Vehicle-mounted intelligent integrated electric cabinet and system

Abstract

The invention provides a vehicle-mounted intelligent integrated electric control box and system, and belongs to the field of vehicle-mounted technology, and the vehicle-mounted intelligent integrated electric control box comprises a box body, and a control module, a multi-power-supply cooperative power supply module and a fault diagnosis module which are disposed in the box body. The control module is used for processing real-time operation parameters of the vehicle and sending out a control instruction according to a processing result; the multi-power-supply cooperative power supply module is configured to dynamically switch power supply links of a plurality of power supplies and calculate residual power supply time of the system in real time; and the fault diagnosis module is used for monitoring voltage, current and communication protocol states, outputting fault codes and maintenance suggestions based on a grading alarm mechanism, giving an alarm in time and accurately prompting fault positions and reasons when faults occur, so that maintenance personnel can perform rapid maintenance in sequence, and the downtime is reduced.

Description

Technical Field

[0001] The present invention belongs to the field of vehicle-mounted technology, and in particular relates to a vehicle-mounted intelligent integrated electric control box and system. Background Art

[0002] With the development of medical rescue, emergency rescue, traffic management and other fields, specialized vehicles need to integrate numerous devices and systems such as communications, monitoring, lighting, and power distribution. Traditional electronic control boxes are unable to meet the needs of centralized control and management of these complex devices. Intelligent integrated electronic control boxes have become the inevitable choice to achieve unified control and coordinated operation of multiple devices. Summary of the Invention

[0003] In order to solve the above technical problems, the present invention provides an on-board intelligent integrated electric control box and system to solve the technical problems of the above background technology.

[0004] On the one hand, the invention provides the following technical solutions: an on-vehicle intelligent integrated electric control box, comprising a box body and a control module, a multi-power collaborative power supply module and a fault diagnosis module arranged in the box body;

[0005] The control module is used to process the real-time operating parameters of the vehicle and issue control instructions based on the processing results;

[0006] The multi-power collaborative power supply module is configured to dynamically switch the power supply links of multiple power sources and calculate the remaining power supply time of the system in real time;

[0007] The fault diagnosis module is used to monitor voltage, current, and communication protocol status, and output fault codes and maintenance suggestions based on a graded alarm mechanism.

[0008] Compared with existing technologies, the present invention offers the following advantages: The multi-power collaborative power supply module dynamically switches power supply links between multiple power sources, calculates the remaining power supply time in real time, and automatically optimizes power distribution to avoid waste and overload. It also collaborates with power generation and energy storage systems to improve energy efficiency and vehicle range. A fault diagnosis module monitors the operating status of each component in real time, providing prompt alarms and accurate indications of the fault location and cause in the event of a fault, allowing maintenance personnel to quickly repair the system and reduce downtime.

[0009] Furthermore, the multi-power collaborative power supply module further includes:

[0010] Solid-state relays and intelligent static switches for performing power switching operations with a switching response time less than a preset threshold;

[0011] The power supply remaining time prediction unit is used to dynamically calculate the remaining power supply time based on load power, generator fuel efficiency and battery charge state.

[0012] Furthermore, the remaining power supply time prediction unit performs the following calculation logic:

[0013] Calculating the remaining time of the generator's independent power supply using the first independent calculation formula to obtain a first calculation time;

[0014] Calculating the remaining time of the battery's independent power supply using a second independent calculation formula to obtain a second calculated time;

[0015] If the first calculation time is less than the second calculation time, calculating the total remaining power supply time using the first total calculation formula;

[0016] If the first calculation time is greater than the second calculation time, the total remaining power supply time is calculated using a second total calculation formula.

[0017] Furthermore, the first separate calculation formula includes:

[0018] t1=V / (P2 / P1×η)

[0019] The second separate calculation formula includes:

[0020] t2=(SOC×C) / P2

[0021] The first overall calculation formula includes:

[0022] t2=(SOC×C) / P2

[0023] The second total calculation formula includes:

[0024] t3=t2+(t1t2)×(P3 / P1)

[0025] Among them, P1 is the load power; P2 is the generator output power; P3 is the maximum power that the battery can provide; η is the generator fuel efficiency; V is the remaining fuel in the generator tank; SOC is the battery state of charge; C is the battery capacity; t1 is the remaining time of the generator power supply alone; t2 is the remaining time of the battery power supply alone; t3 is the total remaining power supply time.

