Heavy truck electric drive bridge system, efficiency optimization control method thereof, electric drive bridge and heavy truck

Abstract

The invention discloses a heavy truck electric drive bridge system, an efficiency optimization control method thereof, an electric drive bridge and a heavy truck. The heavy truck electric drive bridge system comprises a motor, and the motor can achieve switching operation of at least three phase numbers. The sensor group is used for collecting driving parameters of the heavy truck; the variable-machine and variable-phase control system comprises a main controller, a working condition identification module, a phase number switching module and an inverter, the working condition recognition module is electrically connected with the sensor set and obtains heavy truck driving parameters. The main controller is electrically connected with the working condition identification module, the main controller is electrically connected with the phase number switching module, and the main controller judges the working condition of the heavy truck according to the driving parameters of the heavy truck and sends a control instruction to the phase number switching module; and the phase number switching module is electrically connected with the inverter and is used for performing on-off control on a first power switch of a corresponding phase in the inverter according to the control instruction and switching the phase number of the motor. The problem that the heavy truck electric drive axle is difficult to adapt to complex working conditions is solved, and the efficiency of the electric drive axle is improved.

Description

Technical Field

[0001] This invention relates to the field of new energy heavy-duty truck technology, and in particular to a heavy-duty truck electric drive axle system and its efficiency optimization control method, the electric drive axle and the heavy-duty truck. Background Technology

[0002] Heavy-duty trucks (HDTrucks) play a crucial role in the electrification of the heavy-duty truck industry due to their large load capacity. Among these factors, the performance of the HDTruck's electric drive axle is a key determinant of its power, economy, and reliability. HDTrucks operate under complex and diverse conditions, often facing different scenarios such as low-speed heavy loads (e.g., starting, climbing) and high-speed light loads (e.g., highway cruising), which significantly alter the output characteristics and efficiency requirements of the electric drive axle.

[0003] In existing technologies, heavy-duty truck electric drive axles are difficult to adapt to complex operating conditions. Specifically, at low speeds and heavy loads, the motor needs to output large torque, which leads to excessive winding current, a surge in copper losses, and a significant decrease in efficiency; while at high speeds and light loads, the proportion of iron losses and switching losses increases, making efficient operation impossible. Summary of the Invention

[0004] This invention provides a heavy-duty truck electric drive axle system and its efficiency optimization control method, an electric drive axle and a heavy-duty truck, to solve the problem that heavy-duty truck electric drive axles are difficult to adapt to complex working conditions and improve the efficiency of the electric drive axle.

[0005] According to one aspect of the present invention, a heavy-duty truck electric drive axle system is provided, comprising:

[0006] The motor includes a multi-phase winding connected in a star configuration, with each phase of the winding being independently configured; the motor is capable of switching between at least three different phase numbers.

[0007] Sensor array used to collect driving parameters of heavy trucks;

[0008] The variable-phase control system includes a main controller, an operating condition identification module, a phase switching module, and an inverter. The operating condition identification module is electrically connected to the sensor group and acquires the heavy-duty truck's driving parameters. The main controller is electrically connected to the operating condition identification module and the phase switching module. The main controller determines the heavy-duty truck's operating condition based on the driving parameters and sends control commands to the phase switching module. The phase switching module is electrically connected to the inverter and is used to control the on / off state of the first power switch of the corresponding phase in the inverter according to the control commands, thereby switching the number of phases of the motor.

[0009] Optionally, the motor is a 9-phase permanent magnet synchronous motor; the motor can switch between 3-phase operation mode, 6-phase operation mode and 9-phase operation mode;

[0010] Optionally, the heavy-duty truck electric drive axle system further includes a cooling system, the cooling system comprising:

[0011] A heat dissipation structure is provided on the motor side for dissipating heat from the motor;

[0012] A flow regulating pump is mechanically connected to the heat dissipation structure and electrically connected to the main controller; the flow regulating pump is used to receive control from the main controller to regulate the flow of the heat dissipation structure.

[0013] Optionally, the sensor group includes:

[0014] A speed sensor is configured on the motor side; the speed sensor is used to monitor the real-time speed of the motor.

