Integrated control system and method for new energy light truck refrigeration compartment

Abstract

The invention discloses an integrated control system and method for a new energy light truck refrigeration compartment. The integrated control system comprises a remote control terminal, a vehicle-mounted TBOX and an all-in-one controller, wherein the vehicle-mounted TBOX and the all-in-one controller are arranged on a light truck. The remote control terminal is used for inputting a control signal of the refrigerating box and sending the control signal to the vehicle-mounted TBOX; the vehicle-mounted TBOX is reserved with a communication interface connected with a refrigerator in the refrigeration box; a high-voltage electricity taking port connected with the refrigerator power supply interface is reserved in the all-in-one controller; after the refrigerating box is installed on the light truck, the refrigerating machine is connected with the TBOX and the all-in-one controller through the communication interface and the high-voltage electricity taking port, so that communication and power supply connection between the vehicle-mounted TBOX and the refrigerating machine is established. The system has the advantages that starting, temperature setting, humidity setting, shutdown, early warning and the like of the refrigerating machine are controlled through network interaction of the refrigerating machine in the refrigerating compartment and the whole vehicle, and a client can easily operate the whole vehicle APP to start the refrigerating machine to start refrigerating when the client is not on the vehicle or at home.

Description

Technical Field

[0001] This invention relates to the field of refrigeration control for new energy light trucks, and particularly to an integrated control system and method for a refrigerated compartment of a new energy light truck. Background Technology

[0002] Most existing refrigerated vans are retrofitted components. These retrofitted components are limited by hardware and cannot communicate with the OEM's vehicle network, requiring control via the refrigerated van supplier's own app or software. This increases user time and forces frequent switching between the vehicle's app and the refrigerated van's app or software. Furthermore, starting the refrigeration unit requires ensuring the vehicle is under high pressure, which is limited by the vehicle's control logic. This necessitates manual pressure application, adding steps and potentially causing repetitive operations for the user.

[0003] The presence of aftermarket components makes it impossible to centrally control the vehicle and control the temperature of the refrigerated compartment, thus affecting the user experience. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide an integrated control system and method for a refrigerated compartment of a new energy light truck. By interacting with the refrigeration unit in the refrigerated compartment and the vehicle network, the system controls the refrigeration unit's start-up, temperature setting, humidity setting, shutdown, and warning functions. This allows customers to easily operate the vehicle's APP to start the refrigeration unit and begin cooling, whether they are in the vehicle or at home.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: an integrated control system for a refrigerated compartment of a new energy light truck, including a remote control terminal and an on-board TBOX and a multi-function controller installed on the light truck; the remote control terminal is used to input the control signals of the refrigerated compartment and send them to the on-board TBOX; the on-board TBOX has a reserved communication interface for connecting to the refrigeration unit inside the refrigerated compartment; the multi-function controller has a reserved high-voltage power outlet for connecting to the power supply interface of the refrigeration unit; after the refrigerated compartment is installed on the light truck, the refrigeration unit is connected to the TBOX and the multi-function controller through the communication interface and the high-voltage power outlet to establish communication and power supply connections between the on-board TBOX and the refrigeration unit.

[0006] The control system also includes a vehicle controller (VCU) and a battery management system (BMS); the on-board TBOX is connected to the VCU and the BMS via a CAN network.

[0007] After receiving the cooling signal, the vehicle-mounted TBOX wakes up the VCU, BMS, and all-in-one controller via the network and performs the high-voltage operation; at the same time, it sends the chiller start-up and temperature setting parameters to the chiller for execution.

[0008] The remote control terminal sends control signals to the vehicle-mounted TBOX via the cloud platform; end-to-end encrypted channels are used for communication encryption in the communication between the cloud platform and the remote control terminal, as well as between the cloud platform and the TBOX.

[0009] The remote control terminal has a built-in identity recognition module, which allows users to operate and set the cooling control signal only after successful identity recognition.

[0010] After decrypting the control signal received from the remote control terminal, the cloud platform verifies and judges the received control signal through a compliance verification unit, a vehicle status detection unit, and an environmental condition judgment unit. Only after all judgments are passed will the control signal be forwarded to the TBOX, and a wake-up command will be sent to the TBOX to wake up the vehicle TBOX.