[0026] Furthermore, a shielding layer is provided inside the box to make the interior of the box a layered design, the front and rear panels of the box are detachable, the side panels of the box are provided with heat dissipation vents, and an inspection cover is reserved on the top of the box.

[0027] Furthermore, the fault diagnosis module includes:

[0028] Real-time monitoring unit for detecting voltage anomalies, short circuits, and communication timeouts;

[0029] Self-check unit, used to regularly check the health status of relays, sensors and interfaces;

[0030] The historical log storage unit is used to record fault events, operation records and power supply parameters, and supports cloud synchronization.

[0031] Furthermore, a communication module is provided in the box for data transmission with the vehicle-mounted equipment and external systems;

[0032] The communication module supports the following functions:

[0033] Control the vehicle engine speed through the CAN protocol and dynamically adjust the output power of the power take-off generator;

[0034] During driving, excess electrical energy is stored in an additional battery and distributed to compensate when power supply is insufficient.

[0035] Furthermore, the box is also provided with:

[0036] Human-machine interface, integrating industrial-grade touch screen, voice control module and physical buttons for equipment control, parameter setting and status query;

[0037] The dual battery protection module is equipped with a bidirectional isolator, which automatically cuts off the connection with the additional battery when the original vehicle battery voltage falls below the threshold.

[0038] Furthermore, the hierarchical alarm mechanism includes:

[0039] Level 1 warning: When the battery or fuel level reaches 20%, the app will push a notification and the touch screen will flash orange.

[0040] Level 2 emergency alarm: When the remaining power or fuel level reaches 5%, the buzzer alarm is activated and non-critical load equipment is automatically shut down.

[0041] On the other hand, the present invention also provides an on-vehicle intelligent integrated electronic control system, comprising:

[0042] A sensor group connected to the electric control box includes a temperature and humidity sensor, an oil level sensor, a voltage sensor, and a current sensor;

[0043] The actuator group, including relays, contactors and signal converters, is used to adjust the operating status of the equipment according to control instructions. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 This is a schematic diagram of module connections of the vehicle-mounted intelligent integrated electric control box in the first embodiment of the present invention.

[0045] Figure 2 This is a circuit connection diagram of the vehicle-mounted intelligent integrated electric control box in the first embodiment of the present invention.

[0046] Main component markings: 10. Control module; 20. Multi-power collaborative power supply module; 30. Fault diagnosis module; 40. Dual battery protection module; 50. Communication module; 60. Actuator group; 70. Sensor group.

[0047] The following specific embodiments will further illustrate the present invention in conjunction with the above-mentioned drawings. DETAILED DESCRIPTION

[0048] To facilitate understanding of the present invention, the present invention will be described more fully below with reference to the accompanying drawings. The drawings illustrate several embodiments of the present invention. However, the present invention may be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and comprehensive understanding of the present invention.

[0049] It should be noted that when an element is referred to as being "fixed to" another element, it may be directly on the other element or there may be an intermediate element. When an element is referred to as being "connected to" another element, it may be directly connected to the other element or there may be an intermediate element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only.

[0050] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention pertains. The terms used in this specification of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0051] See also Figure 1 As shown, the vehicle-mounted intelligent integrated electric control box in the first embodiment of the present invention includes:

[0052] A box and a control module 10, a multi-power supply collaborative power supply module 20 and a fault diagnosis module 30 arranged in the box;

[0053] The control module 10 is used to process the real-time operating parameters of the vehicle and issue control instructions based on the processing results;

[0054] The multi-power collaborative power supply module 20 is configured to dynamically switch the power supply links of multiple power sources and calculate the remaining power supply time of the system in real time;

[0055] The fault diagnosis module 30 is used to monitor voltage, current, and communication protocol status, and output fault codes and maintenance suggestions based on a graded alarm mechanism.

[0056] It's worth noting that operators need to quickly and accurately obtain operational status information for each vehicle system and device, and make timely adjustments. The intelligent integrated electronic control box provides operators with intuitive, comprehensive information and convenient operation through real-time monitoring and intelligent control, reducing manual errors and delays while improving efficiency and accuracy.

[0057] Special vehicles often operate in harsh environments and complex working conditions, including high and low temperatures, humidity, and bumps. Traditional electronic control boxes are prone to performance degradation and frequent failures in these environments. Intelligent integrated electronic control boxes utilize advanced sensors, protection technologies, and reliable designs to adapt to harsh environments and ensure stable operation of all vehicle systems.

