A control method and system for a range extender of a range extended commercial vehicle

Abstract

The application relates to a control method and system of a range extender of a range extended commercial vehicle, wherein the control method comprises the following steps: a vehicle controller continuously collects vehicle operation parameters, including a load state, a vehicle speed, an accelerator opening degree, a power battery, a range extender operation state and a state maintaining time; the full-load mode or the empty-load mode is switched according to the load state; when the power battery does not reach a forced start-stop threshold value: according to the relationship between the vehicle speed and the first vehicle speed limit value and the second vehicle speed limit value and the relationship 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 stop, 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; and the system method adopts a combination of reasonable adjustment of a range extender economic power interval and engine start-stop control to effectively control the engine and the generator.

Description

Technical Field

[0001] This invention belongs to the field of range extender control technology, specifically a control method and system for a range extender in a range-extended commercial vehicle. Background Technology

[0002] With the deepening of global energy conservation and emission reduction policies and the popularization of new energy technologies, the commercial vehicle sector is accelerating its transformation towards electrification. Compared with traditional fuel-powered commercial vehicles, pure electric commercial vehicles have advantages such as zero emissions, low noise, and low operating costs. However, limited by factors such as battery energy density, charging infrastructure coverage, and charging time, their driving range and operational efficiency still face significant challenges in scenarios such as long-distance transportation and heavy-duty operations. Range-extended electric vehicle (REEV) technology, by integrating an engine and generator system, can charge the battery or directly power the drive motor without directly driving the vehicle, effectively compensating for the short driving range of pure electric vehicles and becoming one of the important transitional solutions for the electrification of commercial vehicles.

[0003] The core of range-extended commercial vehicles lies in the efficient control of the range extender, whose control strategy directly affects the vehicle's fuel economy, emissions performance, power smoothness, and system reliability. Traditional range extender control strategies often adopt a "fixed threshold start-stop" mode (such as forcibly starting or stopping the range extender when the battery charge is below or above a certain value), which does not fully consider the vehicle's real-time operating conditions. This results in frequent start-stops of the range extender or prolonged operation in an inefficient range, causing fuel waste and excessive emissions, leading to insufficient energy management efficiency. Summary of the Invention

[0004] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the invention.

[0005] Given the following technical problems in the existing technology: the problem of low system operating efficiency caused by the existing fixed threshold power generation control mode of range extenders.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a control method for a range extender in a range-extended 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 between full load mode and no load mode according to the load status;

[0009] S3. When the SOC of the power battery has not reached 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 this is maintained for a first preset time, then the range extender will be stopped.

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

[0012] If the vehicle speed is within the range of [second speed limit, third speed limit) and the throttle opening is within the range of [second throttle opening limit, third throttle opening limit), and the third preset time is maintained, then the range extender is controlled to operate within the second economic point range for power generation.

[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 is maintained for the fourth preset time, then the range extender will be controlled to operate in the third power generation economic point range.

[0014] The economic point range for power generation is the high-efficiency operating range defined based on the engine's external characteristic curve.

[0015] As a preferred technical solution for the control method of a range extender in a range-extended commercial vehicle, in the fully loaded mode:

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

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

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

[0019] As a preferred technical solution for the control method of a range extender in 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 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 the control method of a range extender for range-extended commercial vehicles, the economic point range for power generation is determined in the following way:

[0024] The first economic point range for power generation corresponds to low-speed driving conditions, where fuel consumption is reduced by ≥12%.

[0025] The second economic point range for power generation corresponds to medium-speed driving conditions, where fuel consumption is reduced by ≥15%.

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

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

[0028] Vehicle controller: Connects to each control unit via CAN bus, used to collect vehicle parameters in real time and generate range extender control commands;

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

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

[0031] Battery Management System: Monitors the power battery and provides feedback to the vehicle controller;

[0032] Throttle sensor: Collects throttle opening signal in real time and transmits it to the vehicle controller;

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

[0034] As a preferred 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. By coordinating the control of the drive motor torque and the transmission gear, seamless switching between range extender power supply and pure electric drive is achieved.