[0015] A torque sensor is disposed on the motor side; the torque sensor is used to monitor the output torque.

[0016] A current sensor is disposed in each phase of the winding; the current sensor is used to collect the current of the winding.

[0017] A temperature sensor is disposed on the motor side; the temperature sensor is used to monitor the operating temperature of the motor.

[0018] According to another aspect of the present invention, an efficiency optimization control method for a heavy-duty truck electric drive axle system is provided, applied to a heavy-duty truck electric drive axle system as described in any embodiment of the present invention; the method includes:

[0019] The main controller receives the heavy truck driving parameters sent by the working condition identification module in real time, and determines the heavy truck working condition based on the heavy truck driving parameters; wherein, the heavy truck working condition includes low-speed heavy-load working condition, medium-speed medium-load working condition and high-speed light-load working condition.

[0020] If the heavy truck operating condition is the low-speed heavy-load operating condition, the main controller sends a first control command to the phase switching module; the first control command controls the first power switch of all corresponding phases in the inverter to be turned on, and all the windings of the motor to run;

[0021] If the heavy truck operating condition is the medium-speed, medium-load operating condition, the main controller sends a second control command to the phase switching module; the second control command controls the first power switch of the majority phase in the inverter to be turned on, and controls the majority windings of the motor to run;

[0022] If the heavy truck operating condition is the high-speed light-load operating condition, the main controller sends a third control command to the phase switching module; the third control command controls the first power switch of a minority phase in the inverter to be turned on, and controls the operation of a minority winding of the motor.

[0023] Optionally, the motor is a 9-phase permanent magnet synchronous motor;

[0024] In the efficiency optimization control method, if the heavy truck operating condition is the low-speed heavy-load operating condition, the motor operates in a 3-phase mode; if the heavy truck operating condition is the medium-speed medium-load operating condition, the motor operates in a 6-phase mode; if the heavy truck operating condition is the high-speed light-load operating condition, the motor operates in a 9-phase mode.

[0025] Optionally, after the main controller receives the heavy-duty truck driving parameters sent by the operating condition identification module in real time and determines the heavy-duty truck operating condition based on the heavy-duty truck driving parameters, the method further includes:

[0026] During the phase switching process of the motor, the main controller generates complementary voltage vectors through space vector pulse width modulation technology to achieve smooth switching.

[0027] Optionally, when the main controller receives the heavy-duty truck driving parameters sent by the operating condition identification module in real time, and determines the heavy-duty truck operating condition based on the heavy-duty truck driving parameters, the method further includes:

[0028] Determine whether the motor windings are faulty based on the heavy truck's driving parameters;

[0029] If one phase winding of the motor fails, the main controller sends an isolation control command to the phase switching module. The isolation control command controls the first power switch of the faulty phase in the inverter to be turned off, and the remaining phases to be recombined and operated in a symmetrical manner.

[0030] According to another aspect of the present invention, a dynamic configuration electric drive axle for heavy-duty trucks is provided, including a heavy-duty truck electric drive axle system as described in any embodiment of the present invention, and an efficiency optimization control method for the heavy-duty truck electric drive axle system as described in any embodiment of the present invention.

[0031] According to another aspect of the present invention, a new energy heavy-duty truck is provided, including a heavy-duty truck dynamic configuration electric drive axle as described in any embodiment of the present invention.

[0032] This invention, through the configuration of a motor capable of switching the number of phases, a sensor group, and a variable-phase control system, achieves the effect of switching the number of motor phases for different heavy-duty truck operating conditions. Specifically, by using a multi-phase operation mode of the motor, combined with a heavy-duty truck operating condition identification and phase matching strategy, optimal efficiency can be achieved under different operating conditions such as low-speed heavy load, high-speed light load, and medium-speed medium load, reducing energy consumption and achieving efficient adaptation to operating conditions. Furthermore, during the operation of heavy-duty trucks, the torque range between heavy load and light load is large. This invention enables the motor to switch between at least three phases, providing a more precise distinction between motor operating conditions and meeting the high-intensity and high-reliability requirements of heavy-duty trucks.

[0033] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying 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.