[0058] Special vehicles are equipped with numerous electronic devices and consume significant amounts of electricity. To ensure long-term power supply, energy must be managed and allocated efficiently. The intelligent integrated electrical control box automatically optimizes power distribution based on equipment priority and actual usage, avoiding waste and overloads. It also works in conjunction with power generation and storage systems to improve energy efficiency and endurance.

[0059] When a traditional electric control box malfunctions, professional technicians must conduct on-site troubleshooting and repair, which is time-consuming and difficult. The intelligent integrated electric control box features fault diagnosis and early warning capabilities, monitoring the operating status of each component in real time. When a fault occurs, it promptly issues an alarm and accurately indicates the location and cause. This allows maintenance personnel to quickly repair the system, reducing downtime.

[0060] The multi-power collaborative power supply module 20 dynamically switches between multiple power supply links, calculates the remaining power supply time in real time, and automatically optimizes power distribution to avoid waste and overload. It works in conjunction with the power generation and storage systems to improve energy efficiency and vehicle range. The fault diagnosis module 30 monitors the operating status of each component in real time, providing prompt alarms and accurate indication of the fault location and cause, allowing maintenance personnel to quickly repair and minimize downtime.

[0061] Furthermore, the design of the box is as follows:

[0062] The chassis adopts a rack-mount design for easy installation. Made of stainless steel, it has excellent oxidation and corrosion resistance and is suitable for various harsh environments.

[0063] An internal shielding layer effectively prevents electromagnetic interference and ensures stable equipment operation. A modular, layered design categorizes and organizes power and signal lines, distinguishing between AC, DC, and signal lines to prevent interference. Dedicated cable routing channels facilitate line organization and maintenance. Power and signal filtering and grounding further enhance signal stability and security.

[0064] The side panels are equipped with heat dissipation vents to ensure that the equipment can continue to operate normally in high-temperature environments, effectively extending the service life of the equipment. The top is equipped with an inspection cover to facilitate maintenance personnel to inspect and maintain the internal equipment, reducing downtime and improving maintenance efficiency.

[0065] The front and rear panels are removable, making them easy to install and adjust according to your needs. This also helps with ventilation and heat dissipation. The simple and reliable installation of the front and rear panels ensures the stability of the device during operation.

[0066] In this embodiment, the control module 10 is composed of a high-performance microprocessor, memory, input and output interfaces, etc. It is the core part of the intelligent electric control box and is responsible for processing various signals, performing logical judgment and algorithm operations, and issuing control instructions based on the results.

[0067] In this embodiment, the multi-power collaborative power supply module 20 provides a stable AC and DC power supply for the electrical control box and other equipment in the vehicle, typically including generator power supply, mains power supply, UPS power supply, batteries, chargers, and power management circuits. This module has powerful intelligent management capabilities and can automatically optimize power distribution based on the device's priority and actual usage, thereby ensuring reliable power support for the device under various operating conditions. In addition, each circuit can set upper and lower voltage and current limits, and has protection functions such as undervoltage and overload. In the event of a fault, the system can promptly diagnose and alarm, accurately displaying the problem, greatly facilitating personnel judgment and maintenance.

[0068] In this embodiment, the multi-power collaborative power supply module 20 not only provides stable AC and DC power to the electrical control box and other in-vehicle devices, encompassing generator power, mains power, UPS power, batteries, chargers, and power management circuits, but also features intelligent management capabilities, automatically optimizing power distribution based on device priority and actual usage, ensuring reliable power support for devices under various operating conditions. Furthermore, each circuit can be configured with upper and lower voltage and current limits, and features protection features such as undervoltage and overload. In the event of a fault, the system promptly diagnoses and issues an alarm, accurately indicating the problem, greatly facilitating diagnosis and repair.

[0069] Specifically, the module is equipped with solid-state relays and intelligent static switches for power switching operations. The switching response time is less than a preset threshold, enabling rapid switching of 0.7ms to ensure the continuous operation of precision equipment such as satellites. Furthermore, the module includes a remaining power supply time prediction unit that dynamically calculates the remaining power supply time based on load power, generator fuel efficiency, and battery state of charge.

