vehicle BMS through the low-voltage auxiliary power supply to wake up the charging vehicle communication link; S54. The status detection and diagnosis module in the DC charging connection device (163) starts, detects the insulation resistance between the system and the vehicle and receives the insulation status feedback from the BMS. If an abnormality is detected, charging is prohibited and an insulation fault warning is sent to the control panel; S55. The DC charging connection device (163) determines the maximum output current and voltage according to the BMS requirements. If the charging pile end of the DC fast charger cannot meet the BMS requirements, power reduction or charging termination is triggered and reported to the control panel; S56. The domain controller (160) monitors the parameter data and working status of the charging battery and the range extender (100) in real time, and updates and displays the above data on the control panel in real time. The parameter data includes but is not limited to the voltage, current, and temperature of the charging battery, the actual output voltage and current of the range extender (100), and the working status includes but is not limited to the system charging status, the state of charge of the charging battery, and the fault status; S57. Control the range extender energy system to enter the DC charging mode; S58. The domain controller (160) adjusts the voltage and current output of the disc motor (120) according to the above BMS feedback result and responds in a timely manner to the function requirement of the BMS to reduce the current; S59. The normal termination conditions for the battery pack are: the state of charge reaches the set value, the battery voltage reaches the upper limit, and the user manually stops the charging request through the control panel or the charging emergency stop switch. When any of the above termination conditions is met, the BMS sends a charging end request; S510. The domain controller (160) controls the generated current of the range extender to gradually decrease to 0 and disconnects the contact. After confirming that there is no current on both the DC charging gun and the vehicle, the charging gun is unlocked and the machine is stopped to complete the charging process.

7. An extended-range charging system device based on a domain controller, characterized in that, It includes a range extender (100) and a cooling system (200). The range extender (100) is used to start, operate for power generation, and stop under the control instructions sent by the domain controller (160). The cooling system (200) is used to dissipate heat from the range extender (100). The range extender (100) includes an engine (110), a disc motor (120), a fuel tank (130), a cooling fan (140), a storage battery (150), a domain controller (160), a high-voltage socket for DC output power supply (170), and a muffler cover (180). The engine (110) is used to provide power output and drive the disc motor (120) to generate electricity. The disc motor (120) is used to convert mechanical energy into electrical energy to supply power to DC loads and battery packs. The fuel tank (130) is used to store fuel and supply fuel at a constant pressure through the self-priming oil pump and pressure-maintaining filter (270) of the engine (110). The cooling fan (140) is used to assist in heat dissipation and adjusts its rotation speed according to the thermal management instructions of the domain controller (160). The storage battery (150) is used to provide power for the boost DCDC when the system starts and supplement power through the buck DCDC during operation. The domain controller (160) is used to integrate functions such as overall machine control, buck-boost DCDC control, DC charging connection control, and motor control. The high-voltage socket for DC output power supply (170) is used to connect DC loads and charging devices. The muffler cover (180) is used to reduce the noise generated when the range extender (100) operates.

8. The range-extended charging system device based on a domain controller according to claim 7, wherein, The domain controller (160) includes an overall machine control device (161), a buck-boost DCDC control device (162), a DC charging connection device (163), and a motor control device (164): The overall machine control device (161) is used to provide one or more functions in any combination. The functions include but are not limited to human-machine interaction, power-on and power-off control, energy management, fault diagnosis and handling, system status monitoring and thermal management, charging management, communication, and network management. The buck-boost DCDC control device (162) includes a power stage module, a control module, a drive module, and a protection module, and is used to achieve voltage conversion, power regulation, and circuit protection effects. The DC charging connection device (163) includes a battery communication management module, a power supply control module, a status detection and diagnosis module, and a safety monitoring and protection module, and is used to manage the DC charging process and monitor the charging status. The motor control device (164) is used to control motor torque and speed parameters and can perform active discharging and energy recovery operations.

9. The range-extended charging system device based on a domain controller according to claim 8, wherein, The cooling system (200) includes a main radiator (210), a secondary radiator (220), a main water kettle (230), a secondary water kettle (240), a main water pump (250), a secondary water pump (260), and a pressure-maintaining filter (270): The main radiator (210) is wound around the outside of the disc motor (120) and is connected to the inlet and outlet of the range extender (100), and is used as the radiator for the coolant of the range extender (100). The auxiliary radiator (220) is connected to the inlet and outlet of the domain controller (160) and serves as the radiator for the coolant of the domain controller (160). The main water tank (230) serves as the filling port for the coolant of the range extender (100). The auxiliary water tank (240) serves as the filling port for the coolant of the domain controller (160). The main water pump (250) is arranged inside the engine (110). When the range extender (100) starts, it is used to transport the coolant in the engine (110) and the disc motor (120) to the main radiator (210). The auxiliary water pump (260) is arranged inside the domain controller (160). When the domain controller (160) works, it is used to transport the coolant in the domain controller (160) to the auxiliary radiator (220). The pressure maintaining filter (270) is used to ensure that the oil in the fuel tank (130) can be transported to the engine (110) at a constant pressure.

10. The range-extended charging system device based on a domain controller according to claim 9, characterized in that, It further includes a range extender charging control device (300). The range extender charging control device (300) includes a storage module (310), a processing module (320), and a collection module (330). The storage module (310) is used to store the program for implementing the range extender charging system control method. The processing module (320) is used to execute the program for implementing the charging system control method to implement the steps of the charging system control method described in any one of claims 1-6. The collection module (330) is used to collect the real-time values of the range extender charging system based on the domain controller (160).

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