Method and system for controlling range extender of range-extended commercial vehicle

Abstract

The invention relates to a control method and system for a range extender of an extended-range commercial vehicle, and the method comprises the steps: enabling a vehicle controller to continuously collect vehicle operation parameters, including the load state, the vehicle speed, the accelerator opening degree, a power battery, the operation state of the range extender, and the state maintaining time; switching a full-load mode or a no-load mode according to the load state; when the power battery does not reach the forced start-stop threshold value, starting the power battery according to the relation between the vehicle speed and the first vehicle speed limit value and the second vehicle speed limit value and the relation between the accelerator opening degree and the first accelerator opening degree limit value, the second accelerator opening degree limit value and the third accelerator opening degree limit value; the range extender is controlled to execute corresponding instructions of shutdown, operation in a first power generation economic point interval, operation in a second power generation economic point interval or operation in a third power generation economic point interval; according to the system method, the engine and the generator are effectively controlled in the mode that reasonable adjustment of the economic power interval of the range extender and start-stop control of the engine are combined.

Description

Technical Field

[0001] The present invention belongs to the technical field of range extender control, and specifically relates to a range extender control method and system for a range extender of an extended-range commercial vehicle. Background Art

[0002] With the deepening of global energy conservation and emission reduction policies and the widespread adoption of new energy technologies, the commercial vehicle sector is accelerating its transition to electrification. Compared to traditional fuel-powered commercial vehicles, pure electric commercial vehicles offer advantages such as zero emissions, low noise, and low operating costs. However, due to factors such as battery energy density, charging infrastructure coverage, and charging time, their range and operational efficiency still face significant challenges in scenarios such as long-distance transportation and heavy-duty operations. Range-extended technology, by integrating an engine and generator system, can charge the battery or directly power the drive motor without directly driving the vehicle, effectively addressing the range limitations of pure electric vehicles and becoming a key transitional solution for commercial vehicle electrification.

[0003] The core of extended-range commercial vehicles lies in the efficient control of the range extender, whose control strategy directly impacts the vehicle's fuel economy, emissions performance, powertrain smoothness, and system reliability. Traditional range extender control strategies often employ a "fixed threshold start-stop" model (e.g., forcing the range extender to start or stop when the battery charge falls below or rises above a specific threshold). These strategies fail to fully incorporate the vehicle's real-time operating conditions, leading to frequent starts and stops or prolonged operation of the range extender in an inefficient range. This results in wasted fuel, excessive emissions, and inefficient energy management. Summary of the Invention

[0004] The purpose of this section is to summarize some aspects of the embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the abstract and title of this application to avoid obscuring the purpose of this section, the abstract and the title of the invention, and such simplifications or omissions should not be used to limit the scope of the present invention.

[0005] In view of the following technical problems in the prior art: to solve the problem of low system operating efficiency caused by the existing fixed threshold power generation control mode of the range extender.

[0006] To solve the above technical problems, the present invention provides the following technical solutions: a method for controlling a range extender of an extended-range commercial vehicle, comprising the following steps:

[0007] S1. The vehicle controller continuously collects vehicle operating parameters, including load status, vehicle speed, throttle opening, power battery SOC, range extender operating status and status maintenance time;

[0008] S2, switch to full load mode or no load mode according to the load status;

[0009] S3. When the power battery SOC does not reach the forced start-stop threshold:

[0010] If the vehicle speed is less than the first vehicle speed limit and the throttle opening is less than the first throttle opening limit, and the conditions remain the same for a first preset time, the range extender is controlled to shut down;

[0011] If the vehicle speed ∈ [first vehicle speed limit, second vehicle speed limit) and the throttle opening ∈ [first throttle opening limit, second throttle opening limit), and maintain the second preset time, then control the range extender to operate in the first power generation economic point interval;

[0012] If the vehicle speed ∈ [second vehicle speed limit, third vehicle speed limit) and the throttle opening ∈ [second throttle opening limit, third throttle opening limit), and maintain the third preset time, then control the range extender to operate in the second power generation economic point interval;

[0013] If the vehicle speed is greater than or equal to the third vehicle speed limit and the throttle opening is greater than or equal to the third throttle opening limit, and the fourth preset time is maintained, the range extender is controlled to operate in the third power generation economic point interval;

[0014] The power generation economic point interval is a high-efficiency operation interval defined based on the engine external characteristic curve.