[0070] In this embodiment, power switching is performed based on a priority rule: mains > generator > UPS > battery. This ensures both the lowest electricity cost and the highest stability. By using solid-state relays (SSRs) and intelligent static switches (STSs), seamless power supply switching is achieved.

[0071] In this embodiment, the calculation logic of the remaining power supply time prediction unit is as follows:

[0072] First, the remaining time of the generator's independent power supply is calculated using a first independent calculation formula to obtain a first calculation time;

[0073] Next, the remaining time of the battery supplying power independently is calculated using a second independent calculation formula to obtain a second calculated time.

[0074] Then, compare the first calculation time and the second calculation time: if it is less than, use the first total calculation formula t3 = t1 + (t2t1) × (P2 / P1) to calculate the total remaining power supply time; if it is greater than, use the second total calculation formula t3 = t2 + (t1t2) × (P3 / P1) to calculate the total remaining power supply time.

[0075] P1 is the load power; P2 is the generator output power; P3 is the maximum power that the battery can provide; η is the generator fuel efficiency; V is the remaining fuel in the generator tank; SOC is the battery state of charge; C is the battery capacity; t1 is the remaining time for the generator to supply power alone; t2 is the remaining time for the battery to supply power alone; and t3 is the total remaining power supply time.

[0076] The dynamic calculation model calculates the remaining power supply time in real time based on the current load power, generator fuel efficiency, and battery SOC (state of charge). For example, a generator operating at full load can last for 8 hours. When calculating the remaining time for a generator operating independently, if the generator's full load power is P1 and the generator's output power matches the load power at the current load power P2, the generator's fuel consumption rate is r = P2 / P1 × η. The remaining time for the generator operating independently is .

[0077] When calculating the remaining time of the battery supplying power alone, the energy that the battery can provide is. Due to the power, the remaining time of the battery supplying power alone is.

[0078] Calculating the total remaining power supply time requires comprehensive consideration of the remaining power supply time of both the generator and the battery. Assume that both the generator and battery are simultaneously powering the load. When one runs out of power, the other continues to provide power. If this is less than t3, the total remaining power supply time is t3 = t1 + (t2t1) × (P2 / P1). This means that after the generator fuel runs out, the battery continues to calculate the remaining power supply time based on the difference between the remaining power and the load power minus the generator power. If this is greater than t3, the total remaining power supply time is generally less than P1. When the battery runs out of power, the generator continues to calculate the remaining power supply time based on the difference between the remaining fuel and the load power minus the battery power.

[0079] In this embodiment, load prioritization and dynamic power allocation;

[0080] Hierarchical power supply strategy: Users can customize load priorities, for example, communications equipment takes precedence over office equipment, which takes precedence over monitoring equipment. When energy storage is insufficient, the system will disconnect low-priority loads in the set order to ensure the continued operation of core equipment.

[0081] Dynamic power adjustment: When a device exceeds its power limit, such as when the current is too high when the air conditioner is started, the system will automatically take current limiting measures or delay the startup of the device to avoid overloading the entire system and ensure the stability of the power supply.

[0082] In this embodiment, the fault diagnosis module 30 includes the following components:

[0083] Real-time monitoring unit: used to continuously monitor the power supply link (such as voltage anomalies, short circuits, etc.), device communications (such as protocol timeouts, etc.), and sensors (such as temperature, humidity, and oil levels) to detect potential faults in a timely manner.

[0084] Self-check unit: Regularly and automatically checks the health status of key modules (such as relays, interfaces, etc.), identifies potential risks in advance, and ensures stable system operation.

[0085] Historical log storage unit: records fault events, operation records, power supply parameters and other information, which is stored locally and also supports cloud synchronization for subsequent query and analysis.

[0086] The functions of the fault diagnosis module 30 are implemented as follows:

[0087] Real-time monitoring: Continuously monitor the power supply link, device communication, and sensors. Once an anomaly occurs, such as voltage exceeding the set range, short circuit, communication timeout, etc., the system immediately captures it and initiates subsequent diagnostic processes.

[0088] Self-check mode: Automatically checks the health status of key modules such as relays and interfaces according to preset cycles to promptly identify potential faults and prevent minor problems from causing system failures.

[0089] Diagnosis shows:

[0090] Display specific fault codes: When a fault occurs, the system intuitively presents the specific fault code on the display screen, such as "E01: AC input overvoltage" and "E02: RS485 communication interruption", etc., to help maintenance personnel quickly locate the problem.

