Power generation control method and system for extended-range hybrid vehicle, medium and program product

Abstract

The invention provides a power generation control method and system of an extended-range hybrid vehicle, a medium and a product, and relates to the technical field of hybrid vehicles, and the method comprises the following steps: when a range extending system is connected to high-voltage power supply and the vehicle has a power generation demand, sending a first control instruction for zeroing the torque and the rotating speed of a generator to a generator controller; identifying whether the generator is in a running state; when the generator is in a running state, the range extending system is emergently under high pressure; and when the generator is in a non-operation state, a second control instruction used for setting the torque or fuel injection quantity of the generator to zero and starting the starter is sent to the generator controller, a first rotating speed signal of the generator and a second rotating speed signal of the engine are obtained, and when the first rotating speed signal and the second rotating speed signal are forward synchronizing signals, the process is ended, and the engine is started. And the range extending system is controlled to start power generation. According to the method, the power generation opportunity is determined based on judgment of the forward synchronizing signal, and the risk that the engine is reversely dragged can be greatly reduced.

Description

Technical Field

[0001] The present disclosure belongs to the technical field of hybrid vehicles, and particularly relates to a power generation control method, system, medium and program product for an extended-range hybrid vehicle. Background Art

[0002] In the extended-range system of a hybrid vehicle, an engine, a generator and its controller form an extended-range system for providing electric power for the whole vehicle. However, during the matching process of the engine and the generator in the extended-range system, due to reasons such as the resolver sensor of the generator being installed backwards, the timing error of the rotational speed signal of the generator controller (GCU), and the abnormal control of the GCU, the engine may be damaged after reversing to a relatively high speed.

[0003] In some actual cases, due to the misidentification of the steering direction by the GCU, the engine in the actual reverse state is misidentified as the forward rotation state. Coupled with the misanalysis of the torque by the GCU, when the whole vehicle is connected to the high-voltage power supply, the engine is quickly reversed and raised to 2100 rpm, resulting in engine damage due to lack of lubrication, causing serious consequences. Summary of the Invention

[0004] The present disclosure provides a power generation control method, system, medium and program product for an extended-range hybrid vehicle, aiming to at least partly solve the technical problem that in the related art, the engine is prone to damage due to the lack of consideration of the misjudgment of the generator steering direction.

[0005] At least one embodiment of the present disclosure provides a power generation control method for an extended-range hybrid vehicle, where the vehicle includes an extended-range system composed of an engine, a starter, an engine controller, a generator and a generator controller. The method includes a process of adaptively matching the steering directions of the engine and the generator in the extended-range system, and the process includes: When the extended-range system is connected to the high-voltage power supply and the vehicle has a power generation requirement, send a first control instruction to the generator controller to set the torque and rotational speed of the generator to zero; Identify whether the generator is in an operating state after responding to the first control instruction; When the generator is in an operating state, disconnect the extended-range system from the high-voltage power supply; and When the generator is in a non-operating state, send a second control instruction to the generator controller to set the torque or fuel injection amount of the generator to zero and start the starter, obtain a first rotational speed signal of the generator and a second rotational speed signal of the engine, and when the first rotational speed signal and the second rotational speed signal are positive synchronous signals, end the process and control the extended-range system to start generating electricity.

[0006] In the method provided by at least one embodiment of the present disclosure, the process further includes: When the first rotation speed signal and the second rotation speed signal are not positive synchronous signals, send a starter stop working instruction to the engine controller, and send a commutation instruction to the generator controller, so that the starter stops working and the generator switches the rotation direction angle, and obtain the first rotation speed signal and the second rotation speed signal again until the first rotation speed signal and the second rotation speed signal are positive synchronous signals.

[0007] In the method provided by at least one embodiment of the present disclosure, the vehicle further includes a range extender system controller and a vehicle controller, and the method includes: Predict the power generation demand through the vehicle controller, and transmit the power generation demand to the range extender system controller, so that the range extender system controller generates the first control instruction based on the power generation demand; and Monitor the power generation parameters of the generator through the range extender system controller, obtain the error message of the range extender system, and transmit the power generation parameters and the error message to the vehicle controller.

[0008] The method provided by at least one embodiment of the present disclosure further includes: Determine whether the process has been executed before the current moment and there is no abnormality; If so, end the process and generate a first notification message for indicating that there is no need to adaptively match the steering directions of the engine and the generator; and, If not, start the process and generate a second notification message for indicating entry into the steering adaptive matching of the engine and the generator.

[0009] In the method provided by at least one embodiment of the present disclosure, when the range extender system is connected to high-voltage power supply and the vehicle has a power generation demand, sending a first control instruction to the generator controller to zero the torque and rotation speed of the generator includes: Identify whether the range extender system is connected to high-voltage power supply; If so, send the first control instruction to the generator controller when the vehicle has a power generation demand; and, If not, continue to identify whether the range extender system is connected to high-voltage power supply at the next moment.

[0010] In the method provided by at least one embodiment of the present disclosure, when the generator is in an operating state, disconnecting the range extender system from high-voltage power supply includes: Obtain the first rotation speed signal; When the first rotational speed signal is recognized as reverse, an emergency high-voltage cut-off command is sent to the vehicle controller, and a first error message is issued. When the first rotational speed signal is recognized as forward, the second rotational speed signal is obtained. And when the first rotational speed signal and the second rotational speed signal are forward synchronous signals, an emergency high-voltage cut-off command is sent to the vehicle controller, and a second error message is issued. And when the first rotational speed signal and the second rotational speed signal are reverse synchronous signals, a third error message is issued.

[0011] In the method provided by at least one embodiment of the present disclosure, when the first rotational speed signal and the second rotational speed signal are forward synchronous signals, ending the process includes: Obtaining the first rotational speed signal; In response to the first rotational speed signal being reverse, an emergency high-voltage cut-off command is sent to the vehicle controller, and a fourth error message is issued; In response to the first rotational speed signal being forward, the second rotational speed signal is obtained. And when the first rotational speed signal and the second rotational speed signal are reverse synchronous signals, an emergency high-voltage cut-off command is sent to the vehicle controller, and a fifth error message is issued. And when the first rotational speed signal and the second rotational speed signal are forward synchronous signals, the process is ended, and a third notification message for characterizing the correct matching of the first rotational speed signal and the second rotational speed signal is issued.