[0011] Temperature and humidity sensors are installed inside the refrigerated box, and both sensors are connected to the refrigeration unit. After the refrigeration unit performs cooling, it monitors the temperature and humidity data inside the box in real time and feeds it back to the TBOX, which in turn feeds it back to the remote control terminal.

[0012] A control method for an integrated control system of a new energy light truck refrigerated compartment involves connecting the refrigeration unit to the TBOX and a multi-function controller via a reserved communication interface and a high-voltage power supply port after the refrigerated compartment is installed on the light truck, thereby establishing communication and power supply connections between the vehicle-mounted TBOX and the refrigeration unit; after the user inputs setting parameters through a remote control terminal, a control signal is generated and the refrigeration status of the refrigerated compartment is controlled through the vehicle-mounted TBOX.

[0013] After receiving the cooling control signal, the vehicle-mounted TBOX first wakes up the controller via the network to apply high voltage to the entire vehicle. If the high voltage application fails, the VCU sends fault information to the network, which is then fed back to the remote control terminal by the TBOX. If the high voltage application is successful, the TBOX wakes up the cooling unit and sends the set temperature and humidity values. The cooling unit then starts working according to the set temperature and humidity and feeds back temperature and humidity information to the network in real time. The TBOX reads the information from the network and feeds it back to the remote control terminal.

[0014] The remote control terminal has a built-in identity recognition module. After the user enters the cooling control parameters, the module recognizes the user's identity. Only after successful identity recognition will the module execute the command corresponding to the user's cooling control parameters and send it to the vehicle-mounted TBOX.

[0015] The advantages of this invention are: by interacting with the refrigeration unit inside the refrigerated compartment via the vehicle's network, the system controls the refrigeration unit's startup, temperature setting, humidity setting, shutdown, and warnings. This allows customers to easily operate the vehicle's app to start the refrigeration process from outside the vehicle or at home. Customers do not need to pre-pressurize the vehicle. After the refrigeration unit is started, the vehicle automatically applies high pressure first, then the refrigeration unit begins cooling. Once the set values ​​are reached, the refrigeration unit temporarily shuts off. When the temperature and humidity drop to the warning range, the system automatically sends a warning message to the user to alert them. Attached Figure Description

[0016] The following is a brief explanation of the contents of each of the accompanying drawings and the markings in the drawings:

[0017] Figure 1 This is a flowchart of the remote large-scale cooling control process of the present invention. Detailed Implementation

[0018] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and the description of the preferred embodiments.

[0019] This invention controls the refrigeration unit's operation, temperature and humidity settings, shutdown, and alerts via network interaction between the refrigeration unit inside the refrigerated compartment and the entire vehicle. Customers can easily operate the vehicle's app to start the refrigeration process from outside the vehicle or at home, eliminating the need for pre-pressurization. After the refrigeration unit is started, the vehicle automatically applies high pressure before activating the unit. Once the set values ​​are reached, the refrigeration unit temporarily shuts off. When the temperature and humidity drop to the warning range, the system automatically sends a warning message to the user to alert them.

[0020] like Figure 1 As shown in this embodiment, an integrated control system for a refrigerated compartment of a new energy light truck includes a remote control terminal, an on-board TBOX, and a multi-function controller installed on the light truck. The remote control terminal is used to input control signals from the refrigerated compartment and send them to the on-board TBOX. The on-board TBOX has a reserved communication interface for connecting to the refrigeration unit inside the refrigerated compartment. The multi-function controller has a reserved high-voltage power outlet for connecting to the power supply interface of the refrigeration unit. After the refrigerated compartment is installed on the light truck, the refrigeration unit is connected to the TBOX and the multi-function controller through the communication interface and the high-voltage power outlet to establish communication and power supply connections between the on-board TBOX and the refrigeration unit.

[0021] The remote control terminal is a mobile phone with an app. The developed mobile app connects the phone to the TBOX (Trunk Refrigeration Unit). Reserved high-voltage power outlets and communication interfaces establish a connection between the refrigeration unit inside the refrigerator and the vehicle's power supply, as well as a communication connection with the TBOX, providing the basic power and communication requirements for remote control via the mobile app. After the refrigerator is installed on the light truck, the reserved communication interface and high-voltage power outlet connect the refrigeration unit to the TBOX and the multi-function controller, establishing communication and power connections between the vehicle-mounted TBOX and the refrigeration unit. After the user inputs settings through the remote control terminal, a control signal is generated and controlled via the vehicle-mounted TBOX to regulate the refrigeration status of the refrigerator.