[0015] As an optimal technical solution for a range extender control method for a range-extended commercial vehicle, in the full-load mode:

[0016] The first speed limit is 10 km / h, the first throttle opening limit is 15%, and the first preset time is 5 seconds;

[0017] The second speed limit is 30 km / h, the second throttle opening limit is 40%, and the second preset time is 10 seconds;

[0018] The third vehicle speed limit is 60 km / h, the third throttle opening limit is 70%, and the fourth preset time is 5 seconds.

[0019] As an optimal technical solution for a range extender control method for a range-extended commercial vehicle, in the no-load mode:

[0020] The first speed limit is 8 km / h, the first throttle opening limit is 12%, and the first preset time is 5 seconds;

[0021] The second speed limit is 25 km / h, the second throttle opening limit is 35%, and the second preset time is 10 seconds;

[0022] The third vehicle speed limit is 55 km / h, the third throttle opening limit is 65%, and the fourth preset time is 5 seconds.

[0023] As a preferred technical solution for a range extender control method for a range-extended commercial vehicle, the power generation economic point interval is determined by the following method:

[0024] The first power generation economic point range corresponds to low-speed driving conditions, and the fuel consumption rate is reduced by ≥12%;

[0025] The second power generation economic point range corresponds to medium-speed driving conditions, and the fuel consumption rate is reduced by ≥15%;

[0026] The third power generation economic point range corresponds to high-speed driving conditions, and the fuel consumption rate is reduced by ≥18%.

[0027] The present invention also discloses a control system based on the aforementioned range extender control method for a range-extended commercial vehicle, comprising:

[0028] Vehicle controller: connects to each control unit via the CAN bus, collects vehicle parameters in real time and generates range extender control instructions;

[0029] Engine control unit: Receives instructions from the vehicle controller and adjusts engine start / stop and speed to match the target power generation economic point range;

[0030] Generator controller: regulates the generator output power to adapt to battery charging or drive system power supply needs;

[0031] Battery management system: monitors the power battery and provides feedback to the vehicle controller;

[0032] Throttle sensor: collects throttle opening signals in real time and transmits them to the vehicle controller;

[0033] Load identification module: identifies the vehicle load status and uploads it to the vehicle controller.

[0034] As an optimal technical solution for the range extender control system of a range-extended commercial vehicle, the vehicle controller is also connected to the drive motor controller and the transmission controller, and by collaboratively controlling the drive motor torque and transmission gear position, seamless switching between range extender power supply and pure electric drive is achieved.

[0035] As an optimal technical solution for the range extender control system of a range-extended commercial vehicle, it also includes:

[0036] Drive motor, converting electrical energy into mechanical energy to drive the vehicle;

[0037] High-voltage connection lines transmit the electrical energy output by the generator to the battery system or drive motor controller;

[0038] The mechanical connection that transmits engine power to the generator.

[0039] As an optimal technical solution for a range extender control system for a range-extended commercial vehicle, the vehicle controller forces the range extender to start under the following conditions: the power battery SOC is lower than the minimum threshold; or forces the range extender to stop under the following conditions: the power battery SOC is higher than the maximum threshold.

[0040] Beneficial effects of the present invention: The system effectively controls the engine and generator by combining reasonable adjustment of the range extender's economic power range with engine start-stop control. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. Those skilled in the art can also derive other drawings based on these drawings without inventive effort. Among them:

[0042] Figure 1 This is a structural diagram of the range-extending system in the present invention;

[0043] Figure 2 This is the vehicle control logic diagram of the present invention;

[0044] Figure 3 It is a flow chart of the working process of the present invention. DETAILED DESCRIPTION

[0045] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0046] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0047] Secondly, the term "one embodiment" or "embodiment" herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in various places throughout this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive of other embodiments.