[0091] Provide maintenance suggestions: For different fault codes, the system automatically matches and provides corresponding maintenance suggestions, such as "Check the generator fuel valve" and "Restart communication module 50", to assist maintenance personnel in carrying out maintenance work efficiently.

[0092] Historical records and data analysis:

[0093] Log storage: Detailed records of the time, type, and process of fault events are kept, while operation records and power supply parameters are saved. Log storage is both local and supports cloud synchronization, ensuring data security and reliability, and convenient for retrieval and analysis at any time.

[0094] Trend analysis: Leverage historical data to analyze key performance indicators of equipment, such as the battery capacity decay curve. Long-term data monitoring can be used to predict equipment lifespan, allowing for advance planning of equipment maintenance and replacement, reducing the risk of system failures.

[0095] In this embodiment, a communication module 50 is also provided within the box for data transmission with onboard devices and external systems. This communication module 50 supports multiple communication protocols, such as RS485 / RS232, Ethernet, and wireless communication modules 50, enabling data transmission and communication between the electric control box and other onboard devices and external systems, as well as wireless transmission and remote monitoring.

[0096] When the vehicle is parked and powered by a power take-off generator (PTO), the electronic control box uses the CAN protocol to control the vehicle's engine speed based on real-time monitoring of the vehicle's power consumption, thereby adjusting the PTO generator's output power. This allows for dynamic adjustments, saving fuel while ensuring stable power consumption for onboard equipment and smooth operation.

[0097] During driving, when the vehicle's engine speed allows the PTO generator to reach maximum power output, the electronic control box charges and stores excess energy generated by the vehicle's onboard equipment in an additional battery. Furthermore, when the vehicle brakes or decelerates, if the PTO generator's output power cannot meet the onboard equipment's power needs, the electronic control box distributes the energy stored in the additional battery to compensate for the onboard equipment. This enables intelligent sharing and efficient use of electrical energy across the vehicle's systems, improving energy efficiency and ensuring self-sufficiency during extended missions.

[0098] In this embodiment, a human-machine interface and a dual battery protection module 40 are also provided on the box body:

[0099] Human-machine interface: Integrates industrial-grade touch screen, voice control module 10 and physical buttons for device control, parameter setting and status query. Specifically includes:

[0100] Local touch control: The distribution box is integrated with a 7-inch industrial-grade touch screen, which supports real-time status display (voltage, current, remaining time) and operation.

[0101] Wireless Remote Control: Remote monitoring and operation are achieved through a customized APP (compatible with Windows / iOS / Android / Hongmeng system), supporting multi-device control. Supports 4G / 5G, WiFi, wired network, etc., adapting to remote connection needs in different environments.

[0102] Voice interaction: Built-in voice module (such as "Xiaoyi"), supports natural language commands (such as "start the air conditioner" and "switch to mains power").

[0103] Sequential power-on and power-off logic: Individual devices or the entire system can be turned on and off with a single button. With this single button, the system starts and stops devices in a pre-set sequence (e.g., starting low-power devices first, followed by high-power air conditioners), preventing inrush currents and extending device life.

[0104] Dual battery protection module 40: equipped with a bidirectional isolator, it automatically cuts off the connection with the additional battery when the original vehicle battery voltage falls below the threshold. Specifically includes:

[0105] Voltage threshold management: The system monitors the original vehicle battery voltage (≥12.5V for 12V system and ≥25V for 24V system). When the voltage falls below the threshold, the system automatically cuts off the connection with the additional battery, giving priority to ensuring the vehicle's starting ability.

[0106] Bidirectional isolator: uses MOSFET and relay to isolate the circuit to prevent the additional battery from reverse discharge and damage to the original vehicle battery.

[0107] Emergency forced start function: When the original vehicle battery is low on power, the forced closing switch is activated through an external power supply (mains / generator), and the additional battery or inverter power supply temporarily takes over the starting circuit, completing vehicle ignition within 30 seconds.

[0108] In this embodiment:

[0109] Supported protocols: Support RS485 / 232 protocols, compatible with industrial control and audio and video equipment.

[0110] Control range: including audio and video matrix switching (such as HDMI / SDI channel switching), PTZ camera control (rotation, zoom, etc.), lifting rod retraction / lifting operation, infrared remote control (TV, air conditioner, video conferencing terminal and other third-party equipment).