[0012] In the method provided by at least one embodiment of the present disclosure, the range extender system controller is internally provided with a commutation instruction sending times recorder, and the method further includes: While sending the commutation instruction, perform an increment operation on the commutation instruction sending times recorded in the commutation instruction sending times recorder; In response to the commutation instruction sending times not exceeding the set threshold, when the range extender system is connected to high-voltage power supply and the vehicle has a power generation demand, re-enter a new round of the process to adaptively match the rotation directions of the engine and the generator; In response to the commutation instruction sending times exceeding the set threshold, issue a sixth error message indicating that there is a fault in the range extender system controller, and perform a clearing operation on the commutation instruction sending times.

[0013] At least one embodiment of the present disclosure further provides a power generation control system for a range-extended hybrid vehicle. The vehicle includes a range extender system composed of an engine, a starter, a generator, an engine controller, and a generator controller. The power generation control system includes a first subsystem for adaptively matching the rotation directions of the engine and the generator. The first subsystem includes: A preprocessing unit, configured to send a first control instruction for setting the torque and speed of the generator to zero to the generator controller when the range extender system is connected to high-voltage power supply and the vehicle has a power generation demand; A state recognition unit, configured to recognize whether the generator is in an operating state after responding to the first control instruction; A first control unit, configured to disconnect the range extender system from the high-voltage power supply when the generator is in an operating state; A second control unit, configured to send a second control instruction for setting the torque or fuel injection amount of the generator to zero and starting the starter to the generator controller when the generator is in a non-operating state, obtain a first speed signal of the generator and a second speed signal of the engine, and complete the adaptive matching and control the range extender system to start generating electricity when the first speed signal and the second speed signal are positive synchronous signals.

[0014] At least one embodiment of the present disclosure further provides a storage medium storing a program or instruction, and the program or instruction, when executed by a processor, implements the steps of the method provided in any embodiment of the present disclosure.

[0015] At least one embodiment of the present disclosure further provides a program product including a program or instruction, wherein the program or instruction, when executed by a processor, implements the steps of the method provided in any embodiment of the present disclosure.

[0016] Compared with the related art, the power generation control method, system, medium and program product of a range-extended hybrid vehicle provided by the embodiment of the present disclosure can monitor the operating state of the generator in real time, and generate electricity only when the first speed signal and the second speed signal are positive synchronous signals, effectively eliminating the possible nominal steering error, actual steering error and speed and torque control instruction error of the generator in the range-extended hybrid vehicle, and greatly reducing the risk of the engine being dragged in the reverse direction. In addition, the method has wide applicability and can be applied to various types of hybrid vehicles, providing a strong technical guarantee for the stable operation and performance improvement of the gas engine, and solving the technical problem that the engine is prone to damage due to the lack of consideration of the misjudgment of the generator steering in the related art.

[0017] It should be understood that the above general description and the following detailed description are only exemplary and explanatory, and cannot limit the present disclosure. Description of the Drawings

[0018] To more clearly illustrate the technical solutions in the embodiments of the present disclosure, the following will briefly introduce the accompanying drawings required for the description of the embodiments. Obviously, the accompanying drawings in the following description are only some embodiments of the present disclosure. For those of ordinary skill in the art, without creative efforts, other accompanying drawings can be obtained based on these drawings.

[0019] Figure 1 Flowchart of a power generation control method for a range-extended hybrid vehicle provided by at least one embodiment of the present disclosure; Figure 2 Schematic diagram of the composition of a range extender system provided by at least one embodiment of the present disclosure; Figure 3 Flowchart of another power generation control method for a range-extended hybrid vehicle provided by at least one embodiment of the present disclosure; Figure 4 Schematic diagram of the positions of the missing teeth and the synchronizing scale in the positive synchronous signal provided by at least one embodiment of the present disclosure; Figure 5 Schematic diagram of the positions of the missing teeth and the synchronizing scale in the reverse synchronous signal provided by at least one embodiment of the present disclosure; Figure 6 Flowchart of an example of a control method for a range-extended hybrid vehicle provided by at least one embodiment of the present disclosure; Figure 7 Block diagram of the structure of a power generation control system for a range-extended hybrid vehicle provided by at least one embodiment of the present disclosure; Figure 8 Schematic diagram of the composition of a program product provided by at least one embodiment of the present disclosure. Detailed implementation manners

[0020] The following will further describe the present disclosure in detail in conjunction with the accompanying drawings and embodiments. It should be specifically noted that the following embodiments are only used to illustrate the present disclosure, but do not limit the scope of the present disclosure. Similarly, the following embodiments are only some embodiments of the present disclosure rather than all embodiments. All other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of protection of the present disclosure.

[0021] The terms "first", "second", and "third" in the embodiments of the present disclosure are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first", "second", and "third" may explicitly or implicitly include at least one of such features.

[0022] In the description of the present disclosure, "a plurality of" means at least two, such as two or three, etc., unless otherwise specifically and clearly defined.

[0023] In the present disclosure, terms such as "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present disclosure. In this specification, the schematic descriptions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples.

[0024] The terms "comprising" and "having" in the embodiments of the present disclosure and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the listed steps or units, but optionally further includes steps or units not listed, or optionally further includes other steps or components inherent to these processes, methods, products, or devices.

[0025] As used herein, a "program product" is a software product that mainly realizes its solution through a computer program, and is not limited to running on a specific type of electronic device or electronic apparatus.