[0022] To enable remote control of the cold start, a high voltage is required for power supply. Therefore, the system also needs to be connected to the vehicle control unit (VCU) and the battery management system (BMS). The vehicle-mounted TBOX is connected to the VCU and BMS via a CAN network.

[0023] When the vehicle-mounted TBOX receives the cooling signal, it wakes up the VCU, BMS, and all-in-one controller via the network and executes the high-voltage operation. Simultaneously, it sends the chiller startup and temperature setting parameters to the chiller for execution. Upon receiving the cooling control signal, the vehicle-mounted TBOX first wakes up the controller via the network to apply high voltage to the entire vehicle. If high-voltage application fails, the VCU sends a fault message to the network, which is then relayed to the remote control terminal by the TBOX. If high-voltage application is successful, the TBOX wakes up the chiller and sends the set temperature and humidity values. The chiller then begins operating according to the set temperature and humidity, and provides real-time feedback of temperature and humidity information to the network. The TBOX reads this information from the network and relays it to the remote control terminal.

[0024] The remote terminal mobile app forwards control signals through a cloud platform, which can be built and configured using Alibaba Cloud. The cloud platform then forwards the signals to the vehicle-mounted TBOX. The remote control terminal sends control signals to the vehicle-mounted TBOX via the cloud platform. End-to-end encrypted channels are used for communication encryption between the cloud platform and the remote control terminal, and between the cloud platform and the TBOX. This encrypted transmission channel reduces data reliability and security issues during transmission. After decrypting the received control signals from the remote control terminal, the cloud platform verifies and judges the received control signals through a compliance verification unit, a vehicle status detection unit, and an environmental condition judgment unit. Only after all judgments pass is the control signal forwarded to the TBOX, and a wake-up command is sent to the TBOX to activate it.

[0025] In this embodiment, the remote control terminal has a built-in identity recognition module, allowing the user to operate and set the cooling control signal only after successful identity recognition. The remote control terminal's built-in identity recognition module identifies the user after the user enters the cooling control parameters, and only executes the command corresponding to the user's cooling control parameters and sends it to the vehicle-mounted TBOX after successful identity recognition.

[0026] Temperature and humidity sensors are installed inside the refrigerated box, and both sensors are connected to the refrigeration unit. After the refrigeration unit starts cooling, it monitors the temperature and humidity data inside the box in real time and feeds it back to the TBOX, which in turn feeds it back to the remote control terminal. At the same time, a fault diagnosis module is integrated into the refrigeration unit to monitor the refrigeration unit's operating status for faults. When a fault signal is detected and the unit needs to be shut down, the unit will shut down and feed the fault signal back to the TBOX, which will then feed it back to the remote control terminal.

[0027] The integrated control system for the refrigerated compartment of the new energy light truck of the present invention includes:

[0028] APP: Mobile software; you can view vehicle information, refrigeration temperature, humidity and other information on this software, and control the refrigeration unit to start, stop and start the cooling operation.

[0029] TBOX: A smart in-vehicle terminal device that connects the vehicle's CAN bus and an external cloud platform to enable communication and data exchange between vehicles, between vehicles and infrastructure, and between vehicles and the Internet.

[0030] VCU: Vehicle Control Unit, is the central control unit of a new energy vehicle, responsible for managing and controlling many functions of the car, such as powertrain, braking, and steering. The VCU coordinates these functions by receiving information and instructions from other control modules, ensuring they work together safely and efficiently. Furthermore, the VCU can receive input information from the driver and other sensors and adjust the vehicle's performance and behavior as needed.

[0031] BMS: Battery Management System. The main functions of a BMS include real-time monitoring of battery parameters such as voltage, temperature, and current; controlling the charging and discharging process to prevent overcharging and over-discharging; protecting battery safety; and extending battery life. By collecting and analyzing these parameters, the BMS achieves effective battery management, ensuring the stability and safety of the battery system.