[0048] Furthermore, the present invention is described in detail with reference to schematic diagrams. For ease of illustration, when describing the embodiments of the present invention, cross-sectional views illustrating device structures may be partially enlarged and not to scale. Furthermore, the schematic diagrams are merely illustrative and should not limit the scope of protection of the present invention. Furthermore, in actual production, the three-dimensional dimensions of length, width, and depth should be included.

[0049] Example 1

[0050] Reference Figure 1 This embodiment provides a method for controlling a range extender of a range-extended commercial vehicle, which is characterized by comprising the following steps:

[0051] S1. The vehicle controller continuously collects vehicle operating parameters, including load status, vehicle speed, throttle opening, power battery SOC, range extender operating status and status maintenance time;

[0052] S2, switch to full load mode or no load mode according to the load status;

[0053] S3. When the power battery SOC does not reach the forced start-stop threshold:

[0054] If the vehicle speed is less than the first vehicle speed limit and the throttle opening is less than the first throttle opening limit, and the conditions remain the same for a first preset time, the range extender is controlled to shut down;

[0055] If the vehicle speed ∈ [first vehicle speed limit, second vehicle speed limit) and the throttle opening ∈ [first throttle opening limit, second throttle opening limit), and maintain the second preset time, then control the range extender to operate in the first power generation economic point interval;

[0056] If the vehicle speed ∈ [second vehicle speed limit, third vehicle speed limit) and the throttle opening ∈ [second throttle opening limit, third throttle opening limit), and maintain the third preset time, then control the range extender to operate in the second power generation economic point interval;

[0057] If the vehicle speed is greater than or equal to the third vehicle speed limit and the throttle opening is greater than or equal to the third throttle opening limit, and the fourth preset time is maintained, the range extender is controlled to operate in the third power generation economic point interval;

[0058] Among them, the power generation economic point range is the high-efficiency operating range defined based on the engine external characteristic curve.

[0059] Specifically,

[0060] The core of range extender control for extended-range commercial vehicles lies in efficient control of the range extender based on the vehicle's real-time operating load, speed, driver's intentions, etc. The range extender system integrates the engine and generator into one to directly power the battery system or drive system, while the engine does not need to participate in vehicle driving and is mechanically connected to the generator. Therefore, reasonable engine control has positive significance for improving fuel economy and system operating efficiency.

[0061] The vehicle controller collects vehicle-related information in real time. In full-load mode, the power battery SOC does not meet the forced start and shutdown conditions, the vehicle speed is less than the first speed limit V-Mlimit1 and the throttle opening is less than the first throttle opening limit ACC-Mlimit1, and the state is maintained for five seconds. The vehicle controller determines that the vehicle has a tendency to decelerate and stop, and controls the range extender system to be in a shutdown state; the vehicle speed is greater than the first speed limit V-Mlimit1 and less than the second speed limit V-Mlimit2, the throttle opening is greater than the first throttle opening limit ACC-Mlimit1 and less than the second throttle opening limit ACC-Mlimit2, and the state is maintained for ten seconds. The vehicle controller determines that the vehicle has a tendency to drive at a low speed, and controls the range extender system to be in a first Power generation economic point interval P-Meco1; the vehicle speed is greater than the second speed limit V-Mlimit2 and less than the third speed limit V-Mlimit3, the throttle opening is greater than the second throttle opening limit ACC-Mlimit2 and less than the third throttle opening limit ACC-Mlimit3, the state is maintained for ten seconds, the vehicle controller determines that the vehicle has a medium-speed driving trend, and controls the range extender system to be in the second power generation economic point interval P-Meco2; the vehicle speed is greater than the third speed limit V-Mlimit3 and the throttle opening is greater than the third throttle opening limit ACC-Mlimit3, the state is maintained for five seconds, the vehicle controller determines that the vehicle has a high-speed driving trend, and controls the range extender system to be in the third power generation economic point interval P-Meco3. In no-load mode, the power battery SOC does not meet the forced start and shutdown conditions, the vehicle speed is less than the first speed limit V-Klimit1 and the throttle opening is less than the first throttle opening limit ACC-Klimit1, the state is maintained for five seconds, the vehicle controller determines that the vehicle has a tendency to decelerate and stop, and controls the range extender system to be in the shutdown state; the vehicle speed is greater than the first speed limit V-Klimit1 and less than the second speed limit V-Klimit2, the throttle opening is greater than the first throttle opening limit ACC-Klimit1 and less than the second throttle opening limit ACC-Klimit2, the state is maintained for ten seconds, the vehicle controller determines that the vehicle has a tendency to drive at a low speed, and controls the range extender system to be in the first power generation economic point interval P -Keco1; the vehicle speed is greater than the second speed limit V-Klimit2 and less than the third speed limit V-Klimit3, the throttle opening is greater than the second throttle opening limit ACC-Klimit2 and less than the third throttle opening limit ACC-Klimit3, the state is maintained for ten seconds, the vehicle controller determines that the vehicle has a medium-speed driving trend, and controls the range extender system to be in the second power generation economic point interval P-Keco2; the vehicle speed is greater than the third speed limit V-Klimit3 and the throttle opening is greater than the third throttle opening limit ACC-Klimit3, the state is maintained for five seconds, the vehicle controller determines that the vehicle has a high-speed driving trend, and controls the range extender system to be in the third power generation economic point interval P-Keco3.The power generation economic point range is the high-efficiency range of engine operation defined in combination with the engine external characteristic curve. If the engine operates in the high-efficiency range for a long time, the system operating efficiency and fuel economy can be improved, while emissions can be reduced.