[0026] As used herein, "electronic device" includes, but is not limited to, a device configured to receive / transmit communication signals via a wired connection (such as via a public switched telephone network (PSTN), digital subscriber line (DSL), digital cable, or direct cable connection, and / or another data connection / network) and / or via a wireless interface (such as for a cellular network, wireless local area network (WLAN), digital television network such as DVB-H network, satellite network, or AM-FM broadcast transmitter, and / or another communication terminal). A communication terminal configured to communicate via a wireless interface can be referred to as a "wireless communication terminal", "wireless terminal", or "mobile terminal". Examples of mobile terminals include, but are not limited to, satellite or cellular telephones; personal communication system (PCS) terminals that can combine cellular wireless telephone with data processing, fax, and data communication capabilities; PDAs that can include wireless telephones, pagers, Internet / intranet access, web browsers, notepads, calendars, and / or global positioning system (GPS) receivers; and conventional laptop and / or palm receivers or other electronic devices including wireless telephone transceivers.

[0027] In the embodiments of the present disclosure, the term "engine controller" is abbreviated as ECU.

[0028] In the embodiments of the present disclosure, the term "generator controller" is abbreviated as GCU.

[0029] The term "range extender system controller" in the embodiments of the present disclosure, abbreviated as RCU, coordinates the work of the GCU and the ECU, and monitors the relevant states of the GCU and the ECU at the same time.

[0030] The term "vehicle control unit" in the embodiments of the present disclosure, abbreviated as VCU, coordinates the upper and lower high voltages of the vehicle's battery control system and coordinates the power generation of the range extender system.

[0031] The term "resolver sensor" in the embodiments of the present disclosure is a sensor that measures the angular displacement and angular velocity of the generator's rotating shaft using the principle of electromagnetic induction.

[0032] Figure 1 It is a flowchart of a power generation control method for a range-extended hybrid vehicle provided by at least one embodiment of the present disclosure. The vehicle includes a range extender system composed of an engine, a starter, an engine controller, a generator, and a generator controller. The method includes a process of adaptively matching the rotation directions of the engine and the generator in the range extender system. As Figure 1 shown, this process may include the following steps S10 - step S40.

[0033] Step S10: When the range extender system is connected to high-voltage power supply and the vehicle has a power generation demand, send a first control instruction to the generator controller to set the torque and speed of the generator to zero.

[0034] Step S20: Identify whether the generator is in an operating state after responding to the first control instruction.

[0035] Step S30: When the generator is in an operating state, disconnect the range extender system from the high-voltage power supply (emergency high voltage off).

[0036] Step S40: When the generator is in a non-operating state, send a second control instruction to the generator controller to set the torque or fuel injection amount of the generator to zero and start the starter, obtain the first speed signal of the generator and the second speed signal of the engine, and when the first speed signal and the second speed signal are positive synchronous signals, end the process (indicating that the adaptive matching is completed), and control the range extender system to start generating power.

[0037] It should be noted that emergency high voltage refers to quickly cutting off the power supply to the range extender system by controlling the high voltage power supply. This process aims to protect the range extender system and its components from potential damage and ensure the safety of the vehicle and passengers. The range extender system can be applied to the vehicle controller, the range extender system controller, or the cloud controller. The vehicle controller, the range extender system controller, or the cloud controller can all flexibly call and execute the above power generation control process according to the actual operating state and power generation requirements of the vehicle. The vehicle controller is usually integrated inside the vehicle and can monitor the vehicle state in real time and make corresponding control decisions. The range extender system controller focuses on managing the operation of the range extender system to ensure its coordinated operation with the vehicle power system. The cloud controller realizes remote monitoring and control of the vehicle through remote communication technology, providing more intelligent management and services for the vehicle. By applying this method on different controllers, efficient and precise control of the power generation process of the range-extended hybrid vehicle can be achieved, improving the energy efficiency and driving experience of the vehicle.

[0038] Some embodiments of the present disclosure also provide a system, a medium (storage medium), and a program product corresponding to the above method.

[0039] The method provided by at least one embodiment of the present disclosure is applicable to any existing usage scenario of a range extender system that needs to prevent engine damage, and the embodiments of the present disclosure do not limit this. For example, during long-distance driving or in complex road conditions, a range-extended hybrid vehicle may experience nominal steering errors, actual steering errors, and speed and torque control command errors of the generator.

[0040] Compared with the related technology, by applying the method proposed by the present disclosure, the system can monitor the operating state of the generator in real time and generate electricity only when the first speed signal and the second speed signal are positive synchronous signals, effectively eliminating the nominal steering error, actual steering error, and speed and torque control command errors that may occur in a range-extended hybrid vehicle, and greatly reducing the risk of the engine being dragged in reverse. In addition, this method has wide applicability and can be applied to various types of hybrid vehicles, providing strong technical support for the stable operation and performance improvement of the gas engine, and solving the technical problem that the engine is prone to damage in the related technology due to the lack of consideration of the misjudgment of the generator steering.

[0041] Among them, for step S10, after receiving the first control instruction, the generator controller will immediately execute the operation of the first control instruction to ensure that the torque and speed of the generator are accurately set to zero. This step is a key link in the power generation control process, which can effectively avoid the impact on the entire range extender system caused by the unstable state of the generator at the moment of power generation start. By precisely controlling the initial state of the generator, a solid foundation is laid for the subsequent power generation process, thereby further improving the operation efficiency and safety of the range-extended hybrid vehicle.

[0042] For step S20, it involves the confirmation of the generator's response ability to the first control instruction and its actual operating state. Specifically, the system will detect the reaction of the generator in real time through sensors or other monitoring means after receiving the first control instruction, including whether it starts to operate, whether the operation is stable, and whether it reaches the expected speed and torque. Through this step, any problems that may occur during the startup process of the generator, such as startup failure and unstable operation, can be detected and solved in a timely manner, thus ensuring the smooth progress of the power generation process. At the same time, this step also provides important feedback information for subsequent power generation control, which helps the system adjust the control strategy according to the actual situation to achieve the best power generation effect.

[0043] For step S30, when the generator is still in the operating state after responding to the first control instruction, it indicates that the generator may recognize an abnormal speed or torque control instruction, and the high voltage of the range extender system will be lowered urgently. At this time, the system will immediately trigger an emergency protection mechanism. By cutting off the high-voltage power supply of the range extender system, it can quickly and effectively prevent the generator from continuing to operate in an abnormal state, thus avoiding possible equipment damage or safety accidents. This operation of lowering the high voltage urgently is not only a protection for the generator but also an important guarantee for the safety of the entire range-extended hybrid vehicle.