[0032] All-in-one: A controller that integrates MCU, DC-DC, DC-AC, PDU, etc., including the following:

[0033] MCU: Motor controller, which controls the rotation of the motor according to the instructions from the VCU.

[0034] DCDC: Direct-to-DC converter, also known as a DC-DC converter or DC / DC converter. It is a power conversion device whose core function is to convert one DC voltage to another to meet the power supply needs of different electronic devices.

[0035] DCAC: A device that converts direct current (DC) to alternating current (AC). In new energy vehicles, DCAC is mainly used to convert the DC power stored in the battery into AC power to drive the electric motor.

[0036] PDU: In new energy vehicles, the PDU plays a crucial role. It electrically connects high-voltage components via busbars and wiring harnesses, providing several key functions for the high-voltage system of new energy vehicles, including charge / discharge control, high-voltage component power-on control, circuit overload and short-circuit protection, high-voltage sampling, and low-voltage control.

[0037] like Figure 1 As shown, the integrated control method for the refrigerated compartment of a new energy light truck of the present invention includes the following steps:

[0038] 1. The APP sends a cold signal to the TBOX;

[0039] 2. The TBOX network wake-up controller applies high voltage to the entire vehicle; if the high voltage application fails, the VCU sends fault information to the network, which is then uploaded by the TBOX to the APP to alert the user.

[0040] 3. The TBOX wakes up the chiller and sends the set temperature and humidity values. The chiller then begins operating at the set temperature and humidity, providing real-time feedback of temperature and humidity information to the network. The TBOX then sends this information to the app for user reference. If the chiller fails to start, it sends a fault message to the network, which is then sent to the app by the TBOX to alert the user.

[0041] 4. Stop cooling via the APP by sending a stop cooling signal through the TBOX;

[0042] 5. The TBOX stops sending the chiller enable signal, and the chiller enters the shutdown process.

[0043] 6. After the engine is turned off when cold, the VCU controls the vehicle to enter a power-down sleep state or maintain its current state.

[0044] The integrated control method for the refrigerated compartment of a new energy light truck includes the following steps:

[0045] I. User Command Input Stage

[0046] The APP's user interface design adopts the HMI (Human-Machine Interface) standard (ISO 15008) to develop the temperature setting module. Users input their cooling start and stop commands and corresponding temperature settings through this module. The temperature setting range is -30℃ to +25℃, with a step accuracy of 0.5℃. User identification is required during setup; only verified users can operate the refrigerator's temperature and humidity settings via the mobile app, preventing unauthorized personnel from affecting the refrigerator's cooling effect. Identity verification employs a two-factor authentication mechanism to ensure operational security; it uses both SMS verification codes and biometric identification. During control, a mobile verification code is obtained, and the operator's identity is verified through facial or fingerprint recognition. Data transmission is encrypted using a TLS 1.3 protocol to establish an end-to-end encrypted channel. Encryption settings are based on the national cryptographic algorithm SM4 (compliant with GB / T 39786-2021 requirements). The data packet format is JSON encapsulation, including a timestamp, device ID, and verification code.

[0047] II. Vehicle-Cloud Collaborative Communication Phase

[0048] User settings entered into the app are processed by the cloud platform and then forwarded to the vehicle's TBOX. The cloud platform is built using Alibaba Cloud IoT. Upon receiving a command, the Alibaba Cloud IoT platform performs a triple verification: command compliance verification, vehicle status detection, and environmental condition judgment. Only when all three verifications pass will the cloud platform forward the signal to the TBOX. The verifications are as follows:

[0049] The instruction compliance verification checks the temperature range and operation permissions, verifying whether the temperature range set by the user is within the allowed temperature range and whether the user has the necessary operation permissions.

[0050] The vehicle condition detection is used to check the battery charge. If the battery SOC is greater than 30%, the vehicle condition detection is considered to have passed.

[0051] The environmental condition assessment is used to determine whether the ambient temperature is between -40℃ and +50℃. If so, the environmental condition assessment is passed.

[0052] After successful verification, the cloud platform will wake up the TBOX communication. The TBOX is in a low-power wake-up mode in sleep mode. When it is woken up, it will switch from low-power wake-up mode to full-function mode (<200ms).

