Control method of extended-range mining vehicle

Abstract

The invention relates to a control method of an extended-range mining vehicle, which adopts a distributed CAN (Controller Area Network) topological structure and comprises the following steps of: (a) starting process control: electrifying a VCU (Vehicle Control Unit), an ECU (Engine Control Unit), an RCU (Range Control Unit) and an MCU (Microprogrammed Control Unit) together; the vehicle control unit VCU sends a starting instruction to the range extender controller RCU, and the range extender controller RCU enters a starting program; (b) operation process control: enabling the vehicle control unit VCU to monitor the SOC state of the battery pack in real time, and dynamically adjusting the generated power of a range extender in combination with the driving working condition; and (c) shutdown process control: after receiving the generated power return-to-zero request, the range extender controller RCU sends a generated load unloading request to the generator controller MCU, and the generator controller MCU controls the current to unload the generated load. Efficient energy management and dynamic response optimization control of a power system can be achieved, and the method is suitable for hybrid power engineering vehicles under complex working conditions such as mines.

Description

Technical Field

[0001] The present invention relates to the technical field of automobiles, and in particular to a control method for an extended-range mining vehicle. Background Art

[0002] Traditional mining trucks mostly use diesel powertrains, which suffer from low fuel efficiency, high emissions, and poor adaptability to operating conditions. In recent years, extended-range electric mining trucks (mining vehicles) have become a trend due to their long driving range and environmental advantages. Their powertrains, which include a fuel range extender, a battery pack, and a drive motor, require the coordinated implementation of multiple controllers to achieve complex energy flow control.

[0003] Chinese utility model patent application number 202421220152.8 discloses a hybrid CAN network topology structure based on a mining dump truck in the technical field of extended-range hybrid dump trucks, including a first CAN network, including: a first CAN bus, at least two range extender controllers, connected to the first CAN bus; a second CAN network, including: a second CAN bus, at least two drive motor controllers, connected to the second CAN bus; a vehicle control unit VCU, respectively connected to the first CAN bus and the second CAN bus, for realizing data interaction; the application connects the range extender controller and the drive motor controller separately to two different CAN networks, so that the power generation and power control of the whole vehicle are controlled separately, thereby reducing the CAN bus load rate; however, such a hybrid CAN network topology structure is not a distributed topology architecture, and it is difficult to realize complex energy flow control. Summary of the Invention

[0004] The purpose of the present invention is to provide a control method for an extended-range mining vehicle in order to overcome the deficiencies of the prior art.

[0005] To achieve the above object, the present invention adopts a technical solution: a control method for an extended-range mining vehicle, which adopts a distributed CAN topology structure, and the distributed CAN topology structure includes: A first CAN network, comprising a power CAN2 and a vehicle controller VCU and a range extender controller RCU connected to the power CAN2 and communicating bidirectionally; A second CAN network, the second CAN network including an intranet CAN1 and the range extender controller RCU and the generator controller MCU connected to the intranet CAN1 and communicating bidirectionally; A third CAN network, the third CAN network including an intranet CAN0 and the range extender controller RCU and the engine controller ECU connected to the intranet CAN0 and communicating bidirectionally; The following steps are involved: (a) Startup process control: The vehicle controller (VCU), the engine controller (ECU), the range extender controller (RCU), and the generator controller (MCU) are all powered on; the vehicle controller (VCU) issues a start command to the range extender controller (RCU), and the range extender controller (RCU) enters a startup procedure; (b) Operation process control: The vehicle controller VCU monitors the battery pack SOC status in real time and dynamically adjusts the range extender power generation power in combination with the driving conditions; when the range-extended mining vehicle is in a heavy-load uphill condition in a mine, the vehicle controller VCU monitors the load and slope in real time and dynamically adjusts the power distribution ratio between the range extender and the generator to ensure smooth torque output and optimal fuel economy; when the range-extended mining vehicle is in a long-distance downhill condition, the vehicle controller VCU activates the braking energy recovery system to convert kinetic energy into electrical energy and store it in the battery; when the range-extended mining vehicle is in a short-distance transportation condition in a mine, the vehicle controller VCU adopts a predictive energy management algorithm to preheat the range extender in advance based on GPS path planning, reduce cold start emissions, and maintain the battery pack SOC in the range of 40% to 80% to extend battery life; (c) Shutdown process control: After receiving the request to return the generated power to zero, the range extender controller RCU sends a request to remove the generated load to the generator controller MCU, and the generator controller MCU controls the current to remove the generated load; The range extender controller releases the engine constant speed or constant torque control request, and the engine returns to idle speed; the range extender controller RCU triggers a shutdown program, and after the engine returns to idle speed, the range extender controller RCU sends a shutdown command to the engine controller.

