A method and device for controlling a range-extended charging system based on a domain controller

Abstract

This invention discloses a domain controller-based control method and device for a range-extended charging system, relating to the field of hybrid mechanical engineering technology. The method comprises obtaining a startup request, calculating load power in real time, determining the request type, and executing corresponding control of the load power supply or battery charging mode. The device includes a range extender, a cooling system, and a range-extended charging control device. The domain controller is used to integrate overall system control, buck-boost (DC-DC) control, DC charging connection control, and motor control functions. Through hardware integration and functional optimization, the invention addresses the existing problems of complex wiring harnesses, high costs, and high power consumption caused by the decentralized arrangement of multiple controllers. This method significantly improves system reliability, space utilization, and energy efficiency, ensures the normal startup and operation of the range-extended charging system itself, and reduces the weight and volume of the device, as well as hardware and installation costs.

Description

Technical Field

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

[0002] Traditional diesel-powered equipment has high operating costs in scenarios with fluctuating oil prices and long-term operations. Extended-range technology can reduce fuel consumption through "oil-electric synergy", and extended-range equipment can meet requirements such as low noise and low emissions. However, in engineering applications, extended-range equipment mostly adopts a distributed controller control method, which is controlled by the whole machine controller VCU, and achieves the effect by controlling components such as the step-down DCDC, BMS, PDU, and range extender controller (ECU and ISG). Since each controller is a separate system and needs to have power supply, diagnosis, heat dissipation and other functions, multiple high-voltage and low-voltage wiring harnesses, pipelines and electrical components (relays, fuses, etc.) are generated, resulting in a burden in terms of cost, weight, space and size. In addition, due to the relatively scattered locations, each controller needs to be arranged separately. The controllers communicate with each other through CAN signals, which in turn generates network load, resulting in 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, a method and device for controlling a range-extended charging system based on a domain controller are now provided, which can eliminate the drawbacks of the existing technical solutions. Summary of the Invention

[0004] The purpose of the present invention is to provide a domain controller-based extended-range charging system control method and device, so as to solve the problems in the background technology that each controller is self-contained and causes multiple burdens, and each controller is distributed and increases network load and power consumption.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] A method for controlling a range-extended charging system based on a domain controller, with the following specific steps:

[0007] S1. Obtaining a start request for the extended-range charging system;

[0008] S2. Calculate the current load power in real time based on the working parameters;

[0009] 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;

[0010] S4. Determine whether the load is connected and working normally. If the load is connected and working normally, control the range extender energy system to enter the load startup mode, the domain controller starts working, and the range extender supplies power to the DC load;

[0011] S5. Control the range extender energy system to enter a DC charging mode, the domain controller starts working, and the range extender supplies power to the battery pack.

[0012] Preferably, the start request in step S1 is judged by the low-voltage signal line of the DC output power high-voltage socket of the DC load and the DC charging connection device, and 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 marked as A+, A-, CC, CP, S+ and S-.

[0013] Preferably, the steps for calculating the load electric power in step S2 are as follows:

[0014] S21. If the start request is a load start request, calculate the current load power using the domain controller based on the acquired real-time voltage and current data of the motor electronically controlled DC high-voltage bus;

[0015] S22: If the start request is a DC charging request, the domain controller is used to calculate the current load power based on the allowable charging power or the maximum allowable charging voltage and current data of the battery pack obtained by the DC charging connection device.

[0016] Preferably, the process of the domain controller starting to work in step S4 is as follows:

[0017] The domain controller enables the boost DCDC and raises the motor electronic control voltage to the rated voltage. Then, the whole machine control device inside the domain controller interacts with the engine to control the ignition and start of the range extender. After the range extender is started, the boost DCDC is switched to the buck DCDC through the boost-buck DCDC control device to charge the battery. Based on the load power calculated in the current mode, the range extender is controlled to generate electricity to supply power to the DC load.

[0018] Preferably, step S4 further includes: when the operation request is a load start request and the load is not connected and working normally, controlling the range extender energy system to enter the self-start idle mode, the domain controller starts working, the system completes the self-test at the initial startup or the range extender self-starts to power the battery. The system completes the self-test at the initial startup when the system is not connected to the load and the customer requests to start the self-test, which is used to check whether the system start-stop function has a fault and report it in time, and preheat in advance to recharge the battery.