[0044] For step S40, when the start instruction is received, the starter will respond quickly and drive the engine to start running. As the engine starts and runs, the internal mechanical energy is gradually converted into electrical energy and output through the generator to provide the required power support for the vehicle. Therefore, the second speed signal is a synchronous signal of the first speed signal.

[0045] Exemplarily, the second speed signal can be the engine camshaft signal or the crankshaft signal, which is detected by a specific sensor using the principle of electromagnetic induction to obtain the rotation of the corresponding gear. Usually, there is one more tooth on the camshaft signal gear than the number of cylinders, that is, the synchronous signal tooth, and the other teeth are evenly arranged; the crankshaft signal detection teeth are usually located on the engine flywheel, and there are 60 teeth evenly arranged on it, but 2 of them are missing, that is, missing teeth. Only when the synchronous signal tooth of the camshaft and the missing teeth of the crankshaft match according to the established parameters, the engine synchronous signal is correct. If there is a deviation and the deviation exceeds the allowable range, the engine synchronous signal is lost, and the problem of engine non-synchronization occurs. Based on this, it is possible to accurately identify whether the first speed signal and the second speed signal are positive synchronous signals.

[0046] Figure 2 A schematic diagram of the composition of a range extender system provided by at least one embodiment of the present disclosure. As Figure 2As shown, the vehicle control unit (VCU) is connected to the range extender control unit (RCU) via the CAN bus, which is used for the VCU to transmit power generation requirements and instructions to the RCU, and the RCU to transmit power generation status and related fault information to the VCU. The RCU, engine control unit (ECU), and generator control unit (GCU) are connected via separate CAN buses, which are used to coordinate the rotational speed during power generation (the ECU controls the engine) and the torque (the GCU adjusts the load), monitor the actual power generation voltage and current, and ensure the stable operation of the range extender system.

[0047] Figure 3 It is a flowchart of another power generation control method for a range-extended hybrid vehicle provided by at least one embodiment of the present disclosure. Based on Figure 1 this, in order to ensure the stable operation of the generator in the range-extended hybrid vehicle during driving, this process further includes step S50.

[0048] Step S50: When the first rotational speed signal and the second rotational speed signal are not positive synchronous signals, send a starter stop working instruction to the engine control unit and a commutation instruction to the generator control unit, so that the starter stops working and the generator switches the rotation direction angle, and then obtain the first rotational speed signal and the second rotational speed signal again until the first rotational speed signal and the second rotational speed signal are positive synchronous signals.

[0049] Among them, through the implementation of step S50, the stable operation of the generator in the range-extended hybrid vehicle during driving is ensured. Sending a starter stop working instruction to the engine control unit can effectively avoid the starter continuing to work at inappropriate times, thus preventing possible mechanical damage or safety hazards. At the same time, sending a commutation instruction to the generator control unit to make the generator switch the rotation direction angle can ensure that the generator can provide stable power output according to the actual situation of the vehicle.

[0050] In some embodiments, in order to achieve better vehicle control effects, the vehicle further includes a range extender control unit and a vehicle control unit, and this method includes the following steps S01 - step S02.

[0051] Step S01: Predict the power generation demand through the vehicle control unit and transmit the power generation demand to the range extender control unit, so that the range extender control unit generates a first control instruction based on the power generation demand.

[0052] Step S02: Monitor the power generation parameters of the generator through the range extender control unit, obtain the error message of the range extender system, and transmit the power generation parameters and the error message to the vehicle control unit.

[0053] Among them, through step S01 - step S02, the effective collaborative work between the vehicle controller and the range extender system controller is realized. The vehicle controller can accurately predict the power generation demand of the vehicle, which is based on multi-dimensional data such as the current operating state, driving route, and driving habits of the vehicle, ensuring the accuracy and real-time nature of the power generation demand. Subsequently, the vehicle controller transmits this power generation demand to the range extender system controller in a timely manner, enabling the range extender system controller to respond quickly and formulate a reasonable first control instruction based on the power generation demand. This instruction directly acts on the generator, ensuring that the generator can operate according to the predetermined power generation demand, meeting the vehicle's power demand while avoiding unnecessary energy waste. At the same time, the range extender system controller also undertakes the important task of monitoring the generator's power generation parameters and obtaining error messages of the range extender system. Through the real-time monitoring of the power generation parameters, the range extender system controller can promptly detect abnormal conditions of the generator and thus take corresponding protective measures. The acquisition of error messages enables the range extender system controller to quickly locate the fault point, providing strong support for subsequent fault troubleshooting. These messages are transmitted to the vehicle controller in a timely manner, enabling the vehicle controller to comprehensively monitor and manage the vehicle's power system, further enhancing the safety and reliability of the vehicle.

[0054] In some embodiments, to improve the operating efficiency of the system, the method further includes the following steps S03 - step S05.

[0055] Step S03: Determine whether the process has been executed before the current moment and there is no abnormality.

[0056] Step S04: If so (indicating that the correctness of the generator rotation direction and other abnormal information have been confirmed and there is no abnormality), end the process and generate a first notification message for indicating that there is no need to perform adaptive matching of the rotation directions of the engine and the generator.

[0057] Step S05: If not (indicating that the correctness of the generator rotation direction and other abnormal information have not been confirmed, or there was an abnormality before), start the process and generate a second notification message for indicating entry into the adaptive matching of the rotation directions of the engine and the generator.

[0058] Among them, through step S03 - step S04, the range extender system controller can effectively avoid unnecessary adaptive matching processes, thereby improving the operating efficiency of the system. When it is determined that the process has been successfully executed before the current moment and no abnormalities have occurred, the controller will immediately end the current process to avoid resource waste caused by repeated execution. At the same time, the generated first notification message can be timely fed back to the operator or the system monitoring module, enabling relevant personnel to understand the status of the current vehicle power generation system without the need for additional operations. If the process has not been executed before the current moment or there are abnormal situations, the controller will start the adaptive matching process and generate a second notification message. The design of this process ensures the precise matching of the engine and generator rotations for adaptive matching, improves the vehicle's power performance and handling stability, and also provides strong support for the intelligent management of the vehicle.