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

[0036] The drive motor converts electrical energy into mechanical energy to drive the vehicle;

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

[0038] Mechanical connecting components that transmit engine power to the generator.

[0039] As a preferred technical solution for the range extender control system of a range-extended commercial vehicle, the vehicle controller forcibly starts the range extender under the following conditions: the power battery SOC is lower than the minimum threshold; or forcibly stops the system under the following conditions: the power battery is higher than the maximum threshold.

[0040] The beneficial effects of this invention are: 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. Attached Figure Description

[0041] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein:

[0042] Figure 1 This is a structural diagram of the range extender system in this invention;

[0043] Figure 2 This is the vehicle control logic diagram in this invention;

[0044] Figure 3 This is a flowchart of the working process in this invention. Detailed Implementation

[0045] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0046] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0047] Secondly, the term "one embodiment" or "embodiment" as used 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 different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0048] Secondly, the present invention is described in detail with reference to the schematic diagrams. When detailing the embodiments of the present invention, for ease of explanation, the cross-sectional views illustrating the device structure may be partially enlarged, not according to the usual scale. Furthermore, the schematic diagrams are merely examples and should not limit the scope of protection of the present invention. In addition, actual fabrication should include three-dimensional spatial dimensions of length, width, and depth.

[0049] Example 1

[0050] Reference Figure 1 This embodiment provides a control method for a range extender in a range-extended commercial vehicle, characterized by 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 between full load mode and no load mode according to the load status;

[0053] S3. When the SOC of the power battery has not reached 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 this is maintained for a first preset time, then the range extender will be stopped.

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

[0056] If the vehicle speed is within the range of [second speed limit, third speed limit) and the throttle opening is within the range of [second throttle opening limit, third throttle opening limit), and the third preset time is maintained, then the range extender is controlled to operate within the second economic point range for power generation.

[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 is maintained for the fourth preset time, then the range extender will be controlled to operate in the third power generation economic point range.

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

[0059] Specifically,

[0060] The core of range extender control in range-extended commercial vehicles lies in the efficient control of the range extender by combining real-time vehicle operating conditions such as load, speed, and driver intentions. The range extender system integrates the engine and generator into one unit 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 a 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, if the power battery SOC has not reached the forced start and stop 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 this state is maintained for five seconds, the vehicle controller determines that the vehicle is decelerating and stopping, and controls the range extender system to be in a stopped state. If the vehicle speed is greater than the first speed limit V-Mlimit1 and less than the second speed limit V-Mlimit2, and the throttle opening is greater than the first throttle opening limit ACC-Mlimit1 and less than the second throttle opening limit ACC-Mlimit2, and this state is maintained for ten seconds, the vehicle controller determines that the vehicle is driving at low speed and controls the range extender system to be in a first... When the vehicle speed is greater than the second speed limit V-Mlimit2 and less than the third speed limit V-Mlimit3, and the throttle opening is greater than the second throttle opening limit ACC-Mlimit2 and less than the third throttle opening limit ACC-Mlimit3, and the state is maintained for ten seconds, the vehicle controller determines that the vehicle has a tendency to travel at medium speed and controls the range extender system to be in the second economic point range P-Meco2. When 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, and the state is maintained for five seconds, the vehicle controller determines that the vehicle has a tendency to travel at high speed and controls the range extender system to be in the third economic point range P-Meco3. In no-load mode, if the power battery SOC has not reached the forced start and stop 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, and this state is maintained for five seconds, the vehicle controller determines that the vehicle is decelerating and stopping, and controls the range extender system to be in a stopped state. If the vehicle speed is greater than the first speed limit V-Klimit1 and less than the second speed limit V-Klimit2, and the throttle opening is greater than the first throttle opening limit ACC-Klimit1 and less than the second throttle opening limit ACC-Klimit2, and this state is maintained for ten seconds, the vehicle controller determines that the vehicle is driving at low speed and controls the range extender system to be in the first economic point range P. -Keco1; When the vehicle speed is greater than the second speed limit V-Klimit2 and less than the third speed limit V-Klimit3, and the throttle opening is greater than the second throttle opening limit ACC-Klimit2 and less than the third throttle opening limit ACC-Klimit3, and the state is maintained for ten seconds, the vehicle controller determines that the vehicle has a tendency to travel at medium speed and controls the range extender system to be in the second economic point range of power generation P-Keco2; When 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, and the state is maintained for five seconds, the vehicle controller determines that the vehicle has a tendency to travel at high speed and controls the range extender system to be in the third economic point range of power generation P-Keco3.The economic point range for power generation is the high-efficiency range of engine operation defined by the engine's external characteristic curve. If the engine operates in the high-efficiency range for a long time, it can improve system operating efficiency and fuel economy, while reducing emissions.

