Control system of hybrid road roller

Abstract

The invention discloses a control system of a hybrid road roller, energy conservation, noise reduction and performance improvement are realized through collaborative innovation of a power system and an energy management system, the system adopts a range extender architecture in which an engine is rigidly connected with a generator, and the system is completely powered by a battery pack in a pure electric mode to realize zero-emission operation; in the hybrid mode, the engine operates in the optimal efficiency interval to generate electricity, and the controllability of complex working conditions is improved through differential control in cooperation with the front and rear steel wheel walking motors and the vibration motor which are independently driven. The system integrates a walking and vibration dual-channel energy recovery function, the recovery efficiency is dynamically adjusted in cooperation with a braking strength self-adaptive algorithm, and stable heat dissipation under the high-temperature and high-load working condition is achieved in combination with an integrated radiator and an intelligent temperature control module. Through the engine automatic start-stop strategy and the generator reverse drag start technology, the low-temperature environment start bottleneck is broken through, and the pure power endurance time is prolonged in cooperation with the design of an electric-driven air conditioner and a multipurpose electric interface.

Description

Technical Field

[0001] The present invention relates to the application field of road rollers, and in particular to a control system of a hybrid road roller. Background Art

[0002] Road rollers are a key type of road construction machinery. They effectively enhance compaction performance through a combination of high-frequency vibration and static pressure, making them widely used in projects such as road construction, airport runways, and parking lots. Vibratory rollers typically consist of a steel drum, engine, vibration system, and cab. The drum incorporates an eccentric weight, which generates vibration through rotation, enhancing compaction. Depending on the application, rollers are available in various types, including single-drum, dual-drum, and tire-type models, suited to various working conditions. Their efficiency and flexibility make them indispensable equipment in modern infrastructure construction.

[0003] In common hybrid roller technical solutions, the engine usually needs to cover the power requirements of all working conditions, which makes it difficult for it to continue to operate in the optimal efficiency range, increasing fuel consumption and generating higher noise levels. The travel system and vibration system mostly rely on mechanical transmission mechanisms to achieve power distribution, and the differential control accuracy is insufficient, which affects the operational flexibility under complex working conditions. The energy recovery function is often limited to a single system, and the recovery intensity lacks a dynamic adjustment mechanism, which limits the room for improving energy utilization. The components of the heat dissipation system are arranged independently and need to operate at high load continuously to ensure the temperature control effect, resulting in additional energy consumption. In addition, traditional starting devices have response delay problems in low temperature or high pressure environments, which affects the adaptability of the equipment to extreme working conditions and cannot meet the working requirements of roller applications. For this reason, a control system for a hybrid roller is proposed. Summary of the Invention