[0062] Among them, the first speed limit V-Mlimit1 / V-Klimit1: In full-load and no-load modes, the first speed limit is the key threshold for judging whether the vehicle has a tendency to decelerate and stop. When the speed is lower than this limit, it means that the vehicle is about to stop or is in an extremely low speed state. At this time, if the power battery SOC does not reach the forced start and stop conditions, and the throttle opening is also less than the corresponding first throttle opening limit, after a certain period of time, the vehicle controller will control the range extender system to shut down. This setting is mainly to avoid unnecessary fuel consumption and emissions caused by the range extender continuing to run when the vehicle is close to stopping, thereby improving energy utilization efficiency. For example, under conditions of frequent starting and stopping in congested urban roads, this mechanism can effectively reduce the ineffective operation of the range extender.

[0063] The second speed limit V-Mlimit2 / V-Klimit2: This speed limit is used to distinguish between low-speed driving and medium-speed driving conditions. When the vehicle speed is between the first speed limit and the second speed limit, the vehicle controller determines that the vehicle is in a low-speed driving state. At this time, the range extender system will be controlled to operate in the first power generation economic point interval, which is a relatively efficient operating area determined according to the engine external characteristic curve. It can meet the energy requirements of low-speed driving while ensuring a certain fuel economy and lower emissions. For example, in some low-speed driving scenarios on rural roads or in urban areas, the range extender can achieve energy saving and consumption reduction by operating in this interval.

[0064] The third speed limit, V-Mlimit3 / V-Klimit3, is used to define medium-speed and high-speed driving conditions. When the vehicle speed is higher than the second speed limit and lower than the third speed limit, the vehicle is in medium-speed driving, and the range extender system switches to the second power generation economic point range to meet the energy needs of medium-speed driving and further optimize efficiency. When the vehicle speed exceeds the third speed limit, the vehicle enters high-speed driving conditions, and the range extender system operates in the third power generation economic point range, ensuring high fuel economy and system operating efficiency at high speeds. For example, in the general driving speed range of the highway, the range extender operates in the corresponding economic point range, which can reduce fuel costs and emissions during long-distance transportation.

[0065] Throttle opening limit: Each throttle opening limit works together with the vehicle speed limit to serve as the basis for the vehicle controller to judge the vehicle's driving trend and working conditions. For example, even if the vehicle speed is within a certain range, if the throttle opening does not reach the corresponding threshold, the vehicle controller will not immediately adjust the working state of the range extender system. Instead, it will continue to monitor until the set conditions, including vehicle speed, throttle opening, and state maintenance time, are met before making control adjustments. This multi-parameter joint judgment method can more accurately identify the actual operating needs of the vehicle, avoid frequent switching of the working state of the range extender system, and improve the stability and reliability of the system operation.