[0035] Figure 1 This is a schematic diagram of the structure of a heavy-duty truck electric drive axle system provided in an embodiment of the present invention;

[0036] Figure 2 This is a schematic diagram of an inverter and a motor connection provided in an embodiment of the present invention;

[0037] Figure 3 This is a schematic diagram of another heavy-duty truck electric drive axle system provided in an embodiment of the present invention;

[0038] Figure 4 This is a schematic diagram of another heavy-duty truck electric drive axle system provided in an embodiment of the present invention;

[0039] Figure 5 A flowchart illustrating an efficiency optimization control method for a heavy-duty truck electric drive axle system provided in an embodiment of the present invention;

[0040] Figure 6 This is a flowchart illustrating an efficiency optimization control method for a heavy-duty truck electric drive axle system provided in an embodiment of the present invention. Detailed Implementation

[0041] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0042] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0043] Figure 1 This is a schematic diagram of a heavy-duty truck electric drive axle system provided in an embodiment of the present invention. See also... Figure 1 The heavy-duty truck electric drive axle system includes:

[0044] The motor 100 includes a star-connected multiphase winding 110 (stator winding), with each phase winding 110 set independently; the motor 100 can achieve switching operation of at least three phase numbers;

[0045] Sensor group 200 is used to collect heavy truck driving parameters;

[0046] The variable-phase control system 300 includes a main controller 310, a working condition identification module 320, a phase number switching module 330, and an inverter 340. The working condition identification module 320 is electrically connected to the sensor group 200 and acquires the driving parameters of the heavy truck. The main controller 310 is electrically connected to the working condition identification module 320 and the phase number switching module 330. The main controller 310 determines the working condition of the heavy truck based on the driving parameters and sends control commands to the phase number switching module 330. The phase number switching module 330 is electrically connected to the inverter 340 and is used to control the on / off state of the first power switch of the corresponding phase in the inverter 340 according to the control commands, thereby switching the number of phases of the motor 100.

[0047] The heavy-duty truck electric drive axle system can employ an efficiency optimization control method, specifically including: the main controller 310 receives heavy-duty truck driving parameters (such as vehicle speed, torque demand, battery SOC, etc.) sent by the operating condition identification module 320 in real time, and determines the heavy-duty truck operating condition based on the heavy-duty truck driving parameters; among which, the heavy-duty truck operating condition includes low-speed heavy-load operating condition, medium-speed medium-load operating condition, and high-speed light-load operating condition; if the heavy-duty truck operating condition is low-speed heavy-load operating condition, the main controller 310 sends a first control command to the phase switching module 330; the first control command controls the first power switch of all corresponding phases in the inverter 340 to be turned on. All windings 110 of motor 100 are in operation; if the heavy truck operating condition is medium speed and medium load, the main controller 310 sends a second control command to the phase number switching module 330; the second control command controls the first power switch of the majority phase in the inverter 340 to be turned on, controlling the majority windings 110 of motor 100 to operate; if the heavy truck operating condition is high speed and light load, the main controller 310 sends a third control command to the phase number switching module 330; the third control command controls the first power switch of the minority phase in the inverter 340 to be turned on, controlling the minority windings 110 of motor 100 to operate.

[0048] The efficiency of a motor can be represented using a motor efficiency diagram. For a motor with a fixed number of phases, the highest efficiency speed and torque are also fixed values. For example, the highest efficiency operating conditions for a motor are 2000 r / min and 200 N. This embodiment of the invention allows the motor 100 to maintain high efficiency by switching the number of phases of the motor 100 under different heavy-duty truck operating conditions. Specifically, under low-speed, heavy-load conditions, the motor 100 needs to output high torque. By controlling the operation of all windings 110 of the motor 100, the current can be distributed among the windings 110, thereby reducing the current in each phase winding 110 and avoiding the problem of a surge in copper losses and a significant drop in efficiency caused by excessive winding current. Under high-speed, light-load conditions, the motor 100 operates at a higher speed. By controlling the operation of a few windings 110 of the motor 100, the high-order harmonic content in the windings 110 is reduced, thereby reducing the proportion of iron losses and switching losses in the motor and improving motor efficiency. Furthermore, under medium speed and medium load conditions, the motor operates in a high-efficiency state by controlling the operation of most of the windings 110 of the motor 100.