[0111] Scene linkage: Customizable scenes, such as "conference mode" to link the display, microphone, camera, etc. to switch audio and video signals with one click.

[0112] Overvoltage / undervoltage protection: When the input power is abnormal, the system automatically cuts off the power supply and issues an alarm to prevent equipment from being damaged due to voltage instability.

[0113] Short-circuit protection: Using a resettable fuse or electronic fuse (eFuse) can quickly cut off the current when a short circuit occurs in the circuit, protecting the safety of the circuit and equipment.

[0114] Anti-reverse polarity protection: The power input port has a built-in diode and MOSFET anti-reverse polarity circuit to effectively prevent equipment damage caused by reverse power connection.

[0115] Specifically, the hierarchical alarm mechanism includes:

[0116] Level 1 warning: When the remaining battery or fuel level reaches 20%, the app will push a notification and the touch screen will flash orange.

[0117] Level 2 emergency alarm: When the remaining power or fuel level reaches 5%, the buzzer alarm is activated and non-critical load equipment is automatically shut down.

[0118] In a series of special vehicles such as public security, emergency firefighting, transportation, electricity, and medical emergency, intelligent electronic control boxes can uniformly control and manage special equipment, communication systems, lighting systems, power distribution systems, etc., improve operational efficiency and the vehicle's information level, and ensure the smooth progress of on-site work.

[0119] like Figure 2 As shown in the figure, the intelligent integrated electric control box is mainly composed of UPS (uninterruptible power supply), STS (static transfer switch), AC relay module, DC relay module, MCU main control circuit and other parts. The information interaction and control between modules are realized through the 485 communication line.

[0120] 1.UPS (uninterruptible power supply);

[0121] Function: Provides a stable power supply for the system. When the mains power is abnormal or there is a power outage, it automatically switches to battery power mode to ensure the continuous operation of the system.

[0122] Connection: The AC input is connected to the UPS through the UPS control switch, and the output is connected to the STS switch.

[0123] Monitoring: Monitor UPS input and output voltage, current, power and other parameters.

[0124] 2.STS (static transfer switch);

[0125] Function: Realize fast and automatic switching between two power sources (normal power supply and backup power supply) to ensure the continuity and reliability of power supply.

[0126] Connection: One input is from the UPS output, the other input is from the generator (backup power), and the output is connected to the load.

[0127] Control: The switching is controlled by the intelligent circuit breaker and the manual / automatic transfer switch, and the Light1 and Light2 indicator lights are equipped to display the switching status.

[0128] 3.AC relay module;

[0129] Function: Control and protect AC loads and realize on-off control of AC circuits.

[0130] Connection: Input comes from the output of STS, the output is connected to the AC load, and it is connected to the MCU main control circuit through 485 communication to receive control instructions and feedback status information.

[0131] Monitoring: Monitor AC voltage, current, power and other parameters.

[0132] 4. DC relay module;

[0133] Function: Control and protect DC loads and realize on-off control of DC circuits.

[0134] Connection: The input comes from a DC / DC converter (which converts AC power to DC power), the output is connected to a DC load, and it is connected to the MCU main control circuit via 485 communication to receive control instructions and feedback status information.

[0135] Monitoring: Monitor DC voltage, current, power and other parameters.

[0136] 5.MCU main control circuit;

[0137] Function: As the control center of the system, it is responsible for coordinating the control and data processing of each module to realize intelligent management of the system.

[0138] Connection: Connect to UPS, STS, AC relay module, DC relay module, etc. through 485 communication, receive status information of each module and send control instructions.

[0139] Interface: Equipped with 485 / 232, TCP / IP and other communication interfaces to facilitate data interaction with external devices.

[0140] Specific workflow:

[0141] 1. When the mains power is normal, it is input to the UPS through the UPS control switch. The UPS stabilizes the mains power and then outputs it to the common input terminal of the STS. At the same time, the mains power also directly charges the additional battery and the original vehicle battery.

[0142] 2. When the mains power is abnormal or there is a power outage, the UPS automatically switches to battery power mode, and the battery provides power to the system.

[0143] 3. Based on the set switching conditions (such as mains voltage, frequency and other parameters exceeding the allowable range), STS uses intelligent circuit breakers and manual / automatic transfer switches to quickly switch between the normal power supply and the backup power supply (generator), ensuring uninterrupted power supply to the load.