[0006] Optimally, in step (a), the range extender controller RCU is used to determine whether the current remaining power SOC of the power battery is lower than a threshold or whether the range extender controller RCU detects a fault; when the current remaining power SOC of the power battery is lower than the threshold or the range extender controller RCU detects a fault, the engine low-voltage motor is started; the range extender controller RCU sends a start flag T50 to the engine controller ECU through the intranet CAN0, and the engine controller ECU controls the start relay to be energized to enter the starting procedure.

[0007] Furthermore, in step (a), after the starter relay is energized, the engine low-voltage motor drives the flywheel to rotate, engine synchronization is established, the throttle valve is opened, and fuel injection begins after the fuel rail pressure is established; the engine speed starts to rise to the speed threshold at which the engine controller ECU ends the start, and fuel injection in the starting phase is stopped. The engine state is identified as "running", and the engine controller ECU idle torque takes over, resuming normal fuel injection to maintain engine idling operation.

[0008] Furthermore, in step (a), when the remaining charge SOC of the power battery is higher than a threshold value and the range extender controller RCU detects no fault, reverse starting is entered, the range extender controller RCU controls the generator to reverse start the engine, and the range extender controller RCU sends a motor torque request to the generator controller MCU, and the generator controller MCU operates in a constant torque mode to reverse start the engine; When the reverse engine speed is lower than the threshold and the dragging time is greater than the maximum dragging time, the range extender controller RCU determines that the start has failed; when the reverse engine speed is greater than the threshold and exceeds a certain time, the range extender controller RCU determines that the engine start is successful and the reverse torque is cleared.

[0009] Optimally, in step (b), based on the driver's operating habits, the vehicle controller VCU uses OTA to upgrade the "economy-power" dual-mode switching logic, and adds an intelligent memory function to autonomously learn high-frequency route characteristics and automatically optimize the energy distribution strategy.

[0010] Optimally, in step (c), when the driver turns the key to the OFF position or the range extender controller RCU reports a level 3 or above fault, the vehicle controller outputs the generator power demand P0=0 and sends a shutdown command to the range extender controller RCU.

[0011] Furthermore, in step (c), the engine controller ECU executes a shutdown action after receiving the shutdown message, the engine speed drops to zero, and the engine state is identified as "shutdown".

[0012] Due to the application of the above technical solution, the present invention has the following advantages compared with the existing technology: the control method of the extended-range mining vehicle of the present invention combines the vehicle controller VCU, the range extender controller RCU, the engine controller ECU, and the generator controller MCU according to a specific distributed CAN communication topology structure and optimizes the control steps, which can realize efficient energy management and dynamic response optimization control of the power system, and is suitable for hybrid engineering vehicles under complex working conditions such as mines. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a CAN topology diagram used in the extended-range mining vehicle of the present invention; Figure 2 This is a flow chart of the starting process in the control method of the extended-range mining vehicle of the present invention; Figure 3 This is a flow chart of the operation process of the control method of the extended-range mining vehicle of the present invention; Figure 4 The figure is a flow chart of the shutdown process in the control method of the extended-range mining vehicle of the present invention. DETAILED DESCRIPTION

[0014] The present invention will be further described below with reference to the embodiments shown in the accompanying drawings.

[0015] like Figure 1 The distributed CAN topology shown includes a first CAN network, a second CAN network and a third CAN network.