[0019] Preferably, 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 in the domain controller starts working, and 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 starts working, and according to the load power calculated in the current mode, controls the range extender to generate power for the battery pack;

[0020] The steps for the domain controller to DC charge the battery pack via a DC charging gun are as follows:

[0021] S51. Insert the DC charging gun into the vehicle's charging port and lock the mechanical locking device.

[0022] S52, the DC charging connection device detects the gun tip plug-in signal through the CC1 / CC2 contact status;

[0023] S53. When it is detected 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, waking up the charging vehicle communication link;

[0024] S54: The status detection and diagnosis module in the DC charging connection device starts to detect the insulation resistance between the system and the vehicle and the insulation status received from the BMS. If an abnormality is detected, charging is prohibited and an insulation fault warning is sent to the control panel.

[0025] S55. The DC charging connection device determines the maximum output current and voltage based on the BMS requirements. If the DC fast charging pile end cannot meet the BMS requirements, it triggers power reduction or terminates charging and reports to the control panel;

[0026] S56. The domain controller monitors the parameter data and operating status of the rechargeable 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 rechargeable battery, and the actual output voltage and current of the range extender. The operating status includes but is not limited to the system charging status, the charge state of the rechargeable battery, and the fault status.

[0027] S57, controlling the range extender energy system to enter a DC charging mode;

[0028] S58. The domain controller adjusts the voltage and current output of the disc motor according to the BMS feedback result, and promptly responds to the BMS request to reduce the current.

[0029] 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, or 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 charge end request;

[0030] S510: The domain controller controls the range extender to gradually reduce the power generation current to 0 and disconnect the contact. After confirming that there is no current on both the DC charging gun and the vehicle, the charging gun is unlocked and shut down to complete the charging process.

[0031] A range-extended charging system device based on a domain controller includes a range extender and a cooling system. The range extender is used to start, generate electricity, and stop under control instructions 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 battery, a domain controller, a DC output power supply high-voltage socket, and a silent cover.

[0032] The engine is used to provide power output and drive the disc motor to generate electricity;

[0033] The disc motor is used to convert mechanical energy into electrical energy to supply power to the DC load and the battery pack;

[0034] 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-maintaining filter;

[0035] The cooling fan is used to assist in heat dissipation and adjusts its speed according to the thermal management instructions of the domain controller;

[0036] The battery is used to provide power to the boost DCDC when the system is started, and to supplement the power through the buck DCDC during operation;

[0037] The domain controller is used to integrate the whole machine control, buck-boost DCDC control, DC charging connection control and motor control functions;

[0038] The DC output power high voltage socket is used to connect DC loads and charging equipment;

[0039] The silent cover is used to reduce the noise during operation of the range extender.

[0040] Preferably, the domain controller includes a whole machine control device, a buck-boost DCDC control device, a DC charging connection device and a motor control device:

[0041] The whole machine control device is used to provide one or more functions in any combination, including but not limited to human-machine interaction, power on and off control, energy management, fault diagnosis and processing, system status monitoring and thermal management, charging management, communication and network management;

[0042] The buck-boost DCDC control device 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;

[0043] The DC charging connection device includes a battery communication management module, a power 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;

[0044] The motor control device is used to control motor torque and speed parameters, and can perform active discharge and energy recovery operations.

[0045] Preferably, the cooling system includes a main radiator, an auxiliary radiator, a main water tank, an auxiliary water tank, a main water pump, an auxiliary water pump and a pressure-maintaining filter:

[0046] The main heat sink is wound around the outside of the disc motor and connected to the water inlet and outlet of the range extender, serving as a heat sink for the coolant of the range extender;

[0047] The auxiliary heat sink is connected to the water inlet and outlet of the domain controller and is used to serve as a heat sink for the coolant of the domain controller;

[0048] The main kettle is used as the filling port for the range extender coolant;

[0049] The auxiliary water bottle is used as the filling port for the domain controller coolant;

[0050] 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 is started;

[0051] The auxiliary water pump is arranged inside the domain controller, and is used to transport the coolant in the domain controller to the auxiliary heat sink when the domain controller is working;

[0052] The pressure maintaining filter is used to ensure that the oil in the oil tank can be delivered to the engine at a constant pressure.