[0062] Among them, the first speed limit V-Mlimit1 / V-Klimit1: In both fully loaded and unloaded modes, the first speed limit is a key threshold for determining whether the vehicle is decelerating and stopping. When the vehicle speed is below 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 has not reached 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, in the case of frequent start-stop conditions in congested urban areas, this mechanism can effectively reduce the ineffective operation of the range extender.

[0063] The second speed limit, V-Mlimit2 / V-Klimit2, distinguishes between low-speed and medium-speed driving conditions. When the vehicle speed falls between the first and second speed limits, the vehicle controller determines that the vehicle is in a low-speed driving state. In this case, the range extender system will operate within the first economic power generation range, a relatively efficient operating area determined based on the engine's external characteristic curve. This range ensures fuel economy and low emissions while meeting the energy demands of low-speed driving. For example, in low-speed driving scenarios on rural roads or in urban residential areas, operating the range extender within this range can achieve energy savings and reduced emissions.

[0064] The third speed limit, V-Mlimit3 / V-Klimit3, defines medium-speed and high-speed driving conditions. When the vehicle speed is higher than the second speed limit but lower than the third speed limit, the vehicle is in a medium-speed driving state, and the range extender system switches to the second energy-generating economic point range to adapt to the energy demand of medium-speed driving and further optimize efficiency. When the vehicle speed exceeds the third speed limit, the vehicle enters a high-speed driving state, and the range extender system operates in the third energy-generating economic point range to ensure that high fuel economy and system operating efficiency are maintained even at high speeds. For example, in the general driving speed range of highways, the range extender operates in the corresponding economic point range, which can reduce fuel costs and emissions during long-distance transportation.

[0065] Throttle opening limits: These limits work in conjunction with vehicle speed limits to form the basis for the vehicle controller's judgment of vehicle driving trends and operating 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 range extender system's operating state. Instead, it will continuously 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 vehicle's actual operating needs, avoid frequent switching of the range extender system's operating state, and improve the system's stability and reliability.

[0066] Full load mode:

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

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

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

[0070] The full load mode includes the following:

[0071] 1. Deceleration and Stopping Trend Judgment: The first speed limit V-Mlimit1 is set to 10km / 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 has not reached the forced start and stop conditions, the vehicle speed is less than 10km / h and the throttle opening is less than 15%, and this condition is maintained for 5 seconds, the vehicle controller judges that the vehicle has a deceleration and stopping trend, and controls the range extender system to shut down. For example, when the vehicle is fully loaded and 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%, and maintained 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 economic point range P-Meco1. Within this range, it is assumed that the engine's fuel consumption rate is reduced by 15% compared to the non-economic range, and emissions are also reduced accordingly.

[0073] 3. Medium-speed driving conditions: The second speed limit V-Mlimit2 is 30km / h, the third speed limit V-Mlimit3 is 60km / 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 30km / h and 60km / h, and the throttle opening is between 40% and 70%, after maintaining this position for 10 seconds, the range extender system operates in the second economic point range P-Meco2. At this time, compared with the non-economic operating state, fuel economy can be improved by about 20%.

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

[0075] In idle 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 speed limit is 55 km / h, the third throttle opening limit is 65%, and the fourth preset time is 5 seconds.

[0079] The following content is included in the no-load mode.

[0080] 1. Deceleration and Stopping Trend Judgment: The first vehicle speed limit V-Klimit1 is set to 8km / 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 stop, reducing energy waste.