[0059] In some embodiments, to enable the generator to work reliably, step S10 is refined to include the following sub - steps S101 - sub - step S103.

[0060] Sub - step S101: Identify whether the range extender system is connected to high - voltage power supply.

[0061] Sub - step S103: If so, send a first control instruction to the generator controller when there is a power generation demand in the vehicle.

[0062] Sub - step S103: If not, continue to identify whether the range extender system is connected to high - voltage power supply at the next moment.

[0063] Among them, through sub - step S101 - sub - step S103, real - time monitoring of the connection of the range extender system to high - voltage power supply is achieved, ensuring that when there is a power generation demand in the vehicle, the generator can start in time and supply power stably. The design of this refined step not only improves the accuracy and efficiency of power generation control but also effectively avoids problems such as vehicle performance degradation caused by untimely or unstable power supply. At the same time, by continuously cycling to identify whether the range extender system is connected to high - voltage power supply, the system can continuously monitor the vehicle status, providing reliable data support for subsequent power generation control processes.

[0064] In some embodiments, to accurately eliminate various errors (such as nominal generator rotation error, actual generator rotation error, abnormal engine synchronization signal, etc.), step S30 is refined to include the following sub - steps S301 - sub - step S303.

[0065] Sub - step S301: Obtain the first rotational speed signal.

[0066] Sub-step S302: When it is recognized that the first rotational speed signal is reverse, send an emergency high-voltage cut-off command to the vehicle controller, and send a first error message indicating that the generator feedback steering is incorrect (or the generator nominal steering is incorrect) and the generator recognizes abnormal rotational speed or abnormal generator torque control.

[0067] Sub-step S303: When it is recognized that the first rotational speed signal is forward, obtain the second rotational speed signal. And when the first rotational speed signal and the second rotational speed signal are forward synchronous signals, send an emergency high-voltage cut-off command to the vehicle controller, and send a second error message indicating that the actual steering of the generator is incorrect and the generator recognizes abnormal rotational speed or abnormal generator torque control. And when the first rotational speed signal and the second rotational speed signal are reverse synchronous signals, send a third error message indicating that the engine synchronous signal is abnormal and the generator recognizes abnormal rotational speed or abnormal generator torque control.

[0068] Among them, through sub-step S301 - sub-step S303, precise monitoring and error identification of the first rotational speed signal of the generator and the second rotational speed signal of the engine can be achieved, and nominal steering errors, actual steering errors of the generator, and whether the rotational speed and torque control instructions are parsed incorrectly can be identified, greatly reducing the risk of the engine being dragged in reverse and improving the fault troubleshooting efficiency. When it is detected that the first rotational speed signal is reverse, the system responds quickly, cuts off the high voltage emergently through the vehicle controller, prevents potential safety problems caused by abnormal operation of the generator, and at the same time sends the first error message to remind the operator to pay attention to possible abnormal torque control or rotational speed signal errors of the generator. If the first rotational speed signal is forward, the system further obtains the second rotational speed signal, and according to the synchronization state of the engine and the generator, sends the second error message or the third error message respectively to accurately indicate the abnormal type of the working state of the generator. This detailed error identification and hierarchical alarm mechanism greatly improves the safety and reliability of the power generation system of the range-extended hybrid vehicle. During the actual operation of the generator, the accuracy of the rotational speed signal and the stability of the torque control are the keys to ensuring the efficient and safe operation of the system. By monitoring the rotational speed signal in real time and identifying potential errors, the system can react quickly, avoid the generator from continuing to operate in an abnormal state, and thus effectively prevent safety accidents that may be caused by generator failures. At the same time, the design of the hierarchical alarm mechanism enables the operator to quickly locate the abnormal type of the working state of the generator according to different error messages, and then take corresponding treatment measures, ensuring the stable operation of the vehicle and the safety of passengers.

[0069] In some embodiments, in order to further eliminate various errors (generator nominal steering error, generator actual steering error), step S40 is refined to include the following sub-steps S401 - sub-step S403.

[0070] Sub-step S401: Obtain the first rotational speed signal.

[0071] Sub-step S402: When the first rotational speed signal is reverse, send an emergency high-voltage cut-off command to the vehicle controller and send a fourth error message indicating that the generator feedback steering is incorrect.

[0072] Sub-step S403: When the first rotational speed signal is forward, obtain the second rotational speed signal. And when the first rotational speed signal and the second rotational speed signal are reverse synchronous signals, send an emergency high-voltage cut-off command to the vehicle controller and send a fifth error message indicating that the actual steering of the generator is incorrect. And when the first rotational speed signal and the second rotational speed signal are forward synchronous signals, end the process and send a third notification message indicating that the rotation direction is correct. And when the first rotational speed signal and the second rotational speed signal are in the same direction but non-synchronous signals, send an emergency high-voltage cut-off command to the vehicle controller and send a seventh error message indicating that the engine synchronous signal is abnormal.

[0073] Among them, by identifying the reverse "synchronous" signal (the second rotational speed signal) of the engine running in reverse and combining the working state of the generator, the working state of the generator is comprehensively judged. Through sub-step S401 - sub-step S403, precise monitoring and processing of the generator rotational speed signal are realized. This refined step not only improves the response speed and accuracy of the system, but also effectively avoids potential safety hazards caused by abnormal rotational speed signals. In practical applications, when the rotational speed signal of the engine is reverse, the system can quickly identify and take corresponding emergency measures, such as the high-voltage cut-off command, to prevent accidents caused by abnormal power of the vehicle. At the same time, for the situation where the rotational speed signals are in the same direction but not synchronous, the system can also remind the operator by sending error messages to ensure that the operating state of the generator is always within the controllable range. Such a design not only improves the safety of the vehicle, but also provides a more convenient and efficient means for the operator to troubleshoot faults.

[0074] Next, taking a six-cylinder engine as an example, the engine synchronous signal judgment mechanism is described.