[0016] The first CAN network includes the power CAN2, as well as the vehicle controller (VCU) and range extender controller (RCU), which are connected to the power CAN2 and communicate bidirectionally (i.e., the vehicle controller (VCU) and the range extender controller (RCU) communicate bidirectionally via the power CAN2 at a baud rate of 500 kbps). The second CAN network includes the intranet CAN1, as well as the range extender controller (RCU) and the generator controller (MCU), which are connected to the intranet CAN1 and communicate bidirectionally (i.e., the range extender controller (RCU) and the generator controller (MCU) communicate bidirectionally via the intranet CAN1 at a baud rate of 500 kbps). The third CAN network includes the intranet CAN0, as well as the range extender controller (RCU) and the engine controller (ECU), which are connected to the intranet CAN0 and communicate bidirectionally (i.e., the range extender controller (RCU) and the engine controller (ECU) communicate bidirectionally via the intranet CAN0 at a baud rate of 250 kbps).

[0017] The control method of the extended-range mining vehicle based on the above-mentioned distributed CAN topology structure (i.e., the control method of the extended-range mining vehicle adopts the above-mentioned distributed CAN topology structure) comprises the following steps: (a) Start process control: The vehicle control unit (VCU), engine control unit (ECU), range extender (RCU), and generator control unit (MCU) are all powered on simultaneously (specifically, the driver turns the key to the ON position, and the vehicle control unit (VCU), engine control unit (ECU), range extender (RCU), and generator control unit (MCU) are all powered on simultaneously, with the power-on flag T15 set). The driver then turns the key to the start position, causing the vehicle control unit (VCU) to issue a start command to the range extender (RCU), and the range extender (RCU) enters the start sequence. In step (a), the range extender controller RCU is used to determine whether the current remaining power SOC of the power battery is lower than a threshold value or whether the range extender controller RCU detects a fault; when the current remaining power SOC of the power battery is lower than the threshold value or the range extender controller RCU detects a fault, the engine low-voltage motor is started; the range extender controller RCU sends a start flag T50 to the engine controller ECU through the intranet CAN0, and the engine controller ECU controls the start relay to be attracted to enter the starting program.

[0018] In step (a), after the starter relay is energized, the engine low-voltage motor drives the flywheel to rotate, engine synchronization is established, the throttle valve is opened, and fuel injection begins after the fuel rail pressure is established; the engine speed starts to rise to the speed threshold at which the engine controller ECU ends the start, and the starting phase fuel injection is stopped. The engine state is identified as "running", and the engine controller ECU idle torque takes over, resuming normal fuel injection to maintain engine idling.

[0019] In step (a), when the remaining power SOC of the power battery is higher than the threshold and the range extender controller RCU does not detect any fault, the reverse start is entered, the range extender controller RCU controls the generator to reverse the engine start, and the range extender controller RCU sends a motor torque request to the generator controller MCU, and the generator controller MCU works in a constant torque mode to reverse the engine; when the reverse engine speed is lower than the threshold and the dragging time is greater than the maximum dragging time, the range extender controller RCU determines that the start has failed; when the reverse engine speed is greater than the threshold and exceeds a certain time, the range extender controller RCU determines that the engine start is successful, and the reverse torque is cleared at the same time, such as Figure 2 shown.

[0020] (b) Operation process control: The vehicle controller (VCU) monitors the battery pack SOC status in real time and dynamically adjusts the range extender's power generation according to the driving conditions. When the range-extended mining vehicle is in a heavily loaded uphill condition in a mine, the VCU monitors the load and slope in real time and dynamically adjusts the power distribution ratio between the range extender and the generator to ensure smooth torque output and optimal fuel economy. When the range-extended mining vehicle is in a long-distance downhill condition, the VCU activates the brake energy recovery system to convert kinetic energy into electrical energy and store it in the battery (the recovery efficiency can reach more than 85%). At the same time, the electric retarding function is combined to reduce mechanical brake wear and extend the life of the brake system. When the range-extended mining vehicle is in a short-distance transportation condition in a mine (high-frequency start-stop), the VCU adopts a predictive energy management algorithm to preheat the range extender in advance based on GPS path planning, reduce cold start emissions, and maintain the battery pack SOC in the range of 40% to 80% to extend battery life. Based on the driver's operating habits, the vehicle controller VCU uses OTA to upgrade the "economy-power" dual-mode switching logic, and adds an intelligent memory function to autonomously learn high-frequency route characteristics and automatically optimize energy distribution strategies, thereby improving the overall energy efficiency by another 8% (e.g. Figure 3 shown).