[0053] Preferably, the extended-range charging control device includes a storage module, a processing module and an acquisition module. The storage module is used to store a program for implementing the extended-range charging system control method, the processing module is used to execute the program for implementing the charging system control method to implement the steps of the charging system control method, and the acquisition module is used to collect real-time values of the extended-range charging system based on the domain controller.

[0054] Compared with the prior art, the present invention has the following beneficial effects:

[0055] In this domain controller-based extended-range charging system device, the domain controller integrates the traditional whole-machine control device, buck-boost DCDC control device, DC charging connection device, motor control device and ECU controller into one, avoiding increasing network load and power consumption. It fully avoids the need to deploy interactive wiring harnesses inside the vehicle's domain controller to connect various components in existing technical solutions, thereby simplifying the design, reducing hardware and labor costs, and reducing the space occupied by electronic appliances, controllers, water pipes, and wiring harnesses. In addition, it can also realize functions such as whole-machine fault diagnosis, thermal management and internal bus communication, ensuring that the range-extended system itself can start and operate normally, while greatly improving the efficiency and reliability of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Figure 1 Schematic diagram of the control method of the present invention.

[0057] Figure 2 Schematic diagram of step S2 of the present invention.

[0058] Figure 3 This is a schematic diagram of step S5 of the present invention.

[0059] Figure 4 It is a structural schematic diagram of the extended-range charging system device of the present invention.

[0060] Figure 5 It is a schematic structural diagram of the range extender, cooling system and range extender charging control device of the present invention.

[0061] Figure 6 It is a structural diagram of the domain controller of the present invention.

[0062] Figure 7 It is a front view of the soundproof cover of the present invention.

[0063] Figure 8 It is a left side view of the soundproof cover of the present invention.

[0064] Figure 9 This is a schematic diagram of the integrated structure of the range extender and cooling system of the present invention.

[0065] Notes on the accompanying drawings: range extender 100, engine 110, disc motor 120, fuel tank 130, cooling fan 140, battery 150, domain controller 160, whole machine control device 161, buck-boost DCDC control device 162, DC charging connection device 163, motor control device 164, DC output power high-voltage socket 170, silent cover 180, cooling system 200, main heat sink 210, auxiliary heat sink 220, main water tank 230, auxiliary water tank 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 DESCRIPTION

[0066] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments.

[0067] In this embodiment, if Figures 1-9 As shown, a method for controlling a range-extended charging system based on a domain controller is described. The specific steps are as follows:

[0068] S1. Obtaining a start request for the range-extended charging system;

[0069] S2. Calculate the current load electric power in real time based on the working parameters to facilitate adjustment of the speed and power generation of the engine 110;

[0070] 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;

[0071] S4. Determine whether the load is connected and working normally, such as whether the voltage matches or whether there is a short circuit. If the load is connected and working normally, control the range extender energy system to enter the load start mode, the domain controller 160 starts working, and the range extender 100 supplies power to the DC load. If the load is not connected and working normally, enter the self-start idle mode and trigger the protection mechanism;

[0072] S5. Control the range extender energy system to enter the DC charging mode, the domain controller 160 starts working, and the range extender 100 supplies power to the battery pack.

[0073] Among them Figure 2As shown, the start request in step S1 is judged by the low-voltage signal line of the DC output power high-voltage socket 170 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 used for DC fast charging pile connection interaction. The low-voltage charging signal lines are recorded as A+, A-, CC, CP, S+, and S-. If the CC signal line is detected to be activated and the A+ voltage is 12V, it is determined to be a DC charging request. If the A+ and A- signals are activated and there are messages requesting start and power generation agreed with the customer on the S+ and S- signal communication lines, it is a load start request.

[0074] Among them Figure 2 and Figure 3 As shown, the calculation steps of the load electric power in step S2 are as follows:

[0075] S21. If the start request is a load start request, the domain controller 160 calculates the current load power based on the acquired real-time voltage and current data of the motor electronically controlled DC high-voltage bus. The value is calculated using the formula power = voltage × current to facilitate dynamic adjustment of the range extender 100 output.

[0076] S22. If the start request is a DC charging request, the DC charging connection device 163 obtains the allowable charging power or the maximum allowable charging voltage and current data of the battery pack, and uses the domain controller 160 to calculate the current load power to facilitate real-time optimization of the charging power and avoid overload.