[0053] TBOX supports multi-protocol gateway conversion:

[0054]

[0055] III. Vehicle System Wake-up Process

[0056] The controller wake-up sequence includes:

[0057] The TBOX wakes up the VCU via a CAN network (meeting ISO 14229-1 standard), and the VCU hardwires to wake up the all-in-one controller (wake-up current < 50mA); cascade wake-up timing:

[0058] TBOX→VCU(20ms)→BMS(50ms)→PDU(80ms)

[0059] Power management system collaboration

[0060] BMS performs a pre-charge process:

[0061] The main positive relay is closed (contact resistance < 2mΩ).

[0062] Insulation monitoring (>500Ω / V)

[0063] Voltage equalization (individual cell difference < 50mV)

[0064] VCU latency of 150ms design considerations:

[0065] Ensure the high-voltage system pre-charge is complete (RC constant τ = 120ms) and avoid surge current (peak value limited to 300A).

[0066] IV. Start-up Phase of the Refrigeration System

[0067] The PDU power distribution control in the all-in-one controller provides power to the chiller, and the intelligent power distribution unit performs the following operations:

[0068] Contactor closure detection (closure time < 30ms)

[0069] Load current monitoring (accuracy ±1%)

[0070] Arc fault protection (response time < 5ms)

[0071] Cold start self-test;

[0072] After the power distribution unit has passed the required testing, a start-up diagnostic is performed. The diagnostic items include the refrigerant pressure of the chiller and the insulation resistance of the compressor windings. The chiller is only allowed to start operating if the refrigerant pressure and start-up impedance values ​​meet the preset standard values; otherwise, a fault is reported. The testing items include:

[0073]

[0074]

[0075] V. Temperature Control Closed Loop

[0076] Temperature and humidity setpoints are sent to the chiller, and the TBOX writes the target temperature to the chiller via the UDS protocol (0x31 service). Data frame structure:

[0077] [0x22][0xF190][0x0004][0xFFD2] / / -30℃ hexadecimal encoding

[0078] A dynamic control strategy is employed for temperature control of the chiller. A three-level temperature control strategy is used based on the deviation between the real-time temperature and the set temperature. When the deviation is at the first deviation value, a PID fine-tuning mode is used for fine-tuning the temperature. When the deviation is at the second deviation value, a fuzzy control mode is used for coarse temperature adjustment. When the deviation is at the third deviation value, an emergency cooling or heating mode is used for rapid temperature adjustment. The first deviation value is less than the second deviation value, and the third deviation value is less than the third deviation value. The specific three-level temperature tolerance management is as follows:

[0079]

[0080] VI. Fault Monitoring and Early Warning

[0081] Abnormal state handling involves determining the current fault type based on the fault signals uploaded by the chiller's self-test, and then performing multi-level fault classification based on the fault type, including:

[0082] Fault Level 1: The fault is reported in real time and an alarm is sent to the user's mobile app via a combination of audible and visual alarms and cloud-based alarms. The unit continues to operate when cold.

[0083] Fault Level 2: The machine operates at reduced power when cold and reports the fault type to the mobile phone via TBOX.

[0084] Fault Level 3: The chiller system shuts down and performs remote diagnostics to diagnose the fault, and immediately reports the fault. Specific categories are as follows:

[0085]

[0086] Fault data recording in data closed-loop management complies with GB / T 32960.3-2016 standard.

[0087] Cloud-based big data analytics: Fault mode recognition (SVM) algorithm is used to identify faults and generate predictive maintenance suggestions to achieve intelligent scheduling of spare parts inventory.

[0088] The advantages of this solution include:

[0089] 1. This invention can automatically apply high voltage to the entire vehicle and turn on the cold start without the need to pre-energize the vehicle;

[0090] 2. You can check the vehicle's battery level and cold start status using only one app;

[0091] 3. Information such as chiller temperature and humidity can be sent to users via SMS, which can effectively reduce potential losses for users;

[0092] 4. Reduce the rate of cargo damage and abnormalities;

[0093] 5. Reduce manual inspections;

[0094] 6. Temperature and humidity information can be set in advance;

[0095] 7. Pre-cool the food to reduce waiting time.