[0004] The present invention provides the following technical solution: a control system for a hybrid roller, comprising: Power system, travel system, vibration system, energy recovery system, cooling system, power supply system and control system; The power system includes an engine, a generator, an electric motor and a battery pack; the travel system includes front and rear steel wheels, each of which is equipped with at least one travel drive motor and a travel drive motor controller; the vibration system includes a vibration motor and a vibration motor controller; the cooling system includes a motor-driven fan and an integrated radiator; the power supply system includes a DCDC converter; and the control system includes a controller. Since the travel system and the vibration system are both driven by independent motors, the travel drive motors configured for the front and rear steel wheels can achieve precise differential control, thereby improving the control flexibility under complex working conditions. In addition, the electric-driven air conditioner and various electrical equipment are directly powered by the power supply system, thereby extending the battery life in pure electric mode and ensuring all-weather operating comfort. The engine and generator are mechanically connected to form a range extender power generation unit. The generator is connected to a high-voltage distribution box via a generator controller. The high-voltage distribution box is respectively connected to a battery pack, a vibration motor controller, a travel drive motor controller, and a DC / DC converter. The travel drive motor is connected to the travel drive motor controller, and the vibration motor is connected to the vibration motor controller. This allows the vehicle to be fully powered by the battery pack in pure electric mode, achieving zero-emission operation. In hybrid mode, the engine only needs to maintain power generation within the optimal efficiency range, thereby reducing the noise level of the entire vehicle and improving the comfort of the working environment. The energy recovery system realizes energy recovery through the travel drive motor and the vibration motor, and stores the recovered energy in the battery pack. The energy recovery system is additionally provided with a braking energy recovery optimization algorithm, and dynamically adjusts the energy recovery efficiency according to the braking intensity. The inertial energy generated by the travel system and the vibration system during operation can be efficiently recovered by the reverse drag of their respective drive motors. When traveling and decelerating, the travel drive motors of the front and rear steel wheels are converted into generator mode, converting kinetic energy into electrical energy and storing it in the battery pack. When vibrating and decelerating, the vibration motor synchronously performs energy recovery, and cooperates with the braking energy recovery optimization algorithm to dynamically adjust the recovery intensity, thereby significantly improving energy utilization. The integrated radiator includes an engine intercooler, an engine water radiator, an electric drive system radiator and a hydraulic oil radiator. The fan is used to provide heat dissipation for the cooling system. The cooling system is equipped with an intelligent temperature control module. The power supply system includes a DCDC converter. The engine intercooler, engine water radiator, electric drive system radiator and hydraulic oil radiator are highly integrated through the integrated radiator. On-demand heat dissipation is achieved through a motor-driven fan. The added intelligent temperature control module can monitor the temperature of each system in real time and dynamically adjust the fan speed to avoid the risk of overheating while reducing heat dissipation energy consumption, thereby ensuring the stability of the hybrid system under high temperature and high load conditions.

[0005] Preferably, the generator controller is connected to the electrical control end of the generator, and the generator is connected to the battery pack, vibration motor controller, travel drive motor controller and DCDC converter through a high-voltage distribution box. Direct digital signal transmission is used to achieve precise regulation of the generator output power, avoiding the lag of traditional mechanical adjustment. In addition, a modular power supply design is adopted, which can automatically switch the power supply path according to load requirements, thereby improving system stability.

[0006] Preferably, in pure electric mode, the battery pack is connected to the generator, travel drive motor, vibration motor, DCDC converter and cooling system for power supply, and the travel system power output is prioritized through intelligent power distribution, thereby improving the maneuverability of the roller in confined spaces. In hybrid mode, the engine and battery pack are connected to the travel drive motor, vibration motor and DC-DC converter for power supply, and the engine operates in the high-efficiency range, significantly reducing fuel consumption and exhaust emissions. In the engine direct drive mode, the engine drives the travel drive motor and vibration motor through the generator to operate, and achieves stepless speed change through motor speed adjustment, simplifying the traditional gearbox structure.

[0007] Preferably, a steering pump is installed inside the roller, and the steering pump is connected to the generator interface and the travel drive motor controller through wires, and steering assistance is achieved through electro-hydraulic coordinated control to improve low-speed steering flexibility and high-speed driving stability.

[0008] Preferably, the roller is internally equipped with an OBC AC charging interface, which is connected to the battery pack via a wire, so that it can support multi-standard charging protocols, be compatible with different charging devices, and improve the adaptability of the device to different scenarios.

[0009] Preferably, the controller is used to optimize the working mode switching strategy based on real-time working condition data and historical operating habits through an artificial intelligence algorithm. The working mode switching strategy is specifically: under low-load conditions, the pure electric mode is given priority to reduce energy consumption and noise; under high-load conditions, it automatically switches to the hybrid mode or the engine direct drive mode; when the load fluctuates, the power distribution of the generator and the battery pack is dynamically adjusted to keep the engine working in a low fuel consumption area; an operating habit model is established through machine learning to achieve intelligent prediction and seamless switching of working modes.

