A range extender power package device and a control method of an integrated thermal management device thereof

Abstract

The application provides a range extender power pack device and a control method of an integrated thermal management device, which comprises an engine auxiliary device, a power pack interface device, a range extender system and an integrated thermal management device; wherein the engine auxiliary device is connected with the range extender system to provide fuel supply and air supply for the range extender system, and to process exhaust gas of the range extender system; the power pack interface device is connected with the range extender system to provide low-voltage power supply and low-voltage signals for the range extender system, and to connect a high-voltage bus of the range extender system to a whole vehicle device; the integrated thermal management device is connected with the range extender system to realize cooling for the range extender system; through intelligent and efficient integrated control, the integrated thermal management device can accurately and intelligently control an electronic water pump and an electronic fan according to temperature data of a heat dissipation system to adjust the rotating speed and working condition of the water pump and the fan, improve energy utilization efficiency and fuel power conversion efficiency, and prolong the service life of the electronic fan and the water pump.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of range extender power pack devices and integrated thermal management devices thereof, and in particular to a control method for a range extender power pack device and integrated thermal management device thereof. BACKGROUND

[0002] Commercial vehicles and off-road engineering machinery, such as heavy trucks, excavators, loaders, and mine trucks, have always used diesel engines as power sources. With the increasing importance of environmental protection, power machinery in these fields needs to be gradually electrified to meet the increasingly stringent requirements of emission regulations. Therefore, in recent years, the pure electric drive technology of commercial vehicles and off-road engineering machinery has developed rapidly, and the number of vehicles and the penetration rate have increased rapidly. However, pure electric vehicles have problems such as insufficient range, non-uniform charging interfaces, slow charging speed, insufficient fast charging facilities, uneven distribution of charging piles, lack of special charging stations, battery degradation, imperfect recycling system, poor environmental adaptability, temperature and terrain restrictions, lack of industry standards, and subsidy reduction.

[0003] Commercial vehicles and off-road engineering machinery vehicles have the characteristic of long continuous working time, and adding a set of range extender system based on pure electric drive is very practical. The range extender system provides additional power when the battery is low, significantly extending the range and reducing the charging frequency; it is particularly suitable for long-distance transportation and long-time operation, reducing range anxiety. The range extender operates in the high-efficiency range, improving overall energy utilization efficiency; through intelligent control, the range extender operates in the best working condition, reducing energy waste. The range extender can use various energy sources such as fuel and natural gas, improving the flexibility of energy selection; in areas where charging facilities are insufficient, the range extender provides additional power to ensure the normal operation of vehicles and machinery. The presence of the range extender can reduce the dependence on battery capacity and reduce battery costs; compared with pure electric systems, the addition of the range extender is more cost-effective in initial investment. The range extender supplements power, reduces charging frequency, and improves operational efficiency; in cases where charging is not convenient, the range extender ensures continuous operation of equipment and reduces downtime. The range extender operates in the high-efficiency range, reducing tail gas emissions and meeting environmental protection requirements; as a technology for the transition from traditional fuel vehicles to pure electric vehicles, the range extender helps to gradually achieve emission reduction targets. The range extender serves as a backup power source, providing power in the event of a main power failure, improving system reliability; in emergency situations, the range extender ensures that vehicles and machinery can continue to operate. In heavy loads or complex working conditions, the range extender provides additional power to ensure normal operation of equipment; in extreme environments or remote areas, the range extender provides stable power, reducing dependence on charging facilities. The range extender reduces the number of deep discharges of the battery, extending the life of the battery; through intelligent management, the range extender optimizes the battery charging and discharging cycle, improving the life of the battery.

[0004] The power pack based on the range extender system has the characteristics of high integration, light weight and small volume, and high reliability, facilitates the modification of existing vehicles in the stock market, controls the vehicle modification range in a relatively small range, reduces the modification cost, effectively shortens the modification period, and quickly realizes and solves the problems existing in pure electric vehicles.

[0005] However, the combination of existing commercial vehicles and non-road engineering machinery with the range extender system still has the following defects and deficiencies:

[0006] 1) Large space occupation, heavy weight and large volume, low integration, unable to control and adjust the corresponding speed and working conditions of the electronic water pump and the electronic fan according to the real-time temperature data of the heat dissipation system, so that the range extender power pack device has high energy consumption, low energy utilization efficiency, and shortens the service life of the electronic fan and the water pump;

[0007] 2) Low human-vehicle interaction, limited applicability and practicality for complex working conditions and specific scenes;

[0008] 3) High cable modification cost and long cycle for connecting the range extender system.

[0009] Therefore, there is an urgent need to provide a new scheme to solve the defects and deficiencies in the prior art. SUMMARY

[0010] In order to solve the defects and deficiencies in the prior art, the present application provides a range extender power pack device and a control method of an integrated thermal management device thereof.

[0011] The specific scheme provided by the present application is:

[0012] A range extender power pack device, characterized in that: the range extender power pack device comprises an engine auxiliary device, a power pack interface device, a range extender system and an integrated thermal management device; wherein,

[0013] The engine auxiliary device is connected with the range extender system to provide fuel supply and air supply for the range extender system, and to process the exhaust gas of the range extender system;

[0014] The power pack interface device is connected with the range extender system to provide low-voltage power supply and low-voltage signals for the range extender system while connecting the high-voltage bus of the range extender system to the vehicle device;

[0015] The integrated thermal management device is connected with the range extender system to realize cooling for the range extender system.