[0144] 4. The AC relay module and the DC relay module respectively control the on / off of the AC load and the DC load according to the instructions of the MCU main control circuit, and feed back the operating status of the load to the MCU main control circuit.

[0145] 5. The MCU main control circuit collects the status information of each module (such as voltage, current, power, etc.) in real time, performs data analysis and processing, realizes intelligent management of the system, and communicates with external devices through interfaces such as 485 / 232 and TCP / IP to realize remote monitoring and control.

[0146] Example 2

[0147] The figure shows an on-vehicle intelligent integrated electronic control system according to a second embodiment of the present invention, which is characterized by comprising:

[0148] The sensor group 70 connected to the electric control box includes a temperature and humidity sensor, an oil level sensor, a voltage sensor, and a current sensor;

[0149] The actuator group 60 includes relays, contactors and signal converters, and is used to adjust the operating state of the equipment according to control instructions.

[0150] In this embodiment, the composition and functions of the sensor group 70 and the actuator group 60 are as follows:

[0151] Sensor group 70;

[0152] The system includes various types of sensors, including temperature and humidity sensors, fuel level sensors, voltage sensors, and current sensors. These sensors can sense the operating parameters of various systems and equipment of special vehicles in real time, such as the temperature and humidity of the environment, the fuel level in the fuel tank, the voltage and current of the circuit, etc., and convert these physical parameters into electrical signals, which are transmitted to the control module 10 so that the control system can timely understand the operating status of the vehicle.

[0153] Actuator group 60;

[0154] It includes converters, relays, contactors and other devices, and controls the corresponding devices according to the instructions issued by the control module 10 to realize operations such as starting, stopping, and adjusting the devices.

[0155] Converter: includes power converter and signal converter.

[0156] Power converters: These include DC / DC and AC / DC converters, primarily used to convert one voltage to another to meet the power voltage requirements of various in-vehicle devices. For example, they convert 24V to 12V to power in-vehicle electronics.

[0157] Signal converters: These include A / D and D / A converters, used for converting between analog and digital signals. For example, they convert the analog signals generated by temperature and humidity sensors into digital signals so that the control module 10 can acquire and analyze the data. RS485 / RS232 converters are used to convert between different communication protocols, enabling devices with different protocols to communicate with each other.

[0158] Relays and contactors: These use small currents to control the on / off switching of large currents, isolating control circuits from the main circuit and protecting equipment and circuits. Combining multiple relays and contactors can also implement complex logic control functions, such as starting or stopping multiple devices in a preset sequence, enabling automated system operation.

[0159] In summary, the vehicle-mounted intelligent integrated electric control box and system in the above-mentioned embodiments of the present invention utilizes a multi-power collaborative power supply module 20 to dynamically switch power supply links between multiple power sources, calculate the remaining power supply time of the system in real time, and automatically optimize power distribution to avoid waste and overload. It works in conjunction with power generation and energy storage systems to improve energy efficiency and vehicle endurance. The fault diagnosis module 30 monitors the operating status of each component in real time, issues a prompt alarm, and accurately indicates the fault location and cause in the event of a fault, allowing maintenance personnel to quickly repair the system and reduce downtime.

[0160] The on-board intelligent integrated electronic control box has the following advantages:

[0161] Reasonable energy distribution: Maximize energy utilization through dynamic power distribution and coordination of multiple power sources.

[0162] Intelligent operation and maintenance: It has fault self-diagnosis and remote monitoring functions, which greatly reduces maintenance costs and time.

[0163] High reliability: Adopting industrial-grade hardware, it supports millisecond-level power switching and meets the needs of harsh environments.

[0164] Scalability: supports modular additions, such as solar input interface, CAN bus communication, etc.

[0165] Full-scenario adaptation: covering power management, equipment control, communication protocols and other aspects to meet complex integration needs.

[0166] User-friendly: Provides multiple interaction methods such as voice, APP, touch, etc. to lower the operation threshold.

[0167] The electric control box integrates power management, multi-protocol control, remote monitoring and intelligent diagnosis capabilities, and is particularly suitable for complex scenarios that require high reliability, rapid response and remote operation and maintenance.

[0168] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "some examples" means that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0169] The above-described embodiments merely illustrate several implementations of the present invention, and while their descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that a person skilled in the art would be able to make numerous variations and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.