[0075] First, the engine controller ECU captures the falling edge moment of each tooth on the engine flywheel through the crankshaft signal sensor. Based on the moment of the falling edge of the current tooth minus the moment of the falling edge of the previous tooth, the time interval between the current two teeth can be obtained. Compare the time interval of the current tooth with the time interval of the previous tooth. If the threshold condition of missing teeth is met, it is judged that the current tooth is a missing tooth, that is, tooth No. 0, and record the current missing tooth moment T CrankZero , and number the teeth after the missing tooth as 1...57. From the current tooth No. 0 moment T CrankZero and the previous tooth No. 0 moment T CrankZero0 the engine rotational speed (the second rotational speed signal) calculated by the crankshaft can be obtained.

[0076] The mechanism for identifying synchronous teeth and numbering tooth numbers of the camshaft signal is that the engine controller ECU captures the moment of the falling edge of each tooth through the camshaft speed sensor, and subtracts the moment of the falling edge of the previous tooth from the moment of the falling edge of the current tooth to obtain the time interval of the current tooth. Compare the time interval of the current tooth with the time interval of the previous tooth. If the judgment threshold condition of the synchronous tooth is met, the current tooth is judged as the synchronous tooth, that is, tooth No. 0, and the teeth after the synchronous tooth are numbered 1...6. The engine speed calculated by the camshaft can be obtained from the moment of the current synchronous tooth and the moment of the previous synchronous tooth.

[0077] Figure 4 FIG. is a schematic diagram of the positions of missing teeth and synchronous teeth in the forward synchronous signal provided by at least one embodiment of the present disclosure. As Figure 4 shown, the mechanism for identifying the synchronous signal is to compare the synchronous teeth of the camshaft with the crankshaft teeth at the current moment. If the tooth number of the crankshaft is within the allowable range, it is considered that the synchronous signal is correct, that is, the engine controller ECU finds the synchronous signal, otherwise it is considered that the synchronous signal is incorrect.

[0078] The following describes the judgment mechanism of the reverse synchronous signal.

[0079] The mechanism for identifying missing teeth and numbering tooth numbers of the crankshaft signal is the same as that of the forward synchronous signal.

[0080] The mechanism for identifying synchronous teeth and numbering tooth numbers of the camshaft signal disk is the same, but because of the reverse rotation, the judgment method is slightly different. That is, subtract the moment of the falling edge of the previous tooth from the moment of the falling edge of the current tooth to obtain the time interval of the current tooth, and compare the current time interval with the time interval of the previous tooth. If the judgment threshold condition of the synchronous tooth is met, the tooth before the current tooth is judged as the synchronous tooth, that is, tooth No. 0. Number the current tooth and the subsequent teeth 1...6.

[0081] Figure 5 FIG. is a schematic diagram of the positions of missing teeth and synchronous teeth in the reverse synchronous signal provided by at least one embodiment of the present disclosure. The mechanism for identifying the reverse synchronous signal is to compare the synchronous teeth of the camshaft with the crankshaft teeth at the current moment. If the tooth number of the crankshaft is within a specific range (such as the crankshaft tooth number is between 48 and 50), it is considered reverse synchronization, that is, it is judged that the engine is running in reverse.

[0082] In some embodiments, in order to prevent system cycling, the range extender system controller is built with a commutating instruction sending times recorder, and this process further includes the following steps S60-step S80.

[0083] Step S60: While sending the commutating instruction, increment the number of commutating instructions sent recorded in the commutating instruction sending times recorder by one.

[0084] Step S70: In response to the number of commutation instruction transmissions not exceeding the set threshold, when the range extender system is connected to high-voltage power supply and the vehicle has a power generation demand, re-enter a new round of processes to adaptively match the rotations of the engine and the generator.

[0085] Step S80: In response to the number of commutation instruction transmissions exceeding the set threshold, send out a sixth error message indicating that there is a fault in the range extender system controller, and perform a clearing operation on the number of commutation instruction transmissions.

[0086] Among them, through steps S60 - S80, fault detection of the range extender system controller that still cannot correctly match the rotations of the engine and the generator after multiple commutation attempts is achieved. This mechanism effectively avoids energy waste and potential system damage caused by continuous incorrect matching. After step S80 is executed, system administrators or maintenance personnel can perform corresponding fault diagnosis and repair based on the sixth error message to ensure that the range-extended hybrid vehicle can generate electricity stably and efficiently. In addition, through the clearing operation on the number of commutation instruction transmissions, a clear starting point is provided for subsequent commutation attempts, ensuring the continuity and accuracy of the control logic.

[0087] Figure 6 This is an example flowchart of a control method for a range-extended hybrid vehicle provided by at least one embodiment of the present disclosure. As Figure 6 shown, if the correctness of the motor rotation direction and other abnormal information have not been confirmed, when the range extender system controller RCU has powered on the high voltage and the vehicle controller VCU has a power generation request, the range extender system controller RCU first sends an instruction to the generator controller GCU that both the power generation torque and the speed are 0. The range extender system controller RCU determines whether the generator is running. If it is not running, jump to 1). If it is running, jump to 2).

[0088] 1) If the generator is not running, the range extender system controller RCU sends a command to the generator controller GCU with a torque of 0 Nm and a speed of 10 rpm. At this time, the range extender system controller RCU determines the rotation direction of the generator. If it is reverse rotation (the speed is negative), the range extender system controller RCU sends an emergency high-voltage cut-off command to the vehicle controller VCU (after receiving this command, the vehicle controller VCU needs to disconnect from the high-voltage power supply), and reports an error, indicating that the generator feedback steering signal is incorrect. If the generator is rotating forward (the speed is positive), the engine synchronization signal is further determined. At this time, if the engine synchronization signal is reverse synchronization, the range extender system controller RCU sends an emergency high-voltage cut-off command to the vehicle controller VCU and reports an error, indicating that the actual steering signal of the generator is incorrect. Otherwise, it is further determined whether the engine is in forward synchronization. If not (no synchronization, that is, neither forward synchronization nor reverse synchronization), the range extender system controller RCU sends an emergency high-voltage cut-off command to the vehicle controller VCU and reports an error, indicating that the engine synchronization signal is abnormal. If the engine synchronization signal is in forward synchronization, it is confirmed that the rotation directions of the engine and the generator are correct and there is no abnormality, and the normal power generation process can be entered.