[0049] This invention, through the configuration of a motor 100 capable of switching phases, a sensor group 200, and a variable-phase control system 300, achieves the effect of switching the number of phases of the motor 100 for different heavy-duty truck operating conditions. Specifically, by using the multi-phase operation mode of the motor 100, combined with heavy-duty truck operating condition identification and phase matching strategies, optimal efficiency can be achieved under different operating conditions such as low-speed heavy load, high-speed light load, and medium-speed medium load, reducing energy consumption and achieving efficient adaptation to operating conditions. Furthermore, during heavy-duty truck operation, the torque range between heavy load and light load is large. This invention enables the motor 100 to switch between at least three phases, providing a more precise distinction between the operating conditions of the motor 100 and meeting the high-intensity and high-reliability requirements of heavy-duty trucks.

[0050] See also Figure 1 Based on the above embodiments, optionally, the motor 100 is a 9-phase permanent magnet synchronous motor 100; the motor 100 can switch between 3-phase, 6-phase, and 9-phase operating modes. The motor 100 includes 9-phase windings 110, which are star-connected, with each phase winding 110 independently configured, thus supporting switching between 3-phase, 6-phase, and 9-phase operating modes. Specifically, in 3-phase operating mode, only 3 phase windings 110 have current flowing through them, while the remaining 6 phase windings 110 have no current flowing under the control of the first power switch within the inverter 340; in 6-phase operating mode, 6 phase windings 110 have current flowing through them, while the remaining 3 phase windings 110 have no current flowing under the control of the first power switch within the inverter 340; in 9-phase operating mode, all phase windings 110 have current flowing through them.

[0051] Figure 2 This is a schematic diagram illustrating the connection between an inverter and a motor according to an embodiment of the present invention. Figure 3 This is a schematic diagram of another heavy-duty truck electric drive axle system provided in an embodiment of the present invention. See also... Figure 2 and Figure 3 Based on the above embodiments, optionally, the inverter 340 includes bridge arms corresponding to each phase winding 110 of the motor 100. Each phase bridge arm consists of two or more first power switches 341. By controlling the first power switches 341 in each phase bridge arm, the flow of current through the corresponding phase winding 110 can be controlled. The first power switches 341 can be insulated-gate bipolar transistor (IGBT) power devices. For example, each phase bridge arm includes two first power switches 341. Figure 2The first six first power switches 341 and their corresponding clamping diodes 342 constitute the first electronic shifter 3401, the middle six first power switches 341 and their corresponding clamping diodes 342 constitute the second electronic shifter 3401, and the last six first power switches 341 and their corresponding clamping diodes 342 constitute the third electronic shifter 3401. When the first electronic shifter 3401 is running and the second and third electronic shifters 3401 are closed, current flows through the 3-phase windings in the first row, while no current flows through the 6-phase windings in the second and third rows, achieving a 3-phase operation mode. When the first and second electronic shifters 3401 are running and the third electronic shifter 3401 is closed, current flows through the 6-phase windings in the first and second rows, while no current flows through the 3-phase windings in the third row, achieving a 6-phase operation mode. When all three electronic shifters 3401 are running, current flows through all nine windings, achieving a 9-phase operation mode.

[0052] Based on the above embodiments, optionally, the rated power of the motor 100 can be set to 300-500kW, preferably 400kW, according to the requirements of heavy trucks; the rated speed can be set to 1500-3000r / min, preferably 2000r / min. Through the 9-phase winding design, various phase combination operation modes such as 3-phase, 6-phase, and 9-phase can be realized to adapt to different working conditions.

[0053] Based on the above embodiments, optionally, the main controller 310 adopts a microprocessor with a main frequency of 120MHz and a preset fuzzy control algorithm, which can determine the current working condition based on the collected heavy truck driving parameters.

[0054] Based on the above embodiments, optionally, the sampling frequency of the working condition identification module 320 is 1kHz, and the sensor data sent by its sampling sensor group 200 is processed and converted into sampling data that matches the main controller 310.