[0010] Preferably, the controller dynamically adjusts the energy recovery power by adding a brake energy recovery optimization algorithm, and adjusts the recovery power in real time according to the brake pedal stroke and the vehicle speed change rate, and optimizes the energy recovery current and voltage according to the battery pack's charge, temperature and internal resistance, and detects the road slope and wetness through sensors to adjust the response speed and efficiency of energy recovery.

[0011] Preferably, the engine adopts extended range power generation control to operate at low speed and low fuel consumption under low load conditions, and charges the battery pack through the generator, thereby extending the cruising range by matching the generated power; When the engine is under high load conditions, the battery pack and the generator jointly output power. When the load fluctuates, the generator acts as an electric motor to assist the engine in outputting power or as a generator to absorb engine power to reduce engine speed fluctuations and keep the engine operating in a low fuel consumption area, thereby effectively suppressing engine speed fluctuations and improving driving smoothness.

[0012] Preferably, the cooling system uses a motor-driven fan to ensure the heat dissipation performance of the engine, electric drive system and hydraulic system in various working modes.

[0013] Preferably, the travel drive motor of the front steel wheel and the travel drive motor of the rear steel wheel are respectively connected to the travel drive motor controller, and the engine and the generator are mechanically connected through a rigid coupling to form a range extender power generation unit. The range extender power generation unit is used to automatically start when the battery pack power is lower than a set threshold, charge the battery pack or directly power the travel drive motor and the vibration motor, and ensure the continuity of power supply through rapid response.

[0014] In summary, compared with the prior art, the present invention provides a control system for a hybrid road roller, which has the following beneficial effects: 1. This invention mechanically connects the engine and generator to form a range-extender power generation unit. This allows the vehicle to be fully powered by the battery pack in pure electric mode, achieving zero-emission operation. In hybrid mode, the engine only needs to generate electricity within its optimal efficiency range, reducing vehicle noise and improving operating comfort. Furthermore, because both the travel and vibration systems are driven by independent motors, the travel drive motors on the front and rear steel wheels can achieve precise differential speed control, enhancing operational flexibility under complex operating conditions. Furthermore, the electric-driven air conditioner and various electrical devices draw power directly from the power supply system, extending pure electric mode endurance and ensuring all-weather operating comfort. 2. The inertial energy generated by the travel system and vibration system during operation of the present invention can be efficiently recovered through the reverse drag of their respective drive motors. When traveling and decelerating, the travel drive motors of the front and rear steel wheels are converted to generator mode, converting kinetic energy into electrical energy and storing it in the battery pack. During vibration deceleration, the vibration motor simultaneously performs energy recovery, and the recovery intensity is dynamically adjusted in conjunction with the brake energy recovery optimization algorithm, significantly improving energy utilization. At the same time, the engine intercooler, engine water radiator, electric drive system radiator and hydraulic oil radiator are highly integrated through an integrated radiator. On-demand heat dissipation is achieved through a motor-driven fan. The added intelligent temperature control module can monitor the temperature of each system in real time and dynamically adjust the fan speed to avoid the risk of overheating while reducing heat dissipation energy consumption, ensuring the stability of the hybrid system under high temperature and high load conditions. The control system can also automatically execute the engine start-stop strategy based on the battery pack power and operating requirements. In low temperature or high pressure environments, the generator can quickly wake up the engine through the reverse drag start function, avoiding the reliability bottleneck of traditional starters and improving the system response speed under extreme operating conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a system architecture block diagram of the present invention.

[0016] Figure 2 It is a block diagram of the power system architecture of the present invention.