[0016] As a further preferred embodiment of the present application, the engine auxiliary device comprises a diesel tank, an air cleaner, a diesel filter and an aftertreatment system; wherein,

[0017] The diesel filter is connected to the range extender system via a fuel line to provide the required fuel supply to the engine in the range extender system, and the diesel fuel tank is connected to the diesel filter to provide fuel to the diesel filter.

[0018] The air filter is connected to the range extender system via an intake pipe to provide the necessary air supply to the engine in the range extender system.

[0019] The aftertreatment system is connected to the range extender system via an exhaust pipe to treat the exhaust gas from the engine in the range extender system.

[0020] As a further preferred embodiment of the present invention, the power pack interface device includes a 24V power supply plug, a power pack control device, and a power pack high-voltage distribution box; wherein...

[0021] The 24V power supply plug is connected to the vehicle unit at one end and to the range extender system at the other end to provide low-voltage power to the range extender system.

[0022] The power pack control device is connected to the vehicle unit at one end and to the range extender system at the other end to provide a low-voltage signal to the range extender system.

[0023] The high-voltage distribution box of the power pack is connected to the vehicle unit and the range extender system respectively, so that the high-voltage bus of the vehicle unit and the range extender system are integrated and then connected to the vehicle unit.

[0024] As a further preferred embodiment of the present invention, the vehicle assembly includes a 24V vehicle battery, a vehicle control panel, a battery high-voltage distribution box, and a vehicle high-voltage distribution box; wherein...

[0025] The vehicle's 24V battery is connected to the 24V power supply plug to provide power to the 24V power supply plug;

[0026] The vehicle control panel is connected to the power pack control device to provide a control environment for the power pack control device;

[0027] The battery high-voltage distribution box and the vehicle high-voltage distribution box are respectively connected to the power pack high-voltage distribution box. After the power pack high-voltage distribution box is connected to the high-voltage bus of the battery high-voltage distribution box and the high-voltage bus of the range extender system, the high-voltage bus is integrated and then the integrated high-voltage bus is connected to the vehicle high-voltage distribution box.

[0028] As a further preferred embodiment of the present invention, the integrated thermal management device includes an electric fan and shroud, an engine intercooler radiator, an engine coolant radiator, a generator coolant radiator, and a generator electric water pump; wherein...

[0029] The electronic fan and fan cover control the blowing or suction of air to the engine's intercooled air radiator, engine coolant radiator, and generator coolant radiator.

[0030] The engine intercooler air radiator is connected to the range extender system through the engine intercooler pipe to cool the high-temperature air of the engine in the range extender system.

[0031] The engine coolant radiator is connected to the range extender system via engine water cooling pipes to cool the circulating coolant of the engine in the range extender system.

[0032] The generator coolant radiator is connected to the range extender system via water-cooled pipes to cool the circulating cooling water of the generator controller and generator in the range extender system.

[0033] The generator electric water pump is connected to the generator coolant radiator to drive the circulating cooling water therein.

[0034] In a further preferred embodiment of the present invention, the range extender system includes a range extender controller, an engine controller, an engine, a generator controller, and a generator; wherein...

[0035] The engine is connected to the air filter via an intake pipe to receive air from the air filter; the engine is connected to the diesel filter via a fuel line to receive fuel from the diesel filter; and the engine is connected to the aftertreatment system via an exhaust pipe to discharge exhaust gas to the aftertreatment system for processing before discharge.

[0036] The range extender system is connected to a 24V power supply plug to receive the low-voltage power supply provided by it, the range extender system is connected to a power pack control device to receive the low-voltage signal provided by it, and the range extender system is connected to the power pack high-voltage distribution box to connect the integrated high-voltage bus to the high-voltage distribution box through the power pack high-voltage distribution box.

[0037] The engine and the engine intercooler are connected through engine intercooler pipes to cool the high-temperature air. The engine and the engine coolant radiator are connected through engine water cooling pipes to cool the engine's circulating cooling water. The interconnected generator controller and generator are connected to the generator coolant radiator through water cooling pipes to cool the generator's circulating cooling water.

[0038] The range extender controller is connected to the integrated thermal management device to control the electric fan and generator electric water pump in the integrated thermal management device.

[0039] The engine controller is connected to the engine to perform corresponding control of the engine.

[0040] Furthermore, the present invention also provides a control method for an integrated thermal management device in a range extender power pack, wherein the integrated thermal management device is provided with a first electronic fan, a second electronic fan, a third electronic fan, and a fourth electronic fan; wherein,

[0041] When the cooling demand is met, the first electric fan can be turned on independently to cool the engine coolant radiator 43 and the engine intercooler air radiator 42; when the cooling demand is not met, the first electric fan and the second electric fan are turned on simultaneously to cool the engine coolant radiator 43 and the engine intercooler air radiator 42.