[0066] In full load mode:

[0067] The first speed limit is 10 km / h, the first throttle opening limit is 15%, and the first preset time is 5 seconds;

[0068] The second speed limit is 30 km / h, the second throttle opening limit is 40%, and the second preset time is 10 seconds;

[0069] The third vehicle speed limit is 60 km / h, the third throttle opening limit is 70%, and the fourth preset time is 5 seconds.

[0070] In full load mode, the following are included:

[0071] 1. Determining the trend of deceleration and stopping: The first speed limit V-Mlimit1 is set to 10 km / h, and the first throttle opening limit ACC-Mlimit1 is set to 15%. When the vehicle is fully loaded, the power battery SOC is within the normal range and does not meet the forced start and stop conditions, the vehicle speed is less than 10 km / h and the throttle opening is less than 15% for 5 seconds, the vehicle controller determines that the vehicle has a trend of deceleration and stopping and controls the range extender system to shut down. For example, when a fully loaded vehicle approaches a traffic light to stop, this mechanism can cause the range extender to shut down in advance, avoiding unnecessary fuel consumption.

[0072] 2. Low-Speed ​​Driving Condition: The first speed limit, V-Mlimit1, is 10 km / h; the second speed limit, V-Mlimit2, is 30 km / h; the first throttle opening limit, ACC-Mlimit1, is 15%; and the second throttle opening limit, ACC-Mlimit2, is 40%. When the vehicle speed is greater than 10 km / h and less than 30 km / h, and the throttle opening is greater than 15% and less than 40% for 10 seconds, the vehicle controller determines that the vehicle is in a low-speed driving trend and controls the range extender system to operate in the first power generation economic point range, P-Meco1. Within this range, the engine's fuel consumption is assumed to be 15% lower than in the non-economic range, resulting in corresponding reductions in emissions.

[0073] 3. Medium-speed driving condition: The second speed limit V-Mlimit2 is 30 km / h, the third speed limit V-Mlimit3 is 60 km / h, the second throttle opening limit ACC-Mlimit2 is 40%, and the third throttle opening limit ACC-Mlimit3 is 70%. When the vehicle speed is between 30 km / h and 60 km / h and the throttle opening is between 40% and 70% for 10 seconds, the range extender system operates in the second power generation economic point range P-Meco2. At this time, fuel economy can be improved by approximately 20% compared to non-economic operation.

[0074] 4. High-speed driving condition: When the vehicle speed is greater than 60 km / h and the throttle opening is greater than 70% for 5 seconds, the vehicle controller controls the range extender system to operate in the third power generation economic point interval P-Meco3, which can improve the system's fuel efficiency at high speed by about 18%.

[0075] In no-load mode:

[0076] The first speed limit is 8 km / h, the first throttle opening limit is 12%, and the first preset time is 5 seconds;

[0077] The second speed limit is 25 km / h, the second throttle opening limit is 35%, and the second preset time is 10 seconds;

[0078] The third vehicle speed limit is 55 km / h, the third throttle opening limit is 65%, and the fourth preset time is 5 seconds.

[0079] In no-load mode, the following are included

[0080] 1. Deceleration and Stop Trend Judgment: The first speed limit V-Klimit1 is set to 8 km / h, and the first throttle opening limit ACC-Klimit1 is set to 12%. When the vehicle is unloaded and the corresponding conditions are met, the vehicle controller controls the range extender to shut down, reducing energy waste.

[0081] 2. Low-speed, medium-speed, and high-speed driving conditions: The vehicle speed and throttle opening limit settings are similar to those in the full-load mode, but the values ​​are slightly different, such as V-Klimit2 = 25km / h, V-Klimit3 = 55km / h, etc. The range extender can also achieve significant energy saving and emission reduction effects when operating in different economic point ranges. For example, under low-speed driving conditions, fuel consumption is reduced by 12% and emissions are reduced by about 10%.