[0081] 2. Low-speed, medium-speed, and high-speed driving conditions: The 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 achieve significant energy saving and emission reduction effects when operating in different economic point ranges. For example, under low-speed driving conditions, the fuel consumption rate is reduced by 12% and emissions are reduced by about 10%.

[0082] The economic point range for power generation is determined in the following way:

[0083] The first economic point range for power generation corresponds to low-speed driving conditions, where fuel consumption is reduced by ≥12%.

[0084] The second economic point range for power generation corresponds to medium-speed driving conditions, where fuel consumption is reduced by ≥15%.

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

[0086] The present invention provides a range extender control method for range-extended commercial vehicles, which improves energy management efficiency by matching the power demand under operating conditions with the high-efficiency operating range of the range extender in real time, enabling the vehicle to operate efficiently under all operating conditions.

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

[0088] 3. The range extender operates stably in the high-efficiency range for extended periods, improving system operating efficiency and fuel economy, and reducing vehicle operating costs;

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

[0090] Example 2

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

[0092] Vehicle controller: Connects to each control unit via CAN bus, used to collect vehicle parameters in real time and generate range extender control commands;

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

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

[0095] Battery Management System: Monitors the power battery and provides feedback to the vehicle controller;

[0096] Throttle sensor: Collects throttle opening signal in real time and transmits it to the vehicle controller;

[0097] Load recognition module: identifies the vehicle's 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. By coordinating the control of the drive motor torque and the transmission gear, it enables 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 aforementioned range extender control process. During operation, the range extender's start-up and shutdown, as well as the switching of the generator's economic point, rely on the coordinated operation of components such as the engine, generator, and controller shown in the diagram. Power is transmitted through mechanical connections, and electrical energy is transmitted through high-voltage connections, enabling the function of "controlling the range extender according to operating conditions to supply power to the battery / drive system."

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

[0101] 2. Generator: Receives mechanical energy from the engine, converts it into electrical energy, and after being regulated by the generator controller, supplies power to the battery, drive system, etc.

[0102] 3. Generator Controller: Manages the generator's power output, ensuring stable parameters such as voltage and current, and adapting to the power needs of battery charging and drive systems.

[0103] 4. Battery system: Stores electrical energy and can power the drive motor and electric accessories; it can also receive power from the generator and provide auxiliary power supply according to working conditions such as rapid acceleration.

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

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

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

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

[0108] Based on the range extender system architecture diagram, the system's operating scenarios are as follows:

[0109] Range extender power generation scenario: The engine mechanically drives 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 of which can directly power the drive motor controller to drive the vehicle, or power electrical accessories.

[0110] In a pure electric drive scenario: the battery system supplies power to the drive motor controller via a high-voltage connection → the drive motor converts electrical energy into mechanical energy → which is then transmitted to the wheels via the gearbox to drive the vehicle; the battery can also supply power to electrical accessories independently.

[0111] Control coordination: Based on the above working process logic, the range extender engine + generator + controller start and stop, and switch between the economic point range of power generation. By controlling the engine operation and generator power output, and coordinating with battery charging and discharging, the operation of "efficient power supply + adaptable to working conditions" is achieved. For example, at low speeds, the range extender generates electricity in the economic range, and prioritizes the use of battery power to drive the vehicle, thereby achieving energy saving and emission reduction goals.

[0112] Also includes:

[0113] The drive motor converts electrical energy into mechanical energy to drive the vehicle;

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

[0115] Mechanical connecting components that transmit engine power to the generator.

[0116] The vehicle controller will forcibly start the range extender under the following conditions: the power battery SOC is below the minimum threshold; or forcibly shut it down under the following conditions: the power battery SOC is above the maximum threshold.

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

[0118] 1. Vehicle Control Unit (VCU): The core "brain" of the system, integrating functional modules such as load recognition and vehicle speed calculation. It collects and integrates information from the entire vehicle, determines the operating modes 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 SOC, voltage, temperature, etc., 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 control unit (VCU) to reflect the driver's intention and serve as a basis for judging the operating condition.

[0121] 4. Generator Controller (GCU): Receives commands from the vehicle controller (VCU) to precisely control the generator's power output and electrical energy consumption, adapting to the power requirements of battery charging and the drive system.