[0042] When the cooling demand is met, the third electric fan is turned on alone to cool the generator coolant radiator 44; when the cooling demand is not met, the third and fourth electric fans are turned on simultaneously to cool the generator coolant radiator 44.

[0043] Its characteristics include the following steps:

[0044] S1: Input real-time detected temperature, which includes at least engine coolant temperature, engine intake air temperature, generator temperature and generator controller temperature;

[0045] S2: Determine whether the real-time detected engine coolant temperature is higher than the preset threshold. If the determination result is that the engine coolant temperature is higher than the preset threshold, proceed to the next step.

[0046] S3: The remote control unit calculates the duty cycle of the first electronic fan;

[0047] S4: The remote control unit sends a pulse width modulation command to the first electronic fan to directly control and adjust the duty cycle of the first electronic fan;

[0048] S5: Determine whether the real-time detected engine coolant temperature is lower than the preset threshold. If the determination result is that the engine coolant temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S3.

[0049] S6: Put the first electronic fan into standby mode;

[0050] S7: Determine if there is a fault in the integrated thermal management device. If a fault exists, report the fault information to the remote control unit; if there is no fault, report no fault information to the remote control unit.

[0051] S8: Put the integrated thermal management device into standby mode.

[0052] As a further preferred embodiment of the present invention, in step S2, when the determination result is that the engine coolant temperature is not higher than a preset threshold, the following steps are also included:

[0053] S21: Determine whether the real-time detected engine intake air temperature is higher than the preset threshold. If the determination result is that the engine intake air temperature is higher than the preset threshold, proceed to the next step.

[0054] S31: Determine whether the linkage condition of the first electronic fan and the second electronic fan is met. If the determination result is yes, proceed to the next step; otherwise, proceed to step S71.

[0055] S41: The remote control unit calculates the duty cycle of the second electric fan;

[0056] S51: The remote control unit sends a pulse width modulation command to the second electric fan to directly control and adjust the duty cycle of the second electric fan;

[0057] S61: Determine whether the real-time detected engine intake air temperature is lower than a preset threshold. If the determination result is that the engine intake air temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S41.

[0058] S71: Put the second electronic fan into standby mode, and then proceed to step S7.

[0059] As a further preferred embodiment of the present invention, in step S21, when the determination result is that the engine intake air temperature is not higher than a preset threshold, the following step is also included:

[0060] S22: Determine whether the real-time detected generator temperature is higher than the preset threshold. If the determination result is that the generator temperature is higher than the preset threshold, proceed to the next step.

[0061] S32: The remote control unit calculates the duty cycle of the third electronic fan;

[0062] S42: The remote control unit sends a pulse width modulation command to the third electric fan to directly control and adjust the duty cycle of the third electric fan;

[0063] S52: Determine whether the real-time detected generator temperature is lower than a preset threshold. If the determination result is that the generator temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S32.

[0064] S62: Put the third electronic fan into standby mode, and then proceed to step S7.

[0065] As a further preferred embodiment of the present invention, in step S22, when the determination result is that the generator temperature is not higher than a preset threshold, the following step is also included:

[0066] S23: Determine whether the real-time detected generator controller temperature is higher than the preset threshold. If the determination result is that the generator controller temperature is higher than the preset threshold, proceed to the next step.

[0067] S33: Determine whether the linkage condition between the third electronic fan and the fourth electronic fan is met. If the result is yes, proceed to the next step; otherwise, proceed to step S73.

[0068] S43: The remote control unit calculates the duty cycle of the fourth electronic fan;

[0069] S53: The remote control unit sends a pulse width modulation command to the fourth electronic fan to directly control and adjust the duty cycle of the fourth electronic fan;

[0070] S63: Determine whether the real-time detected generator controller temperature is lower than the preset threshold. If the determination result is that the generator controller temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S43.

[0071] S73: Put the fourth electronic fan into standby mode, and then proceed to step S7;

[0072] The linkage condition between the first electronic fan and the second electronic fan is: if the first electronic fan alone cannot meet the cooling demand, the second electronic fan needs to be turned on.

[0073] The linkage condition between the third and fourth electronic fans is: if the cooling demand cannot be met by the third electronic fan alone, the fourth electronic fan needs to be turned on.

[0074] Compared with existing technologies, the technical effects that this invention can achieve include:

[0075] 1) This invention provides a control method for a range extender power pack device and its integrated thermal management device, which features high integration, light weight and small size, and higher reliability. Through intelligent and efficient integrated control, the integrated thermal management device can accurately and intelligently control the electric water pump and electric fan according to the temperature data of the heat dissipation system to adjust the speed and operating conditions of the water pump and fan, reduce noise and vibration, and quickly respond to temperature control, thereby reducing the energy consumption of the range extender power pack device, improving energy utilization efficiency and fuel power generation conversion efficiency, and extending the life of the electric fan and water pump.

[0076] 2) This invention provides a control method for a range extender power pack device and its integrated thermal management device. The vehicle cab is equipped with a control panel, and the driver can actively control the operating conditions and power generation of the range extender power pack device through the power pack control device. It has high human-vehicle interaction, precise power control, maximizes efficiency, can cope with complex working conditions, adapt to different application scenarios and has practicality for specific scenarios, and extends the service life of the range extender power pack.