[0082] The power generation economic point interval is determined by the following method:

[0083] The first power generation economic point range corresponds to low-speed driving conditions, and the fuel consumption rate is reduced by ≥12%;

[0084] The second power generation economic point range corresponds to medium-speed driving conditions, and the fuel consumption rate is reduced by ≥15%;

[0085] The third power generation economic point range corresponds to high-speed driving conditions, and the fuel consumption rate is reduced by ≥18%.

[0086] A range extender control method for a range-extended commercial vehicle of the present invention improves energy management efficiency by matching operating power requirements with the range extender's high-efficiency operating range in real time, thereby enabling the vehicle to operate efficiently under all operating conditions.

[0087] 2. Avoid the extremely rapid and deep high-current discharge of the battery in traditional strategies, maintain the power battery SOC in a healthy range, and reduce the number of battery cycles and polarization losses;

[0088] 3. The range extender remains stable in the high-efficiency operating range for a long time, improving system operating efficiency and fuel economy, and reducing vehicle operating costs;

[0089] 4. While meeting customers' needs for long-range vehicles, it also provides an environmentally friendly and reliable extended-range technology upgrade solution, which has significant engineering value and industry promotion significance.

[0090] Example 2

[0091] Reference Figures 1 to 3 This embodiment further discloses a control system based on the aforementioned range extender control method for a range-extended commercial vehicle, including:

[0092] Vehicle controller: connects to each control unit via the CAN bus, collects vehicle parameters in real time and generates range extender control instructions;

[0093] Engine control unit: Receives instructions from the vehicle controller and adjusts engine start / stop and speed to match the target power generation economic point range;

[0094] Generator controller: regulates the generator output power to adapt to battery charging or drive system power supply needs;

[0095] Battery management system: monitors the power battery and provides feedback to the vehicle controller;

[0096] Throttle sensor: collects throttle opening signals in real time and transmits them to the vehicle controller;

[0097] Load identification module: identifies the vehicle load status and uploads it to the vehicle controller.

[0098] The vehicle controller is also connected to the drive motor controller and the transmission controller, and through the coordinated control of the drive motor torque and transmission gear, it achieves seamless switching between range extender power supply and pure electric drive.

[0099] Reference Figure 2This diagram illustrates the hardware architecture of a range-extended commercial vehicle system, providing the physical foundation for the range extender control process described above. The control logic for starting and stopping the range extender, switching between power generation economic points, and other tasks during operation relies on the coordinated operation of the engine, generator, and controller components shown in the diagram. Mechanical connections transmit power and high-voltage connections transmit electrical energy, enabling the range extender to be controlled based on operating conditions and power the battery / drive system.

[0100] 1. Engine: It does not directly drive the vehicle, but acts as a power source to drive the generator and convert the chemical energy of the fuel into mechanical energy.

[0101] 2. Generator: Receives engine mechanical energy and converts it into electrical energy, which is then controlled by the generator controller to power the battery, drive system, etc.

[0102] 3. Generator controller: manages the generator's power output, ensuring the stability of parameters such as voltage and current, and adapting to the power requirements of battery charging and drive systems.

[0103] 4. Battery system: stores electrical energy and can supply power to the drive motor and electrical accessories; at the same time, it receives power from the generator and can also provide auxiliary power supply according to working conditions such as sudden acceleration.

[0104] 5. Drive motor controller: regulates the electrical energy input of the drive motor, converts it into mechanical energy, transmits it to the wheels through the gearbox, and drives the vehicle.

[0105] 6. Drive motor: converts electrical energy into mechanical energy and is the direct power source for the vehicle.

[0106] 7. Gearbox: transmits the mechanical energy of the drive motor, achieves speed and torque adaptation, and optimizes the vehicle's driving power output.

[0107] 8. Electrical accessories: such as oil pumps, air conditioners, DC / DC, etc., consume the power provided by batteries or generators to meet the needs of vehicle auxiliary functions.

[0108] According to the extended range system structure diagram, the system working scenarios are as follows:

[0109] Range extender power generation scenario: The engine is mechanically connected to drive the generator, the generator generates electricity → processed by the generator controller → transmitted through high-voltage connection, part of which charges the battery system, and part can directly power the drive motor controller to drive the vehicle, or power electrical accessories.