[0055] Based on the above embodiments, optionally, the response time of the phase number switching module 330 is ≤50ms. The phase number switching module 330 can be regarded as the driving module of the first power switch. After receiving the control command sent by the main controller 310, it drives the on and off of each first power switch.

[0056] Figure 4 This is a schematic diagram of another heavy-duty truck electric drive axle system provided in an embodiment of the present invention. See also... Figure 4 Optionally, based on the above embodiments, the heavy-duty truck electric drive axle system further includes a cooling system 400, which includes:

[0057] Heat dissipation structure 410 is disposed on the side of motor 100 and is used to dissipate heat from motor 100;

[0058] The flow regulating pump 420 is mechanically connected to the heat dissipation structure 410 and electrically connected to the main controller 310. The flow regulating pump 420 is used to receive control from the main controller 310 to regulate the flow of the heat dissipation structure 410.

[0059] In this embodiment of the invention, the heat dissipation structure 410 can be a liquid-cooled structure, and the flow regulating pump 420 is an electronic flow regulating pump. The main controller 310 automatically adjusts the cooling flow rate according to the operating temperature of the motor 100 and the number of operating phases; the more operating phases, the greater the cooling flow rate. For example, when operating with 9 phases, the flow regulating pump 420 increases the flow rate to 1.5 times that of 3-phase operation, ensuring that the operating temperature of the motor 100 does not exceed 120°C, thus meeting the long-term, high-intensity operation requirements of heavy trucks.

[0060] Based on the above embodiments, optionally, the liquid cooling medium of the heat dissipation structure 410 is a 50% concentration ethylene glycol solution, with a cooling flow rate of 8 L / min during 3-phase operation and 12 L / min during 9-phase operation.

[0061] This invention provides a cooling system 400 that dynamically adjusts the cooling flow rate according to the heavy truck's operating conditions, ensuring the temperature stability of the motor 100 during high-intensity operation of the heavy truck, thus meeting the demands of the heavy truck and extending the service life of the motor 100.

[0062] Based on the above embodiments, optionally, the sensor group 200 includes:

[0063] A speed sensor is configured on the motor 100 side; the speed sensor is used to monitor the real-time speed of the motor 100.

[0064] A torque sensor is configured on the motor 100 side; the torque sensor is used to monitor the output torque.

[0065] A current sensor is configured in each phase winding 110; the current sensor is used to collect the current of winding 110.

[0066] A temperature sensor is located on the motor 100 side; the temperature sensor is used to monitor the operating temperature of the motor 100.

[0067] For example, the speed sensor has an accuracy of ±1 r / min; the torque sensor has a range of 0-2000 N·m and an accuracy of ±1% FS; the current sensor has a range of 0-500 A and an accuracy of ±0.5% FS; and the temperature sensor has a measurement range of -40℃ to 150℃ and an accuracy of ±1℃.

[0068] Among them, the speed sensor is used to monitor the real-time speed of the motor 100, the torque sensor monitors the output torque, the current sensor collects the current of the winding 110, and the temperature sensor detects the operating temperature of the motor 100 to provide temperature feedback, providing accurate data support for operating condition identification and phase switching.

[0069] This invention also provides an efficiency optimization control method for a heavy-duty truck electric drive axle system, applicable to the heavy-duty truck electric drive axle system provided in any embodiment of this invention. Figure 5 This is a flowchart illustrating an efficiency optimization control method for a heavy-duty truck electric drive axle system provided in an embodiment of the present invention. See also... Figure 5 The method includes the following steps:

[0070] In step S510, the main controller 310 receives the heavy truck driving parameters sent by the working condition identification module 320 in real time, and determines the heavy truck working condition based on the heavy truck driving parameters; wherein, the heavy truck working condition includes low-speed heavy load working condition, medium-speed medium load working condition and high-speed light load working condition.

[0071] Step S520: If the heavy truck is in a low-speed heavy-load condition, the main controller 310 sends a first control command to the phase number switching module 330; the first control command controls the first power switch of all corresponding phases in the inverter 340 to be turned on, and all windings 110 of the motor 100 are running.

[0072] Step S530: If the heavy truck is in medium speed and medium load condition, the main controller 310 sends a second control command to the phase number switching module 330; the second control command controls the first power switch of the majority phase in the inverter 340 to be turned on, and controls the majority windings 110 of the motor 100 to run.