[0077] Among them Figure 2 and Figure 3 As shown, the process of the domain controller 160 starting to work in step S4 is as follows:

[0078] The domain controller 160 enables the boost DCDC function and raises the motor electronic control voltage to the rated voltage. 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 ignition and start of the range extender 100 to achieve rapid ignition. After the range extender 100 is started, the boost DCDC control device 162 switches the boost DCDC function to the buck DCDC function to charge the battery, maintaining the system low-voltage power supply. Based on the load power calculated in the current mode, the range extender 100 is controlled to generate power for the DC load, facilitating dynamic adjustment of power generation according to the load power.

[0079] Among them Figure 1As shown, step S4 also includes: when the operation request is a load start request and the load is not connected and working normally, 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 recharge the battery and preheat the system to reduce cold start wear, the domain controller 160 starts to work, the system completes the self-test at the initial startup or the range extender 100 self-starts to power the battery. The self-test completed at the initial startup of the system can be performed when the system is not connected to the load and the customer requests to start the self-test, which is used to check whether the system start-stop function has a fault and report it in time, and preheat in advance to recharge the battery. The detection includes but is not limited to real-time monitoring of insulation resistance values and single-cell voltage balance differences.

[0080] Among them Figure 1 As shown, step S5 specifically includes: when the operation request is a non-load start request, that is, a DC charging request, the DC charging connection device 163 in the domain controller 160 starts working. When it is determined that the DC charging gun is connected correctly, the range extender energy system is controlled to enter the DC charging mode. The domain controller 160 starts working and controls the range extender 100 to generate power for the battery pack based on the load power calculated in the current mode. After the charging gun is connected, insulation testing and GB / T27930 protocol are performed to ensure charging safety.

[0081] The steps for the domain controller 160 to use a DC charging gun to charge the battery pack are as follows:

[0082] S51. Insert the DC charging gun into the vehicle's charging port and lock the mechanical locking device.

[0083] S52, the DC charging connection device 163 detects the gun tip plug-in signal through the CC1 / CC2 contact status;

[0084] 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 a low-voltage auxiliary power supply to wake up the charging vehicle communication link. The low-voltage auxiliary power supply can be set to 12V or 24V.

[0085] S54: The status detection and diagnosis module in the DC charging connection device 163 is activated to detect the insulation resistance between the system and the vehicle and the insulation status received 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), the BMS sends key battery parameters to the DC charging connection device 163. The key battery parameters include but are not limited to the total battery voltage, the current SOC (state of charge), the maximum allowable charging current, the maximum and minimum cell voltage limits, the temperature range of the battery pack and the cell, the battery capacity, and the health status.

[0086] 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 end cannot meet the BMS requirements, it triggers power reduction or terminates charging and reports to the control panel;

[0087] S56. The domain controller 160 monitors the parameter data and operating status of the rechargeable 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 rechargeable battery, and the actual output voltage and current of the range extender 100. The operating status includes but is not limited to the system charging status, the charge status of the rechargeable battery, and the fault status. The fault status of the rechargeable battery includes three states: overvoltage, overtemperature, and insulation failure. The system charging status includes five states: ready, charging, charging complete, fault, and emergency stop.

[0088] S57, controlling the range extender energy system to enter a DC charging mode;

[0089] S58. The domain controller 160 adjusts the voltage and current output of the disc motor 120 according to the BMS feedback results, such as switching the battery charging state from constant current CC to constant voltage CV mode, responding to the BMS voltage regulation request, and promptly responding to the BMS request to reduce the current function, such as temperature increase or cell voltage imbalance;

[0090] 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, or 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 charge end request;

[0091] S510, the domain controller 160 controls the range extender's power generation current 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 shut down to complete the charging process.

[0092] like Figure 4-Figure 9 As shown, a range extender charging system device based on a domain controller includes a range extender 100 and a cooling system 200. The domain controller 160 coordinates and controls the range extender 100 to ensure that the range extender 100 efficiently and stably supplies power to a DC load or battery pack. At the same time, the cooling system 200 maintains temperature balance. The range extender 100 is used to start, generate electricity, and stop under the control instructions sent by the domain controller 160. The cooling system 200 is used to dissipate heat for 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 battery 150, a domain controller 160, a DC output power high-voltage socket 170, and a silent cover 180.