[0077] 3) This invention provides a control method for a range extender power pack device and its integrated thermal management device. Without changing the original vehicle architecture, the range of vehicle modifications is controlled within a small range through the high-voltage distribution box of the power pack, so as to achieve seamless connection of the high-voltage bus of the range extender system to the vehicle, improve vehicle adaptability, reduce modification costs, and shorten the modification cycle. Attached Figure Description

[0078] Figure 1 The above is a schematic diagram of the logical structure of the range extender power pack device of the present invention;

[0079] Figure 2 This is a schematic diagram of the connection structure of the power pack control device of the present invention;

[0080] Figure 3 This is a schematic diagram of the connection structure of the high-voltage distribution box of the power pack of the present invention;

[0081] Figure 4 This is a flowchart illustrating the steps of the integrated thermal management device control method of the present invention.

[0082] The attached figures are labeled as follows:

[0083] 1-Engine auxiliary equipment; 11-Diesel fuel tank; 12-Air filter; 13-Diesel filter; 14-Aftertreatment system; 2-Power pack interface device; 21-24V power supply plug; 22-Power pack control device; 23-Power pack high-voltage distribution box; 3-Range extender system; 31-Range extender controller; 32-Engine controller; 33-Engine; 34-Generator controller; 35-Generator; 4-Integrated thermal management device; 41-Electric fan and shroud; 42-Engine intercooler air radiator; 43-Engine coolant radiator; 44-Generator coolant radiator; 45-Generator electric water pump. Detailed Implementation

[0084] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0085] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0086] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0087] [First Embodiment]

[0088] like Figures 1-3 The image shows a range extender power pack device provided in the first embodiment of the present invention, such as... Figure 1 As shown, the range extender power pack includes an engine auxiliary device 1, a power pack interface device 2, a range extender system 3, and an integrated thermal management device 4. The engine auxiliary device 1 is connected to the range extender system 3 to provide fuel and air supply and to treat the exhaust gas of the range extender system 3. The power pack interface device 2 is connected to the range extender system 3 to provide low-voltage power and low-voltage signals while connecting the high-voltage bus of the range extender system 3 to the vehicle system. The integrated thermal management device 4 is connected to the range extender system 3 to cool it down.

[0089] like Figure 1 As shown, the engine auxiliary device 1 in this embodiment includes a diesel fuel tank 11, an air filter 12, a diesel filter 13, and an aftertreatment system 14. The diesel filter 13 is connected to the range extender system 3 via a fuel line to provide the required fuel supply to the engine 33 in the range extender system 3. The diesel fuel tank 11 is connected to the diesel filter 13 to provide fuel to the diesel filter 13. The air filter 12 is connected to the range extender system 3 via an intake line to provide the required air supply to the engine 33 in the range extender system 3. The aftertreatment system 14 is connected to the range extender system 3 via an exhaust line to treat the exhaust gas from the engine 33 in the range extender system 3 so that the exhaust gas meets national emission standards.

[0090] like Figures 1-2 As shown, the power pack interface device 2 in this embodiment includes a 24V power supply plug 21, a power pack control device 22, and a power pack high-voltage distribution box 23. The 24V power supply plug 21 is connected at one end to the vehicle unit and at the other end to the range extender system 3 to provide low-voltage power to the range extender system 3. The power pack control device 22 is connected at one end to the vehicle unit and at the other end to the range extender system 3 to provide low-voltage signals to the range extender system 3. The power pack high-voltage distribution box 23 is connected to both the vehicle unit and the range extender system 3 to integrate the high-voltage buses of both the vehicle unit and the range extender system 3 before connecting them to the vehicle unit.

[0091] Among them, such as Figures 1-2 As shown, in this embodiment, the vehicle device includes a 24V battery, a vehicle control panel, a battery high-voltage distribution box, and a vehicle high-voltage distribution box. The 24V battery is connected to a 24V power supply plug-in 21 to provide power to the plug-in 21. The vehicle control panel is connected to a power pack control device 22 to provide a control environment for the power pack control device 22. The battery high-voltage distribution box and the vehicle high-voltage distribution box are respectively connected to the power pack high-voltage distribution box 23. After the power pack high-voltage distribution box 23 is connected to the high-voltage bus of the battery high-voltage distribution box and the high-voltage bus of the range extender system 3, the high-voltage bus is integrated and then connected to the vehicle high-voltage distribution box.

[0092] like Figure 2 As shown, the power pack control device 22 in this embodiment includes at least a range extender start switch, a range extender power enable switch, a range extender power increase switch, and a range extender power decrease switch. The driver can achieve the following functions through signal processing by the power pack control device 22 by operating the vehicle control panel: the driver operates the range extender start switch to send a corresponding command to start the engine; the driver operates the range extender power enable switch to send a corresponding command to make the range extender generate electricity according to the calibrated operating conditions; the driver operates the range extender power increase switch, increasing the power generation power each time it is pressed; and the driver operates the range extender power decrease switch, decreasing the power generation power each time it is pressed.