Claims

1. A vehicle-mounted intelligent integrated electric control box, characterized in that: include: A box body and a control module, a multi-power supply collaborative power supply module and a fault diagnosis module arranged in the box body; The control module is used to process the real-time operating parameters of the vehicle and issue control instructions based on the processing results; The multi-power collaborative power supply module is configured to dynamically switch the power supply links of multiple power sources and calculate the remaining power supply time of the system in real time; The fault diagnosis module is used to monitor voltage, current, and communication protocol status, and output fault codes and maintenance suggestions based on a graded alarm mechanism.

2. The vehicle-mounted intelligent integrated electric control box according to claim 1, characterized in that: The multi-power collaborative power supply module also includes: Solid-state relays and intelligent static switches for performing power switching operations with a switching response time less than a preset threshold; The power supply remaining time prediction unit is used to dynamically calculate the remaining power supply time based on load power, generator fuel efficiency and battery charge state.

3. The vehicle-mounted intelligent integrated electric control box according to claim 1, characterized in that: The remaining power supply time prediction unit performs the following calculation logic: Calculating the remaining time of the generator's independent power supply using the first independent calculation formula to obtain a first calculation time; Calculating the remaining time of the battery's independent power supply using a second independent calculation formula to obtain a second calculated time; If the first calculation time is less than the second calculation time, calculating the total remaining power supply time using the first total calculation formula; If the first calculation time is greater than the second calculation time, the total remaining power supply time is calculated using a second total calculation formula.

4. The vehicle-mounted intelligent integrated electric control box according to claim 3, characterized in that: The first separate calculation formula includes: t1=V / (P2 / P1×η) The second separate calculation formula includes: t2=(SOC×C) / P2 The first overall calculation formula includes: t2=(SOC×C) / P2 The second total calculation formula includes: t3=t2+(t1t2)×(P3 / P1) Among them, P1 is the load power; P2 is the generator output power; P3 is the maximum power that the battery can provide; η is the generator fuel efficiency; V is the remaining fuel in the generator tank; SOC is the battery state of charge; C is the battery capacity; t1 is the remaining time of the generator power supply alone; t2 is the remaining time of the battery power supply alone; t3 is the total remaining power supply time.

5. The vehicle-mounted intelligent integrated electric control box according to claim 1, characterized in that: A shielding layer is provided inside the box to make the interior of the box have a layered design. The front and rear panels of the box are detachable. The side panels of the box are provided with heat dissipation vents. An inspection cover is reserved on the top of the box.

6. The vehicle-mounted intelligent integrated electric control box according to claim 1, characterized in that: The fault diagnosis module includes: Real-time monitoring unit for detecting voltage anomalies, short circuits, and communication timeouts; Self-check unit, used to regularly check the health status of relays, sensors and interfaces; The historical log storage unit is used to record fault events, operation records and power supply parameters, and supports cloud synchronization.

7. The vehicle-mounted intelligent integrated electric control box according to claim 1, characterized in that: The box is also provided with a communication module for data transmission with the vehicle-mounted equipment and external systems; The communication module supports the following functions: Control the vehicle engine speed through the CAN protocol and dynamically adjust the output power of the power take-off generator; During driving, excess electrical energy is stored in an additional battery and distributed to compensate when power supply is insufficient.

8. The vehicle-mounted intelligent integrated electric control box according to claim 1, characterized in that: The box is also provided with: Human-machine interface, integrating industrial-grade touch screen, voice control module and physical buttons for equipment control, parameter setting and status query; The dual battery protection module is equipped with a bidirectional isolator, which automatically cuts off the connection with the additional battery when the original vehicle battery voltage falls below the threshold.

9. The vehicle-mounted intelligent integrated electric control box according to claim 1, characterized in that: The hierarchical alarm mechanism includes: Level 1 warning: When the battery or fuel level reaches 20%, the app will push a notification and the touch screen will flash orange. Level 2 emergency alarm: When the remaining power or fuel level reaches 5%, the buzzer alarm is activated and non-critical load equipment is automatically shut down.

10. An on-vehicle intelligent integrated electronic control system, characterized in that: include: A sensor group connected to the electric control box includes a temperature and humidity sensor, an oil level sensor, a voltage sensor, and a current sensor; The actuator group, including relays, contactors and signal converters, is used to adjust the operating status of the equipment according to control instructions.

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