[0093] The engine 110 is used to provide power output and drive the disc motor 120 to generate electricity. The engine 110 has its own 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 cooling fan 140 to start and stop, and rotate at low speed or high speed to ensure normal system temperature.

[0094] The disc motor 120 is used to convert mechanical energy into electrical energy to power the DC load and the battery pack;

[0095] The fuel tank 130 is used to store fuel and is supplied at a constant pressure through the self-priming fuel pump of the engine 110 and the pressure-maintaining filter 270 , without the need for an electronic fuel pump;

[0096] The cooling fan 140 is used to assist in heat dissipation and adjusts its speed according to the thermal management instructions of the domain controller 160;

[0097] The battery 150 is used to provide power to the boost DC-DC converter when the system is started, and to supplement the power through the buck DC-DC converter during operation, so that the domain controller 160 can be kept in a powered state;

[0098] The domain controller 160 is used to integrate the overall control, buck-boost (DC-DC) control, DC charging connection control, and motor control functions. When the range extender 100 is powering a DC load or battery pack, the domain controller 160 monitors the range extender's power generation efficiency in real time and dynamically adjusts the range extender's output power based on load demand to achieve optimal fuel economy. By replacing the traditional distributed controller architecture with the integrated domain controller 160, efficient coordinated control of the range extender 100, the charging system, and the load is achieved.

[0099] The DC output power high voltage socket 170 is used to connect DC loads and charging equipment;

[0100] The silent cover 180 is used to reduce the noise during operation of the range extender 100. The silent cover 180 is made of a multi-layer composite sound insulation material, filled with sound-absorbing cotton inside, and covered with a high-temperature resistant coating on the outside. It reduces the noise during operation of the range extender 100 while also providing heat dissipation. The material, style and other parameters of the silent cover 180 can be adjusted according to the actual environment to meet the noise reduction indicators.

[0101] Specifically, the above-mentioned components achieve a three-level protection effect of "source suppression-path blocking-end absorption" through layout optimization, filtering shielding and software noise reduction, physically isolate the high-voltage power layer (such as the buck-boost DCDC control device 162) from the low-voltage control layer (such as the sensor), and adopt a partitioned layout. The casing of the range extender 100 is grounded and a silent cover 180 is installed, and filtering and suppression modules and functions are added to the software and circuits.

[0102] Among them Figure 6As 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:

[0103] The whole machine control device 161 is used to provide one or more functions in any combination, including but not limited to human-machine interaction, power on and off control, energy management, fault diagnosis and processing, system status monitoring and thermal management, charging management, communication and network management;

[0104] The buck-boost DCDC control device 162 includes a power stage module, a control module, a drive module, and a protection module to achieve voltage conversion, power regulation, and circuit protection. The power stage module includes switching elements, inductors, and capacitors. The control module includes a PWM controller and feedback network components. The protection module is used to prevent overvoltage, overcurrent, and excessively high or low temperatures.

[0105] The DC charging connection device 163 includes a battery communication management module, a power 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;

[0106] The motor control device 164 is used to control the motor torque and speed parameters, and can perform active discharge and energy recovery operations;

[0107] Specifically, the domain controller 160 can divide and combine the functions of the extended-range charging system device based on the analysis of the functions and application scenarios of each integrated 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 of which adopts Infineon TC397, and the motor control device 164 adopts a single ISG control board, the main control chip of which adopts Infineon TC275. The VCU+DCDC+DC control boards of the above devices interact with each other through internal software, and the VCU+ The DCDC+DC control board and the ISG control board communicate with each other through the intranet CAN, and the domain controller 160 communicates with the control panel or the ECU controller of the engine 110 through the output low-voltage CAN interface. Through the domain controller 160, traditional decentralized functional devices such as the whole machine control device 161, the buck-boost DCDC control device 162, the DC charging connection device 163 and the motor control device 164 can be integrated into one, which significantly reduces the use of high-voltage and low-voltage wiring harnesses and electrical components, reduces the complexity, weight and space occupancy of the system, and reduces manufacturing costs and labor costs.