[0017] Figure 3 It is a block diagram of the walking system architecture of the present invention. DETAILED DESCRIPTION

[0018] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0019] See also Figure 1 The present invention provides a technical solution, a control system for a hybrid roller, comprising: Power system, travel system, vibration system, energy recovery system, cooling system, power supply system and control system; See also Figure 2 , the power system includes engine, generator, electric motor and battery pack, please refer to Figure 3 The travel system includes a front steel wheel and a rear steel wheel, each of which is equipped with at least one travel drive motor and a travel drive motor controller. The vibration system includes a vibration motor and a vibration motor controller. The cooling system includes a motor-driven fan and an integrated radiator. The power supply system includes a DCDC converter. The control system includes a controller. The engine and the generator are mechanically connected to form a range extender power generation unit. The generator is connected to the high-voltage distribution box through the generator controller. The high-voltage distribution box is respectively connected to the battery pack, the vibration motor controller, the travel drive motor controller and the DCDC. The travel drive motor is connected to the travel drive motor controller, the vibration motor is connected to the vibration motor controller, and the generator controller is connected to the electronic control end of the generator. The generator is connected to the battery pack, the vibration motor controller, the travel drive motor controller and the DCDC converter through the high-voltage distribution box. The travel drive motor of the front steel wheel and the travel drive motor of the rear steel wheel are respectively connected to the travel drive motor controller. The engine and the generator are mechanically connected through a rigid coupling and form a range extender power generation unit. The range extender power generation unit is used to automatically start when the battery pack power is lower than the set threshold to charge the battery pack or directly power the travel drive motor and the vibration motor. In pure electric mode, the battery pack is connected to the generator, travel drive motor, vibration motor, DCDC converter and cooling system for power supply; In hybrid mode, the engine and battery pack are connected to the travel drive motor, vibration motor and DCDC converter for power supply; In the engine direct drive mode, the engine drives the travel drive motor and vibration motor through the generator to operate; The energy recovery system recovers energy through the travel drive motor and vibration motor, and stores the recovered energy in the battery pack. The energy recovery system has been equipped with a brake energy recovery optimization algorithm, and dynamically adjusts the energy recovery efficiency according to the braking intensity. The integrated radiator includes the engine intercooler, engine water radiator, electric drive system radiator and hydraulic oil radiator. The fan is used to provide heat dissipation for the cooling system. The cooling system is equipped with an intelligent temperature control module. The cooling system uses a motor to drive the fan to ensure the heat dissipation performance of the engine, electric drive system and hydraulic system in various operating modes. The power supply system includes a DCDC converter. The steering pump is installed inside the roller. The steering pump is connected to the generator interface and the travel drive motor controller via wires. The roller is equipped with an OBC AC charging interface, which is connected to the battery pack via wires. The controller is used to optimize the working mode switching strategy based on real-time working condition data and historical operating habits through artificial intelligence algorithms. The specific working mode switching strategy is: under low-load conditions, pure electric mode is prioritized to reduce energy consumption and noise; under high-load conditions, it automatically switches to hybrid mode or engine direct drive mode. When the load fluctuates, the power distribution between the generator and the battery pack is dynamically adjusted to keep the engine operating in a low fuel consumption area. The controller dynamically adjusts the energy recovery power by adding a brake energy recovery optimization algorithm. The brake energy recovery optimization algorithm uses fuzzy control technology and adjusts the recovery power in real time according to the brake pedal travel and vehicle speed change rate. It also optimizes the energy recovery current and voltage according to the battery pack's charge, temperature and internal resistance. In addition, sensors are used to detect the road slope and wetness to adjust the response speed and efficiency of energy recovery. The specific process of using the brake energy recovery optimization algorithm to dynamically adjust the energy recovery efficiency according to the braking intensity is as follows: Data acquisition and input: The brake pedal sensor collects real-time brake pedal travel data to reflect the driver's braking intention and braking intensity. The vehicle speed sensor collects real-time vehicle speed data and calculates the vehicle speed change rate, i.e., acceleration or deceleration, to determine the vehicle's braking status. The battery management system collects real-time parameters such as battery pack power, temperature, and internal resistance to evaluate the battery's charging capacity and safety. The input variables of the fuzzy control algorithm are divided into three fuzzy levels: "light braking", "medium braking" and "strong braking", the vehicle speed change rate is divided into three fuzzy levels: "slow deceleration", "medium deceleration" and "high deceleration", and the battery status is divided into three fuzzy levels: "low battery", "medium battery" and "high battery". Fuzzy processing converts the collected precise input data (such as brake pedal travel, vehicle speed change rate and battery status) into fuzzy variables through membership functions; Fuzzy rule base,The fuzzy rule base is the core of the fuzzy control algorithm,,which defines the logical relationship between input variables and output,variables, including the following rules; Rule 1: If the brake pedal travel is "light braking", the vehicle speed change rate is "slow deceleration", and the battery status is "high charge", the regenerative power is "low"; Rule 2: If the brake pedal travel is "medium braking", the vehicle speed change rate is "medium deceleration", and the battery status is "medium charge", the regenerative power is "medium"; Rule 3: If the brake pedal travel is "strong braking", the vehicle speed change rate is "high deceleration", and the battery status is "low battery", the regenerative power is "high"; Fuzzy reasoning: Based on the fuzzy rule base and the fuzzy values ​​of the input variables, fuzzy reasoning is used to calculate the fuzzy value of the recovered power. Fuzzy reasoning usually uses the Mamdani method or the Sugeno method, combined with logical operations such as "AND" and "OR", to obtain the fuzzy output of the recovered power; Defuzzification: converting the fuzzy value of the recovered power obtained by fuzzy reasoning into an accurate output value through the defuzzification method; Real-time adjustment of regenerative power: Based on the defuzzified regenerative power value, the controller adjusts the operating status of the travel and vibration motors in real time, enabling them to function as generators during braking or deceleration, converting kinetic energy into electrical energy and storing it in the battery pack. The controller also dynamically adjusts regenerative power based on battery status (such as charge level, temperature, and internal resistance) to prevent overcharging or overheating, ensuring battery safety and lifespan. Under low-load conditions, the engine uses extended-range power generation control to operate at low speed and low fuel consumption, and charges the battery pack through the generator; When the engine is under high load conditions, the battery pack and the generator jointly output power. When the load fluctuates, the generator acts as an electric motor to assist the engine in outputting power or as a generator to absorb engine power to reduce engine speed fluctuations and keep the engine operating in a low fuel consumption area.