[0021] The vehicle controller VCU outputs the generator power demand P0 according to the above strategy and transmits it to the range extender controller RCU through the power CAN2; the range extender controller RCU retrieves the engine speed demand N0 based on P0; the range extender controller RCU calculates the initial torque demand T0 based on P0 and N0, and the calculation formula is: T0=9550*P0 / N0; the range extender controller RCU calculates the generator torque demand T1 based on the initial torque demand T0 and the power generation efficiency η0, and the calculation formula is: T1=T0 / η0 The range extender controller RCU has two control modes: control mode 1 and control mode 2: Control mode 1: The generator is in constant torque control mode, and the engine is in constant speed control mode; Control mode 2: The generator is in constant speed control mode, and the engine is in constant torque control mode.

[0022] When the control mode is calibrated to control mode 1: (1) The range extender controller RCU sends a constant torque control mode request to the generator controller MCU, and the generator controller MCU controls the generator to enter the constant torque control mode; (2) The range extender controller RCU sends a torque request T1 to the generator controller MCU. The generator controller MCU converts it into the corresponding current target value, continuously monitors the output torque (estimated by current), and compares it with T1, eliminating the deviation through closed-loop correction; (3) The range extender controller RCU sends the engine speed target N0 to the engine controller ECU. The ECU continuously monitors the engine speed by adjusting the engine output torque and compares it with N0, eliminating the deviation through closed-loop correction. When the control mode is calibrated to control mode 2: (1) The range extender controller RCU sends a constant speed control mode request to the generator controller MCU, and the generator controller MCU controls the generator to enter the constant speed control mode; (2) The range extender controller RCU sends a speed request N0 to the generator controller MCU. The generator controller MCU converts it into the corresponding current target value, continuously monitors the speed, and compares it with N0 to eliminate the deviation through closed-loop correction; (3) The range extender controller RCU sends the engine torque target T1 to the engine controller ECU. The engine controller ECU combines the current engine status (speed, sensor measurements, etc.) and calculates the required actuator action through the torque model: Tengine = f(throttle opening, fuel injection amount, ignition advance angle, etc.), so that the torque model value Tengine = T1.

[0023] (c) Shutdown process control: When the driver turns the key to OFF or the range extender controller (RCU) reports a level 3 or higher fault, the vehicle controller outputs the generator power demand P0 = 0 and simultaneously sends a shutdown command to the range extender controller (RCU). After receiving the power reset request, the range extender controller (RCU) sends a load shedding request to the generator controller MCU. The generator controller MCU controls the current to shed the power load. The range extender controller releases the engine constant speed or constant torque control request, and the engine returns to idle speed; the range extender controller RCU triggers the shutdown program, and after the engine returns to idle speed, the range extender controller RCU sends a shutdown command to the engine controller; the engine controller ECU executes the shutdown action after receiving the shutdown message, the engine speed drops to zero, and the engine status is identified as "stopped", such as Figure 4 shown.

[0024] The above embodiments are intended only to illustrate the technical concepts and features of the present invention. Their purpose is to enable those skilled in the art to understand the contents of the present invention and implement them accordingly. They are not intended to limit the scope of protection of the present invention. Any equivalent changes or modifications made in accordance with the spirit of the present invention are intended to be covered by the scope of protection of the present invention.