[0108] Among them Figure 4-Figure 8 As shown, the cooling system 200 includes a main radiator 210, an auxiliary radiator 220, a main water tank 230, an auxiliary water tank 240, a main water pump 250, an auxiliary water pump 260 and a pressure filter 270:

[0109] The main heat sink 210 is wrapped around the outside of the disc motor 120 and connected to the water inlet and outlet of the range extender 100. It is used to serve as a heat sink for the coolant of the range extender 100. The auxiliary heat sink 220 and the main heat sink 210 can use independent cooling circuits to avoid mixing of engine coolant.

[0110] The auxiliary heat sink 220 is connected to the water inlet and outlet of the domain controller 160 and serves as a heat sink for the coolant of the domain controller 160. The coolant forms a closed loop flow under the drive of the auxiliary water pump 260.

[0111] The main water bottle 230 is used as a filling port for the coolant of the range extender 100;

[0112] The auxiliary water bottle 240 is used as a filling port for the coolant of the domain controller 160;

[0113] The main water pump 250 is installed 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 use the mechanical structure to make the coolant in the water pipe flow. The higher the speed, the greater the cooling water flow rate.

[0114] The auxiliary water pump 260 is installed 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 the PWM duty cycle (0% to 100%). The larger the PWM duty cycle, the higher the speed and the greater the cooling water flow. The PWM duty cycle can be adjusted according to the internal temperature sensor data to achieve dynamic heat dissipation.

[0115] 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;

[0116] 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 speed of the integrated water pump is controlled to increase the water flow rate and the coolant that takes away the heat directly enters the auxiliary heat sink, thereby achieving fast and sufficient heat dissipation effects.

[0117] Among them Figure 4 and Figure 5As shown, it also includes an extended-range charging control device 300, which includes a storage module 310, a processing module 320 and an acquisition 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 acquisition module 330 is used to collect real-time values of the extended-range charging system based on the domain controller 160. The acquisition 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.

[0118] The above description is merely a specific embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in this application should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be based on the scope of protection of the claims.

Claims

1. A method for controlling a range-extended charging system based on a domain controller, characterized in that: The extended-range charging system includes a domain controller (160) for integrating whole-machine control, buck-boost DCDC control, DC charging connection control, and motor control functions. 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, the functions including human-machine interaction, power on / off control, energy management, fault diagnosis and processing, system status monitoring and thermal management, charging management, communication and network management; The buck-boost DCDC control device (162) comprises 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 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 discharge and energy recovery operations; The specific steps are as follows: S1. Obtaining a start request for the extended-range charging system; S2. Calculate the current load power in real time based on the 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, determining whether the load is connected and working normally. If the load is connected and working normally, controlling the range extender energy system to enter a load start-up mode, the domain controller (160) starts working, and the range extender (100) supplies power to the DC load; S5, controlling the range extender energy system to enter a DC charging mode, the domain controller (160) starts working, and the range extender (100) supplies power to the battery pack; The process of the domain controller (160) starting to work in step S4 is as follows: The domain controller (160) enables the boost DCDC, and after the motor electronic control voltage is increased to the rated voltage, the whole machine control device (161) inside the domain controller (160) interacts with the engine (110) to control the ignition and start of the range extender (100). After the start of the range extender (100) is completed, the boost DCDC is switched to the buck DCDC through the boost-buck DCDC control device (162) to charge the battery, 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 DC load; The step S4 further includes: when the operation request is a load start request and the load is not connected and working normally, controlling the range extender energy system to enter the self-start idle mode, the domain controller (160) starts working, the system completes the self-check at the initial startup or the range extender (100) self-starts to supply power to the battery, and the system completes the self-check at the initial startup can be performed when the system is not connected to the load and the customer requests to start the self-check, and is used to check whether the system start-stop function has a fault and report it in time, and preheat in advance to replenish the battery.

2. The method for controlling a range-extended charging system based on a domain controller according to claim 1, characterized in that: The start request in step S1 is judged by the low-voltage signal line of the DC output power high-voltage socket (170) of the DC load and the DC charging connection device (163), wherein 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 marked as A+, A-, CC, CP, S+ and S-.