[0020] This solution forms a range extender power generation unit through a mechanical connection between the engine and the generator, so that in pure electric mode, the battery pack can be fully powered to achieve zero-emission operation. At the same time, in hybrid mode, the engine only needs to maintain the optimal efficiency range for power generation, thereby reducing the noise level of the entire vehicle and improving the comfort of the working environment. In addition, since the travel system and the vibration system are both driven by independent motors, the travel drive motors configured for the front and rear steel wheels can achieve precise differential control, improving the control flexibility under complex working conditions. In addition, the electric drive air conditioner and various electrical equipment are directly powered by the power supply system, thereby extending the pure electric mode endurance and ensuring all-weather operation comfort. The specific implementation process of the above functions is as follows; During the operation of the hybrid roller, the power system achieves efficient energy management through multi-mode collaborative control. When the operator selects the pure electric mode, the control system immediately cuts off the mechanical connection between the engine and the transmission system, putting the range extender power generation unit in standby mode. At this time, the battery pack becomes the only power source, and transmits high-voltage DC power to the travel drive motor controller and the vibration motor controller through the high-voltage distribution box. The travel drive motor controller inverts DC power into three-phase AC power to drive the independent travel drive motors configured for the front and rear steel wheels. Since the front and rear motors adopt a split control architecture, the controller can implement differential speed adjustment for the left and right motors based on the steering sensor signal. When the roller needs to turn, the inner motor automatically reduces the output speed, and the outer motor maintains or increases the speed, and precise steering control is achieved through the speed difference. Compared with the traditional mechanical differential, this electronically controlled differential mechanism has a faster response speed and no mechanical wear problem; In pure electric drive mode, the electric drive air conditioning system draws power from the battery pack through a dedicated DCDC converter. This converter adopts an isolated design, converting high-voltage DC power into low-voltage DC power, which is directly supplied to the air conditioning compressor and fan. Since the air conditioning system operates independently of the engine, when operating during the high temperature period at noon, the operator can continue to use the air conditioner without starting the engine, which not only avoids the noise and emissions generated by engine idling, but also significantly extends the pure electric driving range. Ancillary electrical appliances such as on-board refrigerators and lighting equipment also draw power through independent power supply circuits, forming a multi-level power network to ensure the rationality of energy distribution between the main drive system and auxiliary systems; When it is detected that the battery pack power is lower than the preset threshold, the control system automatically switches to hybrid mode. At this time, the engine drives the generator through a rigid coupling, and the AC power generated by the generator is rectified and filtered, and then intelligently distributed through the high-voltage distribution box. Under light load conditions, the generator outputs electricity to charge the battery pack first, while supplementing the real-time consumption of the travel system and vibration system; under medium and heavy load conditions, the generator and the battery pack form a parallel power supply, and the engine operates in the economic speed range of 1800-2200rpm. The electricity it generates and the DC power output by the battery pack are converged in the distribution box to jointly drive the travel motor and vibration motor. This energy management strategy enables the engine to always operate in the optimal efficiency range. Compared with traditional rollers, the comprehensive noise value in hybrid mode is significantly reduced, and operators can work for a long time without wearing earplugs; During hybrid mode operation, the energy supply of the vibration system is achieved through a dedicated vibration motor controller. When compaction operations are required, the controller converts the DC power provided by the battery pack or generator into high-frequency AC power to drive the vibration motor to generate excitation force. Since the vibration system and the travel system use independent motor drive architectures, the power output of the two can be decoupled and controlled. Under complex working conditions, the operator can adjust the vibration frequency and travel speed separately. Compared with traditional hydraulic vibration systems, this separate control mechanism has higher energy transfer efficiency and no risk of hydraulic oil leakage. When the roller is temporarily shut down, the control system activates intelligent temperature management. The motor-driven fan, in response to commands from the intelligent temperature control module, pulses heat away from the electric drive system radiator. This on-demand cooling mechanism reduces energy consumption compared to traditional engine-driven fans. The integrated radiator utilizes a layered design, with the engine intercooler, electric drive system radiator, and hydraulic oil radiator forming a three-dimensional heat dissipation matrix. By optimizing the airflow path, cooling air flows sequentially through each heat source component, ensuring that the electric drive system temperature remains within safe thresholds even in high-temperature environments, ensuring continuous operation in pure electric mode.