[0122] 5. Generator Controller (EMS): Working in conjunction with the vehicle controller (VCU), it regulates engine start / stop, speed, and load, allowing the engine to operate in its high-efficiency range, such as the economic point for power generation, thus optimizing fuel economy.

[0123] 6. Drive motor controller MCU: Based on 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 at the same time provides feedback on the motor's operating status.

[0124] 7. Transmission Controller (TCU): Receives collaborative 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] All components and controllers are connected via CAN communication. The vehicle controller (VCU) is bidirectionally connected to each component, sending control commands 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 Acquisition Phase: The battery management system continuously monitors the SOC and health status of the power battery; the throttle sensor captures changes in throttle opening; the generator controller (EMS) provides feedback on real-time engine speed, coolant temperature, etc.; the drive motor controller (MCU) and transmission controller (TCU) report motor and transmission operating parameters. This data is sent to the vehicle control unit (VCU) via communication connection as the basis for control decisions.

[0128] 2. Control Phase: As described above, the vehicle controller (VCU) performs multi-dimensional decision-making and control.

[0129] 3. Feedback and Adjustment Phase: The vehicle control unit (VCU) collects the operating status feedback from each controller on the CAN bus and dynamically fine-tunes the control commands to ensure that the system always adapts to the operating conditions and operates stably and efficiently.

[0130] It should be understood that numerous specific implementation decisions can be made during the development of any practical implementation, such as in any engineering or design project. Such development efforts may be complex and time-consuming, but for those skilled in the art who benefit from this disclosure, the development effort will be a routine work of design, manufacturing, and production without requiring much 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 it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A control method for a range extender in a range-extended commercial vehicle, characterized in that, Includes the following steps: 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 between full load mode and no load mode according to the load status; S3. When the SOC of the power battery has not reached 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 this is maintained for a first preset time, then the range extender will be stopped. If the vehicle speed is ∈ [first vehicle speed limit, second vehicle speed limit) and the throttle opening is ∈ [first throttle opening limit, second throttle opening limit), and is maintained for the second preset time, then the range extender is controlled to operate in the first power generation economic point range; If the vehicle speed is within the range of [second speed limit, third speed limit) and the throttle opening is within the range of [second throttle opening limit, third throttle opening limit), and the third preset time is maintained, then the range extender is controlled to operate within the second economic point range for power generation. 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 is maintained for the fourth preset time, then the range extender will be controlled to operate in the third power generation economic point range. The economic point range for power generation is the high-efficiency operating range defined based on the engine's external characteristic curve.

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

3. The control method for a range extender in 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 speed limit is 55 km / h, the third throttle opening limit is 65%, and the fourth preset time is 5 seconds.

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

5. A control system based on the control method for a range extender in 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 CAN bus, used to collect vehicle parameters in real time and generate range extender control commands; Engine control unit: Receives commands from the vehicle controller and adjusts engine start / stop and speed to match the target economic point range for power generation; Generator controller: regulates the output power of the generator to adapt to the power supply needs of battery charging or drive system; Battery Management System: Monitors the power battery and provides feedback to the vehicle controller; Throttle sensor: Collects throttle opening signal in real time and transmits it to the vehicle controller; Load recognition module: identifies the vehicle's load status and uploads it to the vehicle controller.

6. The range extender control system for range-extended commercial vehicles according to claim 5, characterized in that: The vehicle controller is also connected to the drive motor controller and the transmission controller. By coordinating the control of the drive motor torque and the transmission gear, it enables seamless switching between range extender power supply and pure electric drive.

7. The range extender control system for range-extended commercial vehicles according to claim 5, characterized in that: Also includes: The drive motor converts electrical energy into mechanical energy to drive the vehicle; High-voltage connection lines transmit electrical energy output from the generator to the battery system or drive motor controller; Mechanical connecting components that transmit engine power to the generator.

8. The range extender control system for range-extended commercial vehicles according to claim 5, characterized in that: The vehicle controller will forcibly start the range extender under the following conditions: when the power battery SOC is below the minimum threshold; or forcibly shut it down under the following conditions: when the power battery SOC is above the maximum threshold.

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