3. The method for controlling a range-extended charging system based on a domain controller according to claim 1, 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, the current load power is calculated using the domain controller (160) based on the acquired real-time voltage and current data of the motor electronically controlled DC high-voltage bus; S22: If the start request is a DC charging request, the current load power is calculated 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 method for controlling a range-extended charging system based on a domain controller according to claim 1, characterized in that: The 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, and 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, controls the range extender (100) to generate electricity to supply power to the battery pack; The steps of the domain controller (160) charging the battery pack with DC power via a DC charging gun are as follows: S51. Insert the DC charging gun into the vehicle's charging port and lock the mechanical locking device. S52, the DC charging connection device (163) detects the gun head plug-in signal through the CC1 / CC2 contact state; 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 via a low-voltage auxiliary power supply, waking up the charging vehicle communication link; S54, the state detection and diagnosis module in the DC charging connection device (163) is started, the insulation resistance between the system and the vehicle is detected, and the insulation state received from the BMS is fed back. 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 DC fast charging pile end cannot meet the BMS requirements, it triggers power reduction or terminates charging and reports to the control panel; S56, the domain controller (160) monitors the parameter data and working status of the rechargeable battery and the range extender (100) in real time, and updates and displays the above data on the control panel in real time, wherein the parameter data includes the voltage, current and temperature of the rechargeable battery, the voltage and current actually output by the range extender (100), and the working status includes the system charging status, the charge state of the rechargeable battery and the fault status; S57, controlling the range extender energy system to enter a DC charging mode; S58, the domain controller (160) adjusts the voltage and current output of the disc motor (120) according to the BMS feedback result, and promptly responds to the BMS request to reduce the current function; 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, or 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 charge end request; S510, the domain controller (160) controls the range extender to gradually reduce the power generation current to 0 and disconnect the contact. After confirming that there is no current on both the DC charging gun and the vehicle, the charging gun is unlocked and shut down to complete the charging process.

5. A range-extended charging system device based on a domain controller, applied to the range-extended charging system control method based on a domain controller according to claim 1, characterized in that: The range extender (100) comprises a range extender (100) and a cooling system (200), wherein the range extender (100) is used to start, generate electricity, and stop under a control instruction sent by the domain controller (160), and the cooling system (200) is used to perform a heat dissipation operation on the range extender (100). The range extender (100) comprises an engine (110), a disc motor (120), a fuel tank (130), a cooling fan (140), a battery (150), a domain controller (160), a DC output power supply high-voltage socket (170), and a silent 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 a DC load and a battery pack; 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 its rotation speed is adjusted according to the thermal management instruction of the domain controller (160); The battery (150) is used to provide power to the boost DCDC when the system is started, and to supplement power through the buck DCDC during operation; The DC output power high voltage socket (170) is used to connect a DC load and a charging device; The silent cover (180) is used to reduce the noise during operation of the range extender (100).

6. The extended range charging system device based on a domain controller according to claim 5, characterized in that: The cooling system (200) comprises a main radiating fin (210), an auxiliary radiating fin (220), a main water pot (230), an auxiliary water pot (240), a main water pump (250), an auxiliary water pump (260), and a pressure-maintaining filter (270): The main heat sink (210) is wound around the outside of the disc motor (120) and connected to the water inlet and outlet of the range extender (100), and is used to serve as a heat sink for the coolant of the range extender (100); The auxiliary heat sink (220) is connected to the water inlet and outlet of the domain controller (160) and is used to serve as a heat sink for the cooling liquid of the domain controller (160); The main water kettle (230) is used as a filling port for the range extender (100) coolant; 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 arranged inside the engine (110) and is used to transport the coolant in the engine (110) and the disc motor (120) to the main heat sink (210) when the range extender (100) is started; The auxiliary water pump (260) is arranged inside the domain controller (160) and is used to transport the cooling liquid in the domain controller (160) to the auxiliary heat sink (220) when the domain controller (160) is in operation; 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.

7. The extended range charging system device based on a domain controller according to claim 5, characterized in that: The system further includes an extended-range charging control device (300), the extended-range charging control device (300) including a storage module (310), a processing module (320) and an acquisition module (330), the storage module (310) being used to store a program for implementing a method for controlling an extended-range charging system, the processing module (320) being used to execute the program for implementing the method for controlling an extended-range charging system to implement the steps of the method for controlling an extended-range charging system, and the acquisition module (330) being used to acquire real-time values of the extended-range charging system based on the domain controller (160).

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