[0073] Step S540: If the heavy truck is in a high-speed, light-load condition, the main controller 310 sends a third control command to the phase switching module 330; the third control command controls the first power switch of a minority phase in the inverter 340 to be turned on, and controls the minority winding 110 of the motor 100 to run.

[0074] Among them, the heavy truck driving parameters can be, for example, vehicle speed, torque demand, output torque, and battery SOC; the main controller 310 can use a preset algorithm based on fuzzy control to determine the current working condition based on the collected heavy truck driving parameters and send control commands to the phase switching module 330; after receiving the control commands, the phase switching module 330 controls the on / off of the first power switch of the corresponding phase in the inverter 340 to achieve smooth switching of the number of operating phases of the motor 100.

[0075] For example, the main controller 310 receives data collected by the sensor group in real time and detects the heavy truck's operating conditions based on a preset algorithm of fuzzy control. Specifically, the judgment conditions for each operating condition are as follows: low-speed heavy-load condition: vehicle speed < 30 km / h, torque demand > 70% of rated torque; medium-speed medium-load condition: 30 km / h ≤ vehicle speed < 60 km / h, 30% ≤ torque demand ≤ 70% of rated torque; high-speed light-load condition: vehicle speed ≥ 60 km / h, torque demand < 30% of rated torque. In the low-speed heavy-load condition, the control motor 100 operates in 9-phase mode, reducing the current per phase and minimizing copper losses through multi-phase current splitting; in the medium-speed medium-load condition, the control motor 100 operates in 6-phase mode; and in the high-speed light-load condition, the control motor 100 operates in 3-phase mode to reduce iron losses and switching losses.

[0076] Based on the above embodiments, optionally, the motor 100 is a 9-phase permanent magnet synchronous motor 100. In the efficiency optimization control method, if the heavy truck operation is a low-speed heavy-load operation, the motor 100 operates in a 3-phase mode; if the heavy truck operation is a medium-speed medium-load operation, the motor 100 operates in a 6-phase mode; if the heavy truck operation is a high-speed light-load operation, the motor 100 operates in a 9-phase mode.

[0077] This invention realizes heavy truck operating condition identification and motor phase matching. Specifically, when the heavy truck starts and climbs a hill, the sensor group 200 detects that the vehicle speed is 15km / h and the torque requirement is 80% of the rated torque. The main controller 310 determines that the current operating condition is a low-speed heavy-load condition. The main controller 310 controls the motor 100 to operate in a 9-phase mode, with the current of each phase being 1 / 3 of that in the 3-phase mode, which significantly reduces copper loss.

[0078] When sensor group 200 detects that the heavy truck accelerates to 45km / h and the torque demand is 50% of the rated torque, the main controller 310 determines that the current working condition is medium speed and medium load. The main controller 310 triggers the phase number switching command to complete the switching of motor 100 from 9 phases to 6 phases.

[0079] When the heavy truck travels on the highway, the sensor group 200 detects that the vehicle speed is 70km / h and the torque demand is 20% of the rated torque. The main controller 310 determines that the current working condition is a high-speed light-load working condition. The main controller 310 triggers the phase number switching command to complete the switching of the motor 100 from 6 phases to 3 phases. Iron loss and switching loss can be reduced by more than 20%.

[0080] Based on the above embodiments, optionally, after the main controller 310 receives the heavy truck driving parameters sent by the operating condition identification module 320 in real time and determines the heavy truck operating condition based on the heavy truck driving parameters, the method further includes: during the phase switching process of the motor 100, the main controller 310 generates complementary voltage vectors through space vector pulse width modulation (SVPWM) technology to achieve smooth switching. This setting enables seamless current transition, completes phase switching within 50-100ms, ensures torque fluctuation does not exceed 5% of rated torque, avoids impact on the drive axle and transmission system, and improves the stability of the transmission system.

[0081] For example, when the sensor group 200 detects that the heavy truck accelerates to 45km / h and the torque demand is 50% of the rated torque, the main controller 310 determines that the current working condition is a medium-speed and medium-load working condition. The main controller 310 triggers a phase switching command and completes the switching from 9 phases to 6 phases within 70ms through SVPWM technology. The torque fluctuation is controlled within 3% of the rated torque, and the motor 100 is switched from 9 phases to 6 phases.