[0096] Obviously, the specific implementation of this invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of this invention are within the protection scope of this invention.

Claims

1. An integrated control system for a new energy light truck refrigerated compartment, characterized in that: The system includes a remote control terminal, an onboard TBOX installed on the light truck, and a multi-function controller. The remote control terminal is used to input the control signals of the refrigerated box and send them to the onboard TBOX. The onboard TBOX has a reserved communication interface for connecting to the refrigeration unit inside the refrigerated box. The multi-function controller has a reserved high-voltage power outlet for connecting to the power supply interface of the refrigeration unit. After the refrigerated box is installed on the light truck, the refrigeration unit is connected to the TBOX and the multi-function controller through the communication interface and the high-voltage power outlet to establish communication and power supply connections between the onboard TBOX and the refrigeration unit.

2. The integrated control system for a new energy light truck refrigerated compartment as described in claim 1, characterized in that: The control system also includes a vehicle controller (VCU) and a battery management system (BMS); the on-board TBOX is connected to the VCU and the BMS via a CAN network.

3. The integrated control system for a new energy light truck refrigerated compartment as described in claim 2, characterized in that: After receiving the cooling signal, the vehicle-mounted TBOX wakes up the VCU, BMS, and all-in-one controller via the network and performs the high-voltage operation; at the same time, it sends the chiller start-up and temperature setting parameters to the chiller for execution.

4. The integrated control system for a new energy light truck refrigerated compartment as described in any one of claims 1-3, characterized in that: The remote control terminal sends control signals to the vehicle-mounted TBOX via the cloud platform; end-to-end encrypted channels are used for communication encryption in the communication between the cloud platform and the remote control terminal, as well as between the cloud platform and the TBOX.

5. An integrated control system for a new energy light truck refrigerated compartment as described in any one of claims 1-3, characterized in that: The remote control terminal has a built-in identity recognition module, which allows users to operate and set the cooling control signal only after successful identity recognition.

6. The integrated control system for a new energy light truck refrigerated compartment as described in claim 4, characterized in that: After decrypting the control signal received from the remote control terminal, the cloud platform verifies and judges the received control signal through a compliance verification unit, a vehicle status detection unit, and an environmental condition judgment unit. Only after all judgments are passed will the control signal be forwarded to the TBOX, and a wake-up command will be sent to the TBOX to wake up the vehicle TBOX.

7. An integrated control system for a new energy light truck refrigerated compartment as described in any one of claims 1-6, characterized in that: Temperature and humidity sensors are installed inside the refrigerated box, and both sensors are connected to the refrigeration unit. After the refrigeration unit performs cooling, it monitors the temperature and humidity data inside the box in real time and feeds it back to the TBOX, which in turn feeds it back to the remote control terminal.

8. A control method for an integrated control system of a new energy light truck refrigerated compartment as described in any one of claims 1-7, characterized in that: After the refrigerated box is installed on the light truck, the refrigeration unit is connected to the TBOX and the multi-function controller through the reserved communication interface and high-voltage power supply port to establish communication and power supply connection between the vehicle TBOX and the refrigeration unit; after the user enters the setting parameters through the remote control terminal, the control signal is generated and the refrigeration state of the refrigerated box is controlled through the vehicle TBOX.

9. The control method for the integrated control system of a new energy light truck refrigerated compartment as described in claim 8, characterized in that: After receiving the cooling control signal, the vehicle-mounted TBOX first wakes up the controller via the network to apply high voltage to the entire vehicle. If the high voltage application fails, the VCU sends fault information to the network, which is then fed back to the remote control terminal by the TBOX. If the high voltage application is successful, the TBOX wakes up the cooling unit and sends the set temperature and humidity values. The cooling unit then starts working according to the set temperature and humidity and feeds back temperature and humidity information to the network in real time. The TBOX reads the information from the network and feeds it back to the remote control terminal.

10. The control method for the integrated control system of a new energy light truck refrigerated compartment as described in claim 8 or 9, characterized in that: The remote control terminal has a built-in identity recognition module. After the user enters the cooling control parameters, the module recognizes the user's identity. Only after successful identity recognition will the module execute the command corresponding to the user's cooling control parameters and send it to the vehicle-mounted TBOX.

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