[0093] like Figure 3 As shown, in this embodiment, the high-voltage distribution box 23 of the power pack is connected to the high-voltage bus B of the battery high-voltage distribution box, and at the same time connected to the high-voltage bus E of the range extender system 3. The connected high-voltage bus B and high-voltage bus E are integrated, and then the integrated high-voltage bus P is connected to the vehicle high-voltage distribution box.

[0094] like Figure 1As shown, the integrated thermal management device in this embodiment includes an electric fan and shroud 41, an engine intercooler radiator 42, an engine coolant radiator 43, a generator coolant radiator 44, and a generator electric water pump 45. The electric fan and shroud 41 control the blowing or suction of air from the engine intercooler radiator 42, engine coolant radiator 43, and generator coolant radiator 44 to reduce the temperature of the circulating water and intercooler air. The shroud guides airflow, improving heat dissipation efficiency and ensuring the efficient and stable operation of the thermal management system. The engine intercooler radiator 42 is connected to the range extender system 3 via engine intercooler piping for range extension. The engine 33 in the range extender system 3 is cooled by the high-temperature air from the turbocharger, improving intake efficiency; the engine coolant radiator 43 is connected to the range extender system 3 via engine water cooling pipes to cool the circulating cooling water of the engine 33 in the range extender system 3, preventing engine overheating and avoiding damage; the generator coolant radiator 44 is connected to the range extender system 3 via water cooling pipes to cool the circulating cooling water of the generator controller 34 and generator 35 in the range extender system 3, preventing the generator and electronic control system from overheating and ensuring efficient operation; the generator electric water pump 45 is connected to the generator coolant radiator 44 to drive the circulating cooling water therein.

[0095] like Figure 1 As shown, the range extender system 3 in this embodiment includes a range extender controller 31, an engine controller 32, an engine 33, a generator controller 34, and a generator 35. The range extender controller 31 is connected to an integrated thermal management device 4 to control the electric fan and the generator electric water pump 45 within the integrated thermal management device 4. The engine 33 is connected to the air filter 12 via an intake pipe to receive air from the air filter 12, and is connected to the diesel filter 13 via a fuel line to receive fuel from the diesel filter 13. The engine 33 is also connected to the aftertreatment system 14 via an exhaust pipe to discharge exhaust gas to the aftertreatment system 14 for processing before discharge. The range extender system 3 is connected to a 24V power supply plug 21 to receive low-voltage power from it. Low-voltage power supply: The range extender system 3 is connected to the power pack control device 22 to receive the low-voltage signal provided by it. The range extender system 3 is connected to the power pack high-voltage distribution box 23 to connect the integrated high-voltage bus to the high-voltage distribution box. The engine 33 is connected to the engine intercooler radiator 42 through the engine intercooler pipe to cool the high-temperature air. The engine 33 is connected to the engine coolant radiator 43 through the engine water cooling pipe to cool the circulating cooling water of the engine. The generator controller 34 and the generator 35 are connected to the generator coolant radiator 44 through water cooling pipes to cool the circulating cooling water of the generator. The engine controller 32 is connected to the engine 33 to control the engine 33 accordingly.

[0096] This embodiment provides a range extender power pack device suitable for commercial vehicles and off-road construction machinery. It integrates engine auxiliary components, a power pack interface device, the range extender system, and an integrated thermal management device into one unit. The entire vehicle only needs to provide low-pressure and high-pressure interfaces to achieve all control functions of the range extender system. On one hand, the range extender power pack integrates the engine intake system, engine exhaust system, engine fuel supply system, engine intercooler radiator, engine coolant radiator, and generator system coolant radiator. On the other hand, the power pack control device allows the driver to actively control the operating conditions and power generation of the range extender system, resulting in high human-vehicle interaction, precise power control, maximized efficiency, and the ability to handle complex operating conditions. Therefore, this range extender power pack specifically designed for commercial vehicles and off-road vehicles features high integration, light weight, small size, and higher reliability.

[0097] [Second Embodiment]

[0098] like Figure 4 As shown, the second embodiment of the present invention also provides a control method for the integrated thermal management device in the range extender power pack device mentioned in the first embodiment. In this embodiment, the control strategy of the integrated thermal management device 4 aims to minimize energy consumption. It is equipped with four first electronic fans AD and one electronic water pump. The range extender controller 31 performs intelligent and efficient independent control of the electronic fans and electronic water pump to extend their lifespan. Both the electronic fans and electronic water pump adopt PWM (pulse width modulation) control mode.

[0099] When the cooling demand is met, the first electric fan A can be turned on independently to cool the engine coolant radiator 43 and the engine intercooler air radiator 42 to save energy; when the cooling demand is not met, the first electric fan A and the second electric fan B are turned on simultaneously to cool the engine coolant radiator 43 and the engine intercooler air radiator 42 to help with cooling.

[0100] When the cooling demand is met, the third electric fan C is turned on alone to cool the generator coolant radiator 44 in order to save energy; when the cooling demand is not met, the third electric fan C and the fourth electric fan D are turned on simultaneously to cool the generator coolant radiator 44 in order to help with cooling.