[0110] Pure electric drive scenario: The battery system is connected via high voltage to supply power to the drive motor controller, which converts electrical energy into mechanical energy, which is then transmitted to the wheels via the gearbox to drive the vehicle. The battery can also independently power electrical accessories.

[0111] Control coordination: According to the above working process logic, the range extender engine + generator + controller starts and stops, and switches between economic power generation points. By controlling the engine operation and generator power output, and coordinating with battery charging and discharging, "efficient energy supply + adaptive working conditions" operation is achieved. For example, at low speeds, the range extender is allowed to generate electricity in the economic range, and the battery output power is used first to drive the vehicle, thereby achieving energy saving and emission reduction goals.

[0112] Also includes:

[0113] Drive motor, converting electrical energy into mechanical energy to drive the vehicle;

[0114] High-voltage connection lines transmit the electrical energy output by the generator to the battery system or drive motor controller;

[0115] The mechanical connection that transmits engine power to the generator.

[0116] The vehicle controller forces the range extender to start under the following conditions: the power battery SOC is lower than the minimum threshold; or forces it to stop under the following conditions: the power battery SOC is higher than the maximum threshold

[0117] Reference Figure 3 , the system includes the following components and functions:

[0118] 1. Vehicle Controller (VCU): The system's core "brain," integrating functional modules such as load identification and vehicle speed calculation. It collects and integrates vehicle-wide information, determines the operating mode of the range extender and drive system, and coordinates the operation of various components.

[0119] 2. Battery Management System: Monitors battery status in real time, including remaining power, voltage, and temperature of the power battery SOC, and feeds back battery data to the vehicle controller (VCU) to ensure safe and efficient charging and discharging of the battery.

[0120] 3. Throttle sensor: Collects the driver's throttle opening signal and transmits it to the vehicle controller VCU to reflect the driver's intention as a basis for determining the operating condition.

[0121] 4. Generator Controller GCU: Receives instructions from the Vehicle Controller (VCU) to precisely control the generator's power generation and energy output, adapting to the battery charging and drive system power requirements.

[0122] 5. Generator controller EMS: Cooperates with the vehicle controller VCU to regulate engine start / stop, speed, and load, allowing the engine to operate in a high-efficiency range, such as the power generation economic point, to optimize fuel economy.

[0123] 6. Drive motor controller MCU: According to the instructions of the vehicle controller VCU, it manages the electrical energy input of the drive motor, converts it into mechanical energy to drive the vehicle, and provides feedback on the motor's operating status.

[0124] 7. Transmission Controller (TCU): Receives coordinated instructions from the Vehicle Controller (VCU), controls the transmission shifting logic, matches the speed and torque of the drive motor and wheels, and improves power transmission efficiency.

[0125] Each component and controller is connected via CAN communication, and the vehicle controller VCU is bidirectionally connected to each component, sending control instructions and receiving status feedback to form a closed-loop control adjustment.

[0126] The system's working principle and collaboration logic are as follows:

[0127] 1. Information Collection Phase: The battery management system continuously monitors the battery's SOC and health status. The throttle sensor captures changes in throttle opening. The generator controller (EMS) provides real-time feedback on engine speed, water temperature, and other parameters. The drive motor controller (MCU) and transmission controller (TCU) report motor and transmission operating parameters. This data is transmitted via a communication link to the vehicle control unit (VCU) for use as a basis for control decisions.

[0128] 2. Control phase: According to the working principle described above, the vehicle controller VCU performs multi-dimensional decision-making and control.

[0129] 3. Feedback adjustment stage: The vehicle controller VCU collects the operating status feedback from each controller on the CAN bus and dynamically fine-tunes the control instructions to ensure that the system always adapts to the working conditions and operates stably and efficiently.

[0130] It will be appreciated that in the development of any actual embodiment, as in any engineering or design project, numerous implementation-specific decisions may be made. Such a development effort may be complex and time-consuming, but will, for those of ordinary skill having the benefit of this disclosure, be a routine undertaking of design, fabrication, and production without undue experimentation.

