Self-adaptive hydraulic power generation system of insulated boom truck and control method of self-adaptive hydraulic power generation system

Abstract

The invention discloses a self-adaptive hydraulic power generation system of an insulated boom truck and a control method, and aims to solve the problems that the pressure is abnormal, the flow of hydraulic oil is uncontrollable and charging parameters are not matched with the state of a storage battery in an existing shared oil way. The system comprises a hydraulic oil tank, a proportional valve, an independent pressure oil pipe assembly, a hydraulic power generation assembly, a storage battery and a control module. The hydraulic oil tank is connected with the hydraulic power generation assembly through the independent pressure oil pipe assembly and used for independently supplying oil to the hydraulic power generation assembly, the proportional valve is arranged on the independent pressure oil pipe assembly and used for controlling the amount of oil entering the hydraulic power generation assembly from the hydraulic oil tank, and the hydraulic power generation assembly is connected with the storage battery. The control module is used for adjusting the opening degree of the proportional valve in real time and controlling the charging and discharging process of the storage battery. Hydraulic oil is independently provided through the independent pressure oil pipe assembly, and normal operation and stable power generation of the insulated boom truck are guaranteed through the proportional valve.

Description

Technical Field

[0001] This invention relates to the field of engineering machinery technology, and in particular to an adaptive hydraulic power generation system and control method for an insulated bucket truck. Background Technology

[0002] During the maintenance of power transmission lines, insulation is achieved through structural designs such as partially insulated boom arms, non-metallic buckets, and non-metallic hydraulic lines. This effectively isolates the electrical path between the work platform and the ground, preventing the formation of conductive loops. To optimize the maneuverability of the insulated boom truck, an electro-hydraulic system is employed. A battery is integrated into the platform end, and solenoid valves are used for hydraulic control, enabling basic functions such as boom lifting and extension, turntable and platform rotation control, and platform attitude leveling. However, due to limitations in energy density and continuous power supply capacity, batteries cannot support long-term continuous operation at height. Furthermore, the batteries still require periodic charging, increasing the complexity of system maintenance and reliability risks.

[0003] While some existing hydraulic generators have the function of charging batteries, they have the following problems:

[0004] 1. The hydraulic circuit connected to the hydraulic generator is usually coupled with some boom movements that require less flow, i.e., they share the same oil supply and return lines. This can cause the boom functions of these shared circuits to fail or malfunction during the hydraulic charging process.

[0005] 2. Because the valve blocks controlling the hydraulic motor are all fixed-displacement valves, the amount of oil supplied to the hydraulic generator is constant. During the process of the hydraulic generator charging the battery, the charging current will gradually decrease with the charging time, and it will not reach the optimal charging current for the battery, resulting in a longer charging time. At the same time, there may be a problem with the fixed-displacement valve malfunctioning, resulting in an excessive flow to the hydraulic motor. In this case, the charging voltage may be higher than the battery's limiting voltage, which poses a certain safety risk.

[0006] 3. Existing hydraulic generators generally achieve self-starting function through electronic control system. The charging current is usually fixed and cannot be adapted to the real-time status of the battery, resulting in low charging efficiency or energy waste. In severe cases, it may even cause structural damage. Summary of the Invention

[0007] (I) Purpose of the Invention

[0008] The purpose of this invention is to provide an adaptive hydraulic power generation system and control method for insulated bucket trucks, aiming to solve the problems of abnormal pressure, uncontrollable hydraulic oil flow, and mismatch between charging parameters and battery status in existing shared oil circuits.

[0009] (II) Technical Solution

[0010] To address the aforementioned problems, a first aspect of the present invention provides an adaptive hydraulic power generation system for an insulated bucket truck. The system is mounted on the insulated boom of the insulated bucket truck and includes a hydraulic oil tank, a proportional metering valve, an independent pressure oil pipe assembly, a hydraulic power generation assembly, a battery, and a control module.

[0011] The hydraulic oil tank is connected to the hydraulic power generation component through the independent pressure oil pipe assembly, which is used to supply oil to the hydraulic power generation component separately. The proportional metering valve is installed on the independent pressure oil pipe assembly to control the amount of oil entering the hydraulic power generation component from the hydraulic oil tank. The hydraulic power generation component is connected to the storage battery.

[0012] The control module is used to adjust the opening of the proportional metering valve in real time and control the charging and discharging process of the battery.

[0013] Preferably, the hydraulic power generation assembly includes a hydraulic motor, a coupling, and a generator. The hydraulic motor is connected to the independent pressure oil pipe assembly, and the coupling connects the hydraulic motor and the generator to drive the generator to generate electricity. The output end of the generator is electrically connected to the battery.

[0014] Preferably, the independent oil pipe assembly includes an oil outlet pipe and a oil return pipe. The hydraulic oil in the hydraulic oil tank flows along the oil outlet pipe to the hydraulic power generation component and along the oil return pipe to the hydraulic oil tank. Both the oil outlet pipe and the oil return pipe are connected to the proportional metering valve.

[0015] Preferably, the system further includes a first sensor and a second sensor. The first sensor is communicatively connected to the control module and is used to detect the hydraulic oil flow rate of the independent pressure oil pipe assembly. The second sensor is communicatively connected to the control module and is used to detect the power generation parameters of the hydraulic power generation assembly.

[0016] Preferably, the control module includes a charging control unit, a battery management unit, and an upper operating console. The charging control unit and the battery management unit are communicatively connected to the upper operating console, and the first sensor and the second sensor are communicatively connected to the upper operating console.

[0017] The hydraulic power generation component is connected to the battery through the charging control unit, which is used to control the hydraulic power generation component to charge the battery;

[0018] The battery management unit is linked to the battery and is used to control the discharge parameters of the battery.

[0019] Preferably, the hydraulic oil tank and the insulated bucket truck share a single oil tank. The hydraulic oil tank is connected to a hydraulic valve assembly