[0089] 2) If the generator is running, it is further determined whether the motor sends a forward rotation speed signal. If not (the speed is negative), the range extender system controller RCU sends an emergency high-voltage cut-off command to the vehicle controller VCU and reports an error, indicating that the motor feedback steering is incorrect and the generator identification speed or torque control command is abnormal. If so (the transmitted speed is positive), it is further determined whether the engine synchronization signal is reverse synchronization. If so (reverse synchronization), the range extender system controller RCU sends an emergency high-voltage cut-off command to the vehicle controller VCU and reports an error, indicating that the actual steering of the generator is incorrect and the generator identification speed or torque control command is abnormal. If not, it is further determined whether the engine is in forward synchronization. If not (no synchronization, that is, neither forward synchronization nor reverse synchronization), the range extender system controller RCU sends an emergency high-voltage cut-off command to the vehicle controller VCU and reports an error, indicating that the engine synchronization signal is abnormal and the generator identification speed or torque control command is abnormal. If so (forward synchronization), the range extender system controller RCU sends an emergency high-voltage cut-off command to the vehicle controller VCU and reports an error, indicating that the steering has been confirmed to be correct, but the generator identification speed or torque control command is abnormal.

[0090] Figure 7 The block diagram of a power generation control system for a range-extended hybrid vehicle provided by at least one embodiment of the present disclosure. The vehicle includes a range extender system composed of an engine, a starter, a generator, an engine controller, and a generator controller. The system includes a first subsystem for adaptively matching the steering directions of the engine and the generator. As Figure 7As shown, the power generation control system 1 of the range-extended hybrid vehicle includes a first subsystem composed of a preprocessing unit 10, a state recognition unit 20, a first control unit 30, and a second control unit 40.

[0091] The preprocessing unit 10 is configured to send a first control instruction for setting the torque and speed of the generator to zero to the generator controller when the range extender system is connected to high-voltage power supply and the vehicle has a power generation demand.

[0092] The state recognition unit 20 is configured to identify whether the generator is in an operating state after responding to the first control instruction.

[0093] The first control unit 30 is configured to disconnect the range extender system from the high-voltage power supply (emergency high voltage) when the generator is in an operating state. The first control unit 30 includes a first controller and a first actuator, and the first actuator can be, but is not limited to, a switch provided on the power supply branch.

[0094] The second control unit 40 is configured to send a second control instruction for setting the torque or fuel injection amount of the generator to zero and starting the starter to the generator controller when the generator is in a non-operating state, obtain the first speed signal of the generator and the second speed signal of the engine, complete adaptive matching when the first speed signal and the second speed signal are positive synchronous signals, and control the range extender system to start generating power. The second control unit 40 includes a second controller and a second actuator, and the second actuator can be, but is not limited to, a power transmission device on the power transmission path between the generator and the engine, such as a throttle.

[0095] The specific ways of performing operations by each unit in the above system embodiments have been described in detail in the embodiments related to the method, and will not be elaborated here.

[0096] The embodiments of the present disclosure also provide a storage medium storing a program or instructions, and the program or instructions, when executed by a processor, implement the steps of the above method embodiments.

[0097] The embodiments of the present disclosure also provide a program product, as Figure 8 shown, the program product includes one or more processors 21 and a memory 22, Figure 8 taking one processor 21 as an example.

[0098] The controller may further include: an input device 23 and an output device 24.

[0099] The processor 21, the memory 22, the input device 23, and the output device 24 may be connected through a bus or other means, Figure 8 taking connection through a bus as an example.

[0100] The processor 21 may be a Central Processing Unit (CPU for short), or the processor 21 may also be other general-purpose processors, Digital Signal Processors (DSP for short), Application Specific Integrated Circuits (ASIC for short), Field-Programmable Gate Arrays (FPGA for short), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc., or a combination of the above types of chips. The general-purpose processor may be a microprocessor or any conventional processor.

[0101] The memory 22, as a non-transitory computer-readable storage medium, can be used to store non-transitory software programs, non-transitory computer-executable programs, and modules, such as the program instructions / modules corresponding to the methods in the embodiments of the present disclosure. The processor 21 executes various functional applications and data processing of the server by running the non-transitory software programs, instructions, and modules stored in the memory 22, that is, implements the steps of the above method embodiments.

[0102] The memory 22 may include a program storage area and a data storage area. Among them, the program storage area can store an operating system and application programs required for at least one function; the data storage area can store data created according to the use of the processing device of the server operation, etc. In addition, the memory 22 may include high-speed random access memory, and may also include non-transitory memory, such as at least one magnetic disk storage device, flash memory device, or other non-transitory solid-state storage devices. In some embodiments, the memory 22 may optionally include a memory remotely set relative to the processor 21, and these remote memories can be connected to the network connection device through a network. Examples of the above networks include, but are not limited to, the Internet, enterprise intranets, local area networks, mobile communication networks, and combinations thereof.

[0103] The input device 23 can receive input digital or character information, and generate key signal inputs related to the user settings and function controls of the processing device of the server. The output device 24 may include a display device such as a display screen.

[0104] One or more modules are stored in the memory 22, and when executed by one or more processors 21, they execute the method as Figure 1 shown.

[0105] Those skilled in the art can understand that to implement all or part of the processes in the above method embodiments, it can be completed by instructing relevant hardware through a computer program. The program can be stored in a computer-readable storage medium. When the program is executed, it can include the processes in the above method embodiments. Among them, the storage medium can be a magnetic disk, an optical disk, a read-only memory (ROM for short), a random access memory (RAM for short), a flash memory (FM for short), a hard disk drive (HDD for short), or a solid-state drive (SSD for short), etc.; the storage medium can also include a combination of the above types of memories.

[0106] Although the embodiments of the present disclosure have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present disclosure, and such modifications and variations all fall within the scope defined by the appended claims.