[0101] The operating conditions of the first electronic fan A and the second electronic fan B are controlled according to the engine coolant temperature and the engine intake air temperature, and the operating conditions of the third electronic fan C and the fourth electronic fan D are controlled according to the generator temperature and the generator controller temperature. When the temperature is higher than the corresponding preset threshold, the corresponding electronic fan is controlled to work, and when the temperature is lower than the corresponding preset threshold, the electronic fan is controlled to standby mode and not work. And when the electronic fan is working, the higher the temperature, the higher the speed of the electronic fan is controlled.

[0102] It is also equipped with an electronic water pump, which adjusts its speed according to the generator temperature and the generator controller temperature; the higher the temperature, the higher the speed of the electronic water pump.

[0103] The control of each electronic fan in this embodiment includes the following steps:

[0104] S1: Input the real-time detected temperature, which includes at least the engine coolant temperature, engine intake air temperature, generator temperature, and generator controller temperature.

[0105] S2: Determine whether the real-time detected engine coolant temperature is higher than the preset threshold. If the determination result is that the engine coolant temperature is higher than the preset threshold, proceed to the next step.

[0106] S3: The remote control unit calculates the duty cycle of the first electronic fan A;

[0107] S4: The remote control unit sends a pulse width modulation command to the first electronic fan A to directly control and adjust the duty cycle of the first electronic fan A;

[0108] S5: Determine whether the real-time detected engine coolant temperature is lower than the preset threshold. If the determination result is that the engine coolant temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S3.

[0109] S6: Put the first electronic fan A into standby mode;

[0110] S7: Determine if there is a fault in the integrated thermal management device. If a fault exists, report the fault information to the remote control unit; if there is no fault, report no fault information to the remote control unit.

[0111] S8: Put the integrated thermal management device into standby mode.

[0112] In step S2, when the determination result is that the engine coolant temperature is not higher than the preset threshold, the following steps are also included:

[0113] S21: Determine whether the real-time detected engine intake air temperature is higher than the preset threshold. If the determination result is that the engine intake air temperature is higher than the preset threshold, proceed to the next step.

[0114] S31: Determine whether the linkage condition of the first electronic fan A and the second electronic fan B is met. If the result is yes, proceed to the next step; otherwise, return to step S71.

[0115] S41: The remote control unit calculates the duty cycle of the second electronic fan B;

[0116] S51: The remote control unit sends a pulse width modulation command to the second electronic fan B to directly control and adjust the duty cycle of the second electronic fan B;

[0117] S61: Determine whether the real-time detected engine intake air temperature is lower than a preset threshold. If the determination result is that the engine intake air temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S41.

[0118] S71: Put the second electronic fan B into standby mode, and then proceed to step S7;

[0119] In step S21, when the determination result is that the engine intake air temperature is not higher than a preset threshold, the following steps are also included:

[0120] S22: Determine whether the real-time detected generator temperature is higher than the preset threshold. If the determination result is that the generator temperature is higher than the preset threshold, proceed to the next step.

[0121] S32: The remote control unit calculates the duty cycle of the third electronic fan C;

[0122] S42: The remote control unit sends a pulse width modulation command to the third electronic fan C to directly control and adjust the duty cycle of the third electronic fan C;

[0123] S52: Determine whether the real-time detected generator temperature is lower than a preset threshold. If the determination result is that the generator temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S32.

[0124] S62: Put the third electronic fan C into standby mode, and then proceed to step S7;

[0125] In step S22, when the determination result is that the generator temperature is not higher than a preset threshold, the following steps are also included:

[0126] S23: Determine whether the real-time detected generator controller temperature is higher than the preset threshold. If the determination result is that the generator controller temperature is higher than the preset threshold, proceed to the next step.

[0127] S33: Determine whether the linkage condition between the third electronic fan C and the fourth electronic fan D is met. If the result is yes, proceed to the next step; otherwise, return to step S73.

[0128] S43: The remote control unit calculates the duty cycle of the fourth electronic fan D;

[0129] S53: The remote control unit sends a pulse width modulation command to the fourth electronic fan D to directly control and adjust the duty cycle of the fourth electronic fan D;

[0130] S63: Determine whether the real-time detected generator controller temperature is lower than the preset threshold. If the determination result is that the generator controller temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S43.

[0131] S73: Put the fourth electronic fan D into standby mode, and then proceed to step S7.

[0132] like Figure 5 As shown, the control process for the generator electronic water pump 45 includes the following steps:

[0133] T1: Input the real-time temperature, which includes the generator temperature and the generator controller temperature;

[0134] T2: Determine whether the generator temperature or generator controller temperature is higher than the preset threshold. If the result is that it is higher than the preset threshold, proceed to the next step.

[0135] T3: The remote control unit calculates the duty cycle of the generator electronic water pump 45;

[0136] T4: The remote control unit sends a pulse width modulation command to the generator electronic water pump 45 to directly control and adjust the duty cycle of the generator electronic water pump 45.

[0137] T5: Determine whether the real-time detected generator temperature and generator controller temperature are both lower than the preset threshold. If the result is that they are lower than the preset threshold, proceed to the next step; otherwise, return to step T3.