[0082] Figure 6 This is a flowchart illustrating an efficiency optimization control method for a heavy-duty truck electric drive axle system provided in an embodiment of the present invention. See also... Figure 6 Based on the above embodiments, optionally, when the main controller 310 receives the heavy truck driving parameters sent by the working condition identification module 320 in real time and determines the heavy truck working condition based on the heavy truck driving parameters, it further includes:

[0083] Step S550: Determine whether the winding 110 of the motor 100 is faulty based on the heavy truck driving parameters;

[0084] Step S560: If one phase winding 110 of motor 100 fails, the main controller 310 sends an isolation control command to the phase switching module 330. The isolation control command controls the first power switch of the faulty phase in inverter 340 to shut down, and the remaining phases to be recombined and operated in a symmetrical manner. This setting can ensure that the motor continuously outputs no less than 80% of the rated power, improving the reliability of heavy truck operation.

[0085] For example, if a fault occurs in one phase winding, such as a short circuit, the main controller 310 detects and isolates the faulty phase within 100ms. The remaining eight phases then reassemble and operate symmetrically, maintaining the output power at 330kW (i.e., 82.5% of the rated power), ensuring the heavy truck can travel normally to the maintenance station. Therefore, this embodiment of the invention has strong fault tolerance and will not cause the motor 100 to fail due to a fault in one phase winding 110, thus improving the driving safety of the heavy truck.

[0086] Step S570: If the motor 100 is fault-free, control the number of phases of the motor 100 according to the method of adapting to the working conditions.

[0087] This invention also provides a dynamic configuration electric drive axle for heavy-duty trucks, which includes the heavy-duty truck electric drive axle system as provided in any embodiment of this invention, and an efficiency optimization control method for the heavy-duty truck electric drive axle system as provided in any embodiment of this invention.

[0088] In summary, the embodiments of the present invention can achieve at least the following beneficial effects:

[0089] Firstly, it is highly adaptable to different operating conditions: through the multi-phase operation mode of the 9-phase motor, combined with the operating condition identification and phase matching strategy, it can achieve optimal efficiency operation and reduce energy consumption under different operating conditions such as low-speed heavy load, medium-speed medium load and high-speed light load of heavy trucks.

[0090] Secondly, the switching is smooth and stable: SVPWM technology is used to achieve seamless switching of the number of phases, with small torque fluctuations, avoiding impact on the drive axle and transmission system, and ensuring the driving stability of heavy trucks.

[0091] Thirdly, high fault tolerance and reliability: It has the functions of fault phase isolation and residual phase recombination, and can still maintain high power output when a local fault occurs, which significantly improves the safety and reliability of heavy truck operation.

[0092] Fourthly, adapting to the needs of heavy-duty trucks: the cooling system dynamically adjusts the flow rate according to the working conditions to ensure the temperature stability of the motor during the high-intensity operation of heavy-duty trucks and extend its service life.

[0093] This invention also provides a new energy heavy-duty truck, including the heavy-duty truck dynamic configuration electric drive axle as provided in any embodiment of this invention, and has corresponding beneficial effects.

[0094] It should be understood that the various forms of processes shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this invention can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this invention can be achieved, and this is not limited herein.

[0095] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A heavy-duty truck electric drive axle system, characterized in that, include: The motor includes a multi-phase winding connected in a star configuration, with each phase of the winding being independently configured; the motor is capable of switching between at least three different phase numbers. Sensor array used to collect driving parameters of heavy trucks; The variable-phase control system includes a main controller, an operating condition identification module, a phase switching module, and an inverter. The operating condition identification module is electrically connected to the sensor group and acquires the heavy-duty truck's driving parameters. The main controller is electrically connected to the operating condition identification module and the phase switching module. The main controller determines the heavy-duty truck's operating condition based on the driving parameters and sends control commands to the phase switching module. The phase switching module is electrically connected to the inverter and is used to control the on / off state of the first power switch of the corresponding phase in the inverter according to the control commands, thereby switching the number of phases of the motor.