[0107] Although the embodiments of the present disclosure have been shown and described above, it can be understood that the above embodiments are exemplary and should not be construed as limiting the present disclosure. Those of ordinary skill in the art can make changes, modifications, substitutions, and variations to the above embodiments within the scope of the present disclosure.

Claims

1. A power generation control method for a range-extended hybrid vehicle, the vehicle comprising a range-extended system consisting of an engine, a starter, an engine controller, a generator, and a generator controller, characterized in that, The method includes a process of adaptively matching the rotations of the engine and the generator in the range extender system, and the process includes: When the range extender system is connected to high-voltage power supply and the vehicle has a power generation demand, sending a first control command to the generator controller to set the torque and speed of the generator to zero; Identifying whether the generator is in an operating state after responding to the first control command; When the generator is in an operating state, disconnecting the range extender system from the high-voltage power supply; and, When the generator is in a non-operating state, sending a second control command to the generator controller to set the torque or fuel injection amount of the generator to zero and start the starter, obtaining a first speed signal of the generator and a second speed signal of the engine, and when the first speed signal and the second speed signal are positive synchronous signals, ending the process and controlling the range extender system to start generating electricity.

2. The method according to claim 1, wherein The process further includes: When the first speed signal and the second speed signal are not positive synchronous signals, sending a starter stop work command to the engine controller and a commutation command to the generator controller, so that the starter stops working and the generator switches the rotation direction angle, and obtaining the first speed signal and the second speed signal again until the first speed signal and the second speed signal are positive synchronous signals.

3. The method according to claim 1 or 2, characterized in that, The vehicle further includes a range extender system controller and a vehicle controller, and the method includes: Predicting the power generation demand through the vehicle controller and transmitting the power generation demand to the range extender system controller, so that the range extender system controller generates the first control command based on the power generation demand; and, Monitoring the power generation parameters of the generator through the range extender system controller, obtaining the error message of the range extender system, and transmitting the power generation parameters and the error message to the vehicle controller.

4. The method according to claim 1 or 2, characterized in that The method further includes: Determining whether the process has been executed before the current moment and there is no abnormality; If so, ending the process and generating a first notification message for indicating that there is no need to adaptively match the rotations of the engine and the generator; and, If not, starting the process and generating a second notification message for indicating entering the rotation adaptive matching of the engine and the generator.

5. The method according to claim 1 or 2, characterized in that, The step of, when the range extender system is connected to high-voltage power supply and the vehicle has a power generation demand, sending a first control command to the generator controller to set the torque and speed of the generator to zero, includes: Identifying whether the range extender system is connected to high-voltage power supply; If so, sending the first control command to the generator controller when the vehicle has a power generation demand; and, If not, continuing to identify whether the range extender system is connected to high-voltage power supply at the next moment.

6. The method according to claim 3, characterized in that The step of, when the generator is in an operating state, disconnecting the range extender system from the high-voltage power supply, includes: Obtaining the first speed signal; When identifying that the first speed signal is reverse, sending an emergency high-voltage disconnection command to the vehicle controller and sending a first error message; When the first rotational speed signal is identified as positive, obtain the second rotational speed signal. And when the first rotational speed signal and the second rotational speed signal are positive synchronous signals, send an emergency high-voltage cut-off instruction to the vehicle controller, and send a second error message. And when the first rotational speed signal and the second rotational speed signal are reverse synchronous signals, send a third error message.

7. The method according to claim 3, wherein When the first rotational speed signal and the second rotational speed signal are positive synchronous signals, ending the process includes: Obtain the first rotational speed signal; In response to the first rotational speed signal being reverse, send an emergency high-voltage cut-off instruction to the vehicle controller, and send a fourth error message; In response to the first rotational speed signal being positive, obtain the second rotational speed signal. And when the first rotational speed signal and the second rotational speed signal are reverse synchronous signals, send an emergency high-voltage cut-off instruction to the vehicle controller, and send a fifth error message. And when the first rotational speed signal and the second rotational speed signal are positive synchronous signals, end the process, and send a third notification message indicating that the first rotational speed signal and the second rotational speed signal are correctly matched.

8. The method according to claim 3, characterized in that, The range extender system controller is internally provided with a commutation instruction sending times recorder, and the method further includes: When sending a commutation instruction, perform an increment operation on the commutation instruction sending times recorded in the commutation instruction sending times recorder; In response to the commutation instruction sending times not exceeding a set threshold, when the range extender system is connected to high-voltage power supply and the vehicle has a power generation demand, re-enter a new round of the process to adaptively match the rotations of the engine and the generator; In response to the commutation instruction sending times exceeding the set threshold, send a sixth error message indicating that there is a fault in the range extender system controller, and perform a clearing operation on the commutation instruction sending times.

9. A power generation control system for a range-extended hybrid vehicle, the vehicle comprising a range-extended system consisting of an engine, a starter, a generator, an engine controller, and a generator controller, characterized in that, The power generation control system includes a first subsystem for adaptively matching the rotations of the engine and the generator. The first subsystem includes: A preprocessing unit configured to send a first control instruction for setting the torque and rotational speed of the generator to zero to the generator controller when the range extender system is connected to high-voltage power supply and the vehicle has a power generation demand; A state identification unit configured to identify whether the generator is in an operating state after responding to the first control instruction; A first control unit configured to disconnect the range extender system from the high-voltage power supply when the generator is in an operating state; A second control unit configured to send a second control instruction for setting the torque or fuel injection amount of the generator to zero and starting the starter to the generator controller when the generator is in a non-operating state, obtain the first rotational speed signal of the generator and the second rotational speed signal of the engine, and when the first rotational speed signal and the second rotational speed signal are positive synchronous signals, complete the adaptive matching and control the range extender system to start generating electricity.

10. A storage medium, characterized in that, The storage medium stores a program or instruction, and the program or instruction, when executed by a processor, implements the steps of the method according to any one of claims 1 to 8.

11. A program product, comprising a program or instructions, characterized in that, The steps of the method according to any one of claims 1 to 8 are implemented when the program or instruction is executed by a processor.

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