[0138] T6: Put the generator electronic water pump 45 into standby mode;

[0139] T7: Determine if there is a fault in the integrated thermal management device. If a fault exists, report the fault information to the remote control unit; if there is no fault, report no fault information to the remote control unit.

[0140] T8: Set the integrated thermal management device to standby mode.

[0141] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A control method for an integrated thermal management device in a range extender power pack, wherein the integrated thermal management device (4) is provided with a first electronic fan, a second electronic fan, a third electronic fan, and a fourth electronic fan; wherein, When the cooling demand is met, the first electric fan can be turned on independently to cool the engine coolant radiator (43) and the engine intercooler air radiator (42); when the cooling demand is not met, the first electric fan and the second electric fan are turned on simultaneously to cool the engine coolant radiator (43) and the engine intercooler air radiator (42). When the cooling demand is met, the third electronic fan is turned on alone to cool the generator coolant radiator (44); when the cooling demand is not met, the third electronic fan and the fourth electronic fan are turned on simultaneously to cool the generator coolant radiator (44). Its characteristics include the following steps: S1: Input real-time detected temperature, which includes at least engine coolant temperature, engine intake air temperature, generator temperature and generator controller temperature; S2: Determine whether the real-time detected engine coolant temperature is higher than the preset threshold. If the determination result is that the engine coolant temperature is higher than the preset threshold, proceed to the next step. S3: The remote control unit calculates the duty cycle of the first electronic fan; S4: The remote control unit sends a pulse width modulation command to the first electronic fan to directly control and adjust the duty cycle of the first electronic fan; S5: Determine whether the real-time detected engine coolant temperature is lower than the preset threshold. If the determination result is that the engine coolant temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S3. S6: Put the first electronic fan into standby mode; S7: Determine if there is a fault in the integrated thermal management device. If a fault exists, report the fault information to the remote control unit; if there is no fault, report no fault information to the remote control unit. S8: Put the integrated thermal management device into standby mode.

2. The control method for an integrated thermal management device in a range extender power pack according to claim 1, characterized in that: In step S2, when the determination result is that the engine coolant temperature is not higher than a preset threshold, the following steps are also included: S21: Determine whether the real-time detected engine intake air temperature is higher than the preset threshold. If the determination result is that the engine intake air temperature is higher than the preset threshold, proceed to the next step. S31: Determine whether the linkage condition between the first electronic fan and the second electronic fan is met. If the determination result is yes, proceed to the next step; otherwise, proceed to step S71. S41: The remote control unit calculates the duty cycle of the second electronic fan; S51: The remote control unit sends a pulse width modulation command to the second electric fan to directly control and adjust the duty cycle of the second electric fan; S61: Determine whether the real-time detected engine intake air temperature is lower than a preset threshold. If the determination result is that the engine intake air temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S41. S71: Put the second electronic fan into standby mode, and then proceed to step S7.

3. The control method for an integrated thermal management device in a range extender power pack according to claim 2, characterized in that: In step S21, when the determination result is that the engine intake air temperature is not higher than a preset threshold, the following steps are also included: S22: Determine whether the real-time detected generator temperature is higher than the preset threshold. If the determination result is that the generator temperature is higher than the preset threshold, proceed to the next step. S32: The remote control unit calculates the duty cycle of the third electronic fan; S42: The remote control unit sends a pulse width modulation command to the third electric fan to directly control and adjust the duty cycle of the third electric fan; S52: Determine whether the real-time detected generator temperature is lower than a preset threshold. If the determination result is that the generator temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S32. S62: Put the third electronic fan into standby mode, and then proceed to step S7.

4. The control method for an integrated thermal management device in a range extender power pack according to claim 3, characterized in that: In step S22, when the determination result is that the generator temperature is not higher than a preset threshold, the following steps are also included: S23: Determine whether the real-time detected generator controller temperature is higher than the preset threshold. If the determination result is that the generator controller temperature is higher than the preset threshold, proceed to the next step. S33: Determine whether the linkage condition between the third electronic fan and the fourth electronic fan is met. If the result is yes, proceed to the next step; otherwise, proceed to step S73. S43: The remote control unit calculates the duty cycle of the fourth electronic fan; S53: The remote control unit sends a pulse width modulation command to the fourth electronic fan to directly control and adjust the duty cycle of the fourth electronic fan; S63: Determine whether the real-time detected generator controller temperature is lower than the preset threshold. If the determination result is that the generator controller temperature is lower than the preset threshold, proceed to the next step; otherwise, return to step S43. S73: Put the fourth electronic fan into standby mode, and then proceed to step S7; The linkage condition between the first electronic fan and the second electronic fan is: if the first electronic fan alone cannot meet the cooling demand, the second electronic fan needs to be turned on. The linkage condition between the third and fourth electronic fans is: if the cooling demand cannot be met by the third electronic fan alone, the fourth electronic fan needs to be turned on.