[0021] The inertial energy generated by the travel system and vibration system of this solution during operation can be efficiently recovered through the reverse driving of their respective drive motors. When traveling and decelerating, the travel drive motors of the front and rear steel wheels are converted into generator mode, converting kinetic energy into electrical energy and storing it in the battery pack. When vibrating and decelerating, the vibration motor synchronously performs energy recovery, and cooperates with the brake energy recovery optimization algorithm to dynamically adjust the recovery intensity, significantly improving energy utilization. The specific implementation process of the above functions is as follows; During the operation of the hybrid roller, the energy recovery system converts kinetic energy into electrical energy and stores it through the coordinated work of multiple components. When the operator applies the brakes or needs to reduce the driving speed, the travel system immediately activates the energy recovery program. At this time, the travel drive motors configured for the front and rear steel wheels synchronously switch their operating modes, from driving to generating. The motor controller switches the three-phase winding from electric operation mode to generating operation mode by changing the switching timing of the power semiconductor devices, causing the motor rotor to continue rotating under the action of inertia, cutting the magnetic flux lines, thereby generating an induced electromotive force; The electric energy is initially rectified by the travel motor controller, converted into high-voltage direct current, and then transmitted to the high-voltage distribution box. As the energy routing hub, the high-voltage distribution box intelligently distributes the flow of recovered electric energy based on the real-time status evaluation results of the battery management system. When the battery pack temperature is within a reasonable range and has not reached a fully charged state, the recovered electric energy is preferentially voltage-adapted through the bidirectional DCDC converter, and the battery pack is trickle-charged with the optimal charging curve. If it is detected that the battery pack is already in a high-charge state, the system automatically adjusts the power distribution strategy and directly supplies part of the recovered electric energy to the vibration system or cooling system; When the vibration system decelerates, the vibration motor simultaneously initiates energy recovery. The vibration motor controller adjusts the inverter output frequency to generate braking torque in the motor's stator magnetic field, suppressing the vibration wheel's speed while converting mechanical energy into electrical energy. This electrical energy is processed by a dedicated rectifier module and then combined with the energy recovered from the travel system and fed into the high-voltage distribution box. This is when the braking energy recovery optimization algorithm begins to play a key regulatory role, enabling dynamic adjustment through multi-dimensional parameter input. The algorithm first obtains the driver's braking intention through the brake pedal displacement sensor and, combined with the real-time speed change rate collected by the vehicle speed sensor, establishes a braking intensity assessment model. When an emergency braking condition is detected, the algorithm automatically increases the priority of energy recovery to maximize the efficiency of electric energy conversion while ensuring braking safety. In light braking scenarios, the algorithm focuses on maintaining the smoothness of the recovery process. At the same time, the battery management system's real-time feedback on voltage, current, temperature, and internal resistance parameters enables the algorithm to dynamically adjust the charging power limit to avoid overcharging risks and extend battery cycle life. The environmental perception system uses a slope sensor and a slippery road detection module to provide a safety margin for the energy recovery strategy. When a downhill slope is detected, the algorithm automatically increases energy recovery intensity and uses gravitational potential energy for auxiliary braking. On slippery roads, the algorithm appropriately reduces the energy recovery efficiency to prevent excessive energy recovery from locking the drive wheels. This multi-parameter coordinated control mechanism ensures that the energy recovery system maintains efficient and stable operation even in complex conditions. After intelligent distribution, the recovered electric energy is preferentially stored in high-energy-density battery packs. The battery management system adopts a distributed architecture, independently monitors each battery module, and ensures the consistency of status between modules through a balanced charging strategy. When a voltage deviation of a module is detected, the system automatically starts the passive balancing circuit to transfer the energy of the high-voltage module to the low-voltage module, thereby improving the overall energy storage efficiency. The electric energy that is not immediately stored is reduced in voltage by the DCDC converter and used to drive the cooling system fan or power the on-board electrical appliances, realizing the cascade utilization of energy. This layered energy storage and multi-level utilization mechanism significantly improves the energy utilization rate of the entire machine; At the same time, the engine intercooler, engine water radiator, electric drive system radiator and hydraulic oil radiator are highly integrated through the integrated radiator, and on-demand heat dissipation is achieved through the motor-driven fan. The added intelligent temperature control module can monitor the temperature of each system in real time and dynamically adjust the fan speed to avoid the risk of overheating while reducing heat dissipation energy consumption, ensuring the stability of the hybrid system under high temperature and high load conditions. The control system can automatically execute the engine start-stop strategy according to the battery pack power and operating requirements, so that in low temperature or high pressure environments, the generator can quickly wake up the engine through the reverse start function, avoiding the reliability bottleneck of traditional starters and improving the system response speed under extreme conditions.