[0131] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A range extender control method for a range-extended commercial vehicle, characterized in that: The following steps are involved: S1. The vehicle controller continuously collects vehicle operating parameters, including load status, vehicle speed, throttle opening, power battery SOC, range extender operating status and status maintenance time; S2, switch to full load mode or no load mode according to the load status; S3. When the power battery SOC does not reach the forced start-stop threshold: If the vehicle speed is less than the first vehicle speed limit and the throttle opening is less than the first throttle opening limit, and the conditions remain the same for a first preset time, the range extender is controlled to shut down; If the vehicle speed ∈ [first vehicle speed limit, second vehicle speed limit) and the throttle opening ∈ [first throttle opening limit, second throttle opening limit), and maintain the second preset time, then control the range extender to operate in the first power generation economic point interval; If the vehicle speed ∈ [second vehicle speed limit, third vehicle speed limit) and the throttle opening ∈ [second throttle opening limit, third throttle opening limit), and maintain the third preset time, then control the range extender to operate in the second power generation economic point interval; If the vehicle speed is greater than or equal to the third vehicle speed limit and the throttle opening is greater than or equal to the third throttle opening limit, and the fourth preset time is maintained, the range extender is controlled to operate in the third power generation economic point interval; The power generation economic point interval is a high-efficiency operation interval defined based on the engine external characteristic curve.

2. The range extender control method for a range-extended commercial vehicle according to claim 1, characterized in that: In the full load mode: The first speed limit is 10 km / h, the first throttle opening limit is 15%, and the first preset time is 5 seconds; The second speed limit is 30 km / h, the second throttle opening limit is 40%, and the second preset time is 10 seconds; The third vehicle speed limit is 60 km / h, the third throttle opening limit is 70%, and the fourth preset time is 5 seconds.

3. The range extender control method for a range-extended commercial vehicle according to claim 1, characterized in that: In the no-load mode: The first speed limit is 8 km / h, the first throttle opening limit is 12%, and the first preset time is 5 seconds; The second speed limit is 25 km / h, the second throttle opening limit is 35%, and the second preset time is 10 seconds; The third vehicle speed limit is 55 km / h, the third throttle opening limit is 65%, and the fourth preset time is 5 seconds.

4. The range extender control method for a range-extended commercial vehicle according to any one of claims 1 to 3, characterized in that: The power generation economic point interval is determined by the following method: The first power generation economic point range corresponds to low-speed driving conditions, and the fuel consumption rate is reduced by ≥12%; The second power generation economic point range corresponds to medium-speed driving conditions, and the fuel consumption rate is reduced by ≥15%; The third power generation economic point range corresponds to high-speed driving conditions, and the fuel consumption rate is reduced by ≥18%.

5. A control system based on the range extender control method for a range-extended commercial vehicle according to any one of claims 1 to 4, characterized in that: include: Vehicle controller: connects to each control unit via the CAN bus, collects vehicle parameters in real time and generates range extender control instructions; Engine control unit: Receives instructions from the vehicle controller and adjusts engine start / stop and speed to match the target power generation economic point range; Generator controller: regulates the generator output power to adapt to battery charging or drive system power supply needs; Battery management system: monitors the power battery and provides feedback to the vehicle controller; Throttle sensor: collects throttle opening signals in real time and transmits them to the vehicle controller; Load identification module: identifies the vehicle load status and uploads it to the vehicle controller.

6. The range extender control system for a range-extended commercial vehicle according to claim 5, characterized in that: The vehicle controller is also connected to the drive motor controller and the transmission controller, and achieves seamless switching between range extender power supply and pure electric drive by collaboratively controlling the drive motor torque and transmission gear position.

7. The range extender control system for a range-extended commercial vehicle according to claim 5, characterized in that: Also includes: Drive motor, converting electrical energy into mechanical energy to drive the vehicle; High-voltage connection lines transmit the electrical energy output by the generator to the battery system or drive motor controller; The mechanical connection that transmits engine power to the generator.

8. The range extender control system for a range-extended commercial vehicle according to claim 5, characterized in that: The vehicle controller is forced to start the range extender under the following conditions: the power battery SOC is lower than the minimum threshold; or forced to stop under the following conditions: the power battery SOC is higher than the maximum threshold.

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