2. The heavy-duty truck electric drive axle system according to claim 1, characterized in that, The motor is a 9-phase permanent magnet synchronous motor; the motor can switch between 3-phase operation mode, 6-phase operation mode and 9-phase operation mode.

3. The heavy-duty truck electric drive axle system according to claim 1 or 2, characterized in that, It also includes a cooling system, which comprises: A heat dissipation structure is provided on the motor side for dissipating heat from the motor; A flow regulating pump is mechanically connected to the heat dissipation structure and electrically connected to the main controller; the flow regulating pump is used to receive control from the main controller to regulate the flow of the heat dissipation structure.

4. The heavy-duty truck electric drive axle system according to claim 3, characterized in that, The sensor group includes: A speed sensor is configured on the motor side; the speed sensor is used to monitor the real-time speed of the motor. A torque sensor is disposed on the motor side; the torque sensor is used to monitor the output torque. A current sensor is disposed in each phase of the winding; the current sensor is used to collect the current of the winding. A temperature sensor is disposed on the motor side; the temperature sensor is used to monitor the operating temperature of the motor.

5. An efficiency optimization control method for a heavy-duty truck electric drive axle system, characterized in that, Applied to the heavy-duty truck electric drive axle system as described in any one of claims 1-4; the method includes: The main controller receives the heavy truck driving parameters sent by the working condition identification module in real time, and determines the heavy truck working condition based on the heavy truck driving parameters; wherein, the heavy truck working condition includes low-speed heavy-load working condition, medium-speed medium-load working condition and high-speed light-load working condition. If the heavy truck operating condition is the low-speed heavy-load operating condition, the main controller sends a first control command to the phase switching module; the first control command controls the first power switch of all corresponding phases in the inverter to be turned on, and all the windings of the motor to run; If the heavy truck operating condition is the medium-speed, medium-load operating condition, the main controller sends a second control command to the phase switching module; the second control command controls the first power switch of the majority phase in the inverter to be turned on, and controls the majority windings of the motor to run; If the heavy truck operating condition is the high-speed light-load operating condition, the main controller sends a third control command to the phase switching module; the third control command controls the first power switch of a minority phase in the inverter to be turned on, and controls the operation of a minority winding of the motor.

6. The efficiency optimization control method for a heavy-duty truck electric drive axle system according to claim 5, characterized in that, The motor is a 9-phase permanent magnet synchronous motor; In the efficiency optimization control method, if the heavy truck operating condition is the low-speed heavy-load operating condition, the motor operates in a 3-phase mode; if the heavy truck operating condition is the medium-speed medium-load operating condition, the motor operates in a 6-phase mode; if the heavy truck operating condition is the high-speed light-load operating condition, the motor operates in a 9-phase mode.

7. The efficiency optimization control method for a heavy-duty truck electric drive axle system according to claim 5, characterized in that, After the main controller receives the heavy truck driving parameters sent by the operating condition identification module in real time, and determines the heavy truck operating condition based on the heavy truck driving parameters, the system further includes: During the phase switching process of the motor, the main controller generates complementary voltage vectors through space vector pulse width modulation technology to achieve smooth switching.

8. The efficiency optimization control method for a heavy-duty truck electric drive axle system according to claim 5, characterized in that, When the main controller receives the heavy truck driving parameters sent by the operating condition identification module in real time, and determines the heavy truck operating condition based on the heavy truck driving parameters, the method further includes: Determine whether the motor windings are faulty based on the heavy truck's driving parameters; If one phase winding of the motor fails, the main controller sends an isolation control command to the phase switching module. The isolation control command controls the first power switch of the faulty phase in the inverter to be turned off, and the remaining phases to be recombined and operated in a symmetrical manner.

9. A dynamic configuration electric drive axle for heavy-duty trucks, characterized in that, The system includes a heavy-duty truck electric drive axle system as described in any one of claims 1-4, and an efficiency optimization control method for a heavy-duty truck electric drive axle system as described in any one of claims 5-8.

10. A new energy heavy-duty truck, characterized in that, Includes the heavy-duty truck dynamic configuration electric drive axle as described in claim 9.

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