[0022] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0023] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A control system for a hybrid roller, characterized in that: include: Power system, travel system, vibration system, energy recovery system, cooling system, power supply system and control system; The power system includes an engine, a generator, an electric motor and a battery pack; the travel system includes front and rear steel wheels, each of which is equipped with at least one travel drive motor and a travel drive motor controller; the vibration system includes a vibration motor and a vibration motor controller; the cooling system includes a motor-driven fan and an integrated radiator; the power supply system includes a DC-DC converter; and the control system includes a controller; The engine and the generator are mechanically connected to form a range extender power generation unit. The generator is connected to a high-voltage distribution box via a generator controller. The high-voltage distribution box is respectively connected to a battery pack, a vibration motor controller, a travel drive motor controller and a DCDC. The travel drive motor is connected to the travel drive motor controller, and the vibration motor is connected to the vibration motor controller. The energy recovery system recovers energy through the travel drive motor and the vibration motor, and stores the recovered energy in the battery pack. The energy recovery system is equipped with a braking energy recovery optimization algorithm, and dynamically adjusts the energy recovery efficiency according to the braking intensity; The integrated radiator includes an engine intercooler, an engine water radiator, an electric drive system radiator and a hydraulic oil radiator. The fan is used to provide heat dissipation for the cooling system. An intelligent temperature control module is installed in the cooling system, and the power supply system includes a DCDC converter.