5. A range extender power pack device, wherein the device employs the control method according to any one of claims 1-4, characterized in that: The range extender power pack unit includes an engine auxiliary device (1), a power pack interface device (2), a range extender system (3), and an integrated thermal management device (4); wherein, The engine auxiliary device (1) is connected to the range extender system (3) to provide fuel and air supply to the range extender system (3) and to treat the exhaust of the range extender system (3); The power pack interface device (2) is connected to the range extender system (3) to provide low-voltage power supply and low-voltage signal to the range extender system (3), while connecting the high-voltage bus of the range extender system (3) to the vehicle device. The integrated thermal management device (4) is connected to the range extender system (3) to cool the range extender system (3); The integrated thermal management device (4) includes an electric fan and shroud (41), an engine intercooler air radiator (42), an engine coolant radiator (43), a generator coolant radiator (44), and a generator electric water pump (45); wherein, The electronic fan and fan cover (41) control the blowing or suction of air to the engine cool air radiator (42), engine coolant radiator (43) and generator coolant radiator (44). The engine intercooler air radiator (42) is connected to the range extender system (3) through the engine intercooler pipe to cool the high temperature air of the engine (33) in the range extender system (3); The engine coolant radiator (43) is connected to the range extender system (3) through the engine water cooling pipeline to cool the circulating cooling water of the engine (33) in the range extender system (3); The generator coolant radiator (44) is connected to the range extender system (3) through a water cooling pipeline to cool the circulating cooling water of the generator controller (34) and generator (35) in the range extender system (3); The generator electric water pump (45) is connected to the generator coolant radiator (44) to drive the circulating cooling water therein.

6. The range extender power pack device according to claim 5, characterized in that: The engine auxiliary device (1) includes a diesel fuel tank (11), an air filter (12), a diesel filter (13), and an aftertreatment system (14); wherein, The diesel filter (13) is connected to the range extender system (3) via a fuel line to provide the required fuel supply to the engine (33) in the range extender system (3). The diesel fuel tank (11) is connected to the diesel filter (13) to provide fuel to the diesel filter (13). The air filter (12) is connected to the range extender system (3) via the intake pipe to provide the required air supply to the engine (33) in the range extender system (3); The aftertreatment system (14) is connected to the range extender system (3) via an exhaust pipe to treat the exhaust gas from the engine (33) in the range extender system (3).

7. A range extender power pack device according to claim 6, characterized in that: The power pack interface device (2) includes a 24V power supply plug (21), a power pack control device (22), and a power pack high-voltage distribution box (23); wherein, The 24V power supply plug (21) is connected to the vehicle unit at one end and to the range extender system (3) at the other end to provide low-voltage power to the range extender system (3); The power pack control device (22) is connected to the vehicle unit at one end and to the range extender system (3) at the other end to provide a low-voltage signal to the range extender system (3); The power pack high-voltage distribution box (23) is connected to the vehicle unit and the range extender system (3) respectively, so that the high-voltage busbars of the vehicle unit and the range extender system (3) are integrated and then connected to the vehicle unit.

8. A range extender power pack device according to claim 7, characterized in that: The vehicle assembly includes a 24V vehicle battery, a vehicle control panel, a battery high-voltage distribution box, and a vehicle high-voltage distribution box; wherein... The vehicle's 24V battery is connected to the 24V power supply plug (21) to provide power to the 24V power supply plug (21); The vehicle control panel is connected to the power pack control device (22) to provide a control environment for the power pack control device (22); The battery high-voltage distribution box and the vehicle high-voltage distribution box are respectively connected to the power pack high-voltage distribution box (23). After the power pack high-voltage distribution box (23) is connected to the high-voltage bus of the battery high-voltage distribution box and the high-voltage bus of the range extender system (3), the high-voltage bus is integrated and then the integrated high-voltage bus is connected to the vehicle high-voltage distribution box.

9. A range extender power pack device according to claim 8, characterized in that: The range extender system (3) includes a range extender controller (31), an engine controller (32), an engine (33), a generator controller (34), and a generator (35); wherein, The engine (33) is connected to the air filter (12) via an intake pipe to receive air supplied by the air filter (12), the engine (33) is connected to the diesel filter (13) via a fuel pipe to receive fuel supplied by the diesel filter (13), and the engine (33) is connected to the aftertreatment system (14) via an exhaust pipe to discharge exhaust gas to the aftertreatment system (14) for processing before discharge; The range extender system (3) is connected to the 24V power supply plug (21) to receive the low-voltage power supply provided by it. The range extender system (3) is connected to the power pack control device (22) to receive the low-voltage signal provided by it. The range extender system (3) is connected to the power pack high-voltage distribution box (23) to connect the integrated high-voltage bus to the vehicle high-voltage distribution box through the power pack high-voltage distribution box (23). The engine (33) and the engine intercooler air radiator (42) are connected through the engine intercooler pipe to cool the high temperature air. The engine (33) and the engine coolant radiator (43) are connected through the engine water cooling pipe to cool the circulating cooling water of the engine (33). The generator controller (34) and the generator (35) are connected to each other through the water cooling pipe to the generator coolant radiator (44) to cool the circulating cooling water of the generator (35). The range extender controller (31) is connected to the integrated thermal management device (4) to control the electric fan and shroud (41) and the generator electric water pump (45) in the integrated thermal management device (4); The engine controller (32) is connected to the engine (33) to perform corresponding control on the engine (33).

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