Claims

1. A control method for an extended-range mining vehicle, characterized in that: A distributed CAN topology is adopted, and the distributed CAN topology includes: A first CAN network, comprising a power CAN2 and a vehicle controller VCU and a range extender controller RCU connected to the power CAN2 and communicating bidirectionally; A second CAN network, the second CAN network including an intranet CAN1 and the range extender controller RCU and the generator controller MCU connected to the intranet CAN1 and communicating bidirectionally; A third CAN network, the third CAN network including an intranet CAN0 and the range extender controller RCU and the engine controller ECU connected to the intranet CAN0 and communicating bidirectionally; The following steps are involved: (a) Startup process control: The vehicle controller (VCU), the engine controller (ECU), the range extender controller (RCU), and the generator controller (MCU) are all powered on; the vehicle controller (VCU) issues a start command to the range extender controller (RCU), and the range extender controller (RCU) enters a startup procedure; (b) Operation process control: The vehicle controller VCU monitors the battery pack SOC status in real time and dynamically adjusts the range extender power generation power in combination with the driving conditions; when the range-extended mining vehicle is in a heavy-load uphill condition in a mine, the vehicle controller VCU monitors the load and slope in real time and dynamically adjusts the power distribution ratio between the range extender and the generator to ensure smooth torque output and optimal fuel economy; when the range-extended mining vehicle is in a long-distance downhill condition, the vehicle controller VCU activates the braking energy recovery system to convert kinetic energy into electrical energy and store it in the battery; when the range-extended mining vehicle is in a short-distance transportation condition in a mine, the vehicle controller VCU adopts a predictive energy management algorithm to preheat the range extender in advance based on GPS path planning, reduce cold start emissions, and maintain the battery pack SOC in the range of 40% to 80% to extend battery life; (c) Shutdown process control: After receiving the request to return the generated power to zero, the range extender controller RCU sends a request to remove the generated load to the generator controller MCU, and the generator controller MCU controls the current to remove the generated load; The range extender controller releases the engine constant speed or constant torque control request, and the engine returns to idle speed; the range extender controller RCU triggers a shutdown program, and after the engine returns to idle speed, the range extender controller RCU sends a shutdown command to the engine controller.

2. The control method for an extended-range mining vehicle according to claim 1, characterized in that: In step (a), the range extender controller RCU is used to determine whether the current remaining power SOC of the power battery is lower than a threshold value or whether the range extender controller RCU detects a fault; when the current remaining power SOC of the power battery is lower than the threshold value or the range extender controller RCU detects a fault, the engine low-voltage motor is started; the range extender controller RCU sends a start flag T50 to the engine controller ECU through the intranet CAN0, and the engine controller ECU controls the start relay to be energized to enter the starting procedure.

3. The control method for an extended-range mining vehicle according to claim 2, characterized in that: In step (a), after the starter relay is energized, the engine low-voltage motor drives the flywheel to rotate, engine synchronization is established, the throttle valve is opened, and fuel injection begins after the fuel rail pressure is established; the engine speed starts to rise to the speed threshold at which the engine controller ECU terminates the start, and fuel injection during the start phase is stopped. The engine state is identified as "running", and the engine controller ECU takes over the idle torque, resuming normal fuel injection to maintain engine idling.

4. The control method for an extended-range mining vehicle according to claim 3, characterized in that: In step (a), when the remaining charge (SOC) of the power battery is higher than a threshold value and the range extender controller (RCU) detects no fault, reverse starting is performed, the range extender controller (RCU) controls the generator to reverse start the engine, and the range extender controller (RCU) sends a motor torque request to the generator controller (MCU), and the generator controller (MCU) operates in a constant torque mode to reverse start the engine; When the reverse engine speed is lower than the threshold and the dragging time is greater than the maximum dragging time, the range extender controller RCU determines that the start has failed; when the reverse engine speed is greater than the threshold and exceeds a certain time, the range extender controller RCU determines that the engine start is successful and the reverse torque is cleared.

5. The control method for an extended-range mining vehicle according to claim 1, characterized in that: In step (b), based on the driver's operating habits, the vehicle controller VCU uses OTA to upgrade the "economy-power" dual-mode switching logic, and adds an intelligent memory function to autonomously learn high-frequency route characteristics and automatically optimize energy distribution strategies.

6. The control method of the extended-range mining vehicle according to claim 1, characterized in that: In step (c), when the driver turns the key to OFF or the range extender controller RCU reports a level 3 or above fault, the vehicle controller outputs the generator power demand P0=0 and sends a shutdown command to the range extender controller RCU.

7. The control method for an extended-range mining vehicle according to claim 6, characterized in that: In step (c), the engine controller ECU executes a shutdown action after receiving the shutdown message, the engine speed drops to zero, and the engine state is identified as "shutdown".

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