2. The control system of a hybrid roller according to claim 1, characterized in that: The generator controller is connected to the electrical control end of the generator, and the generator is connected to the battery pack, the vibration motor controller, the travel drive motor controller and the DCDC converter through the high-voltage distribution box.

3. The control system of a hybrid roller according to claim 1, characterized in that: In pure electric mode, the battery pack is connected to the generator, travel drive motor, vibration motor, DCDC converter and cooling system for power supply; In hybrid mode, the engine and battery pack are connected to the travel drive motor, vibration motor and DCDC converter for power supply; In the engine direct drive mode, the engine drives the travel drive motor and vibration motor through the generator to operate.

4. The control system of a hybrid roller according to claim 1, characterized in that: A steering pump is installed inside the roller, and the steering pump is connected to the generator interface and the travel drive motor controller through a wire.

5. The control system of a hybrid roller according to claim 1, characterized in that: The roller is equipped with an OBC AC charging interface inside, and the OBC AC charging interface is connected to the battery pack through a wire.

6. The control system of a hybrid roller according to claim 1, characterized in that: The controller is used to optimize the working mode switching strategy based on real-time working condition data and historical operating habits, and through an artificial intelligence algorithm. The working mode switching strategy is specifically: under low-load conditions, the pure electric mode is prioritized to reduce energy consumption and noise; under high-load conditions, it automatically switches to hybrid mode or engine direct drive mode; when the load fluctuates, the power distribution of the generator and battery pack is dynamically adjusted to keep the engine operating in a low fuel consumption area.

7. The control system of a hybrid roller according to claim 1, characterized in that: The controller dynamically adjusts the energy recovery power by adding a brake energy recovery optimization algorithm, and adjusts the recovery power in real time according to the brake pedal stroke and vehicle speed change rate. It also optimizes the energy recovery current and voltage according to the battery pack's charge, temperature and internal resistance, and adjusts the energy recovery response speed and efficiency by detecting the road slope and wetness through sensors.

8. The control system of a hybrid roller according to claim 1, characterized in that: The engine operates at low speed and low fuel consumption using extended range power generation control under low load conditions, and charges the battery pack through the generator; When the engine is under high load conditions, the battery pack and the generator jointly output power. When the load fluctuates, the generator acts as an electric motor to assist the engine in outputting power or as a generator to absorb engine power to reduce engine speed fluctuations and keep the engine operating in a low fuel consumption range.

9. The control system of a hybrid roller according to claim 1, characterized in that: The cooling system uses a motor-driven fan to ensure the heat dissipation performance of the engine, electric drive system and hydraulic system in various working modes.

10. The control system of a hybrid roller according to claim 1, characterized in that: The travel drive motor of the front steel wheel and the travel drive motor of the rear steel wheel are respectively connected to the travel drive motor controller, and the engine and the generator are mechanically connected through a rigid coupling to form a range extender power generation unit. The range extender power generation unit is used to automatically start when the battery pack power is lower than a set threshold to charge the battery pack or directly power the travel drive motor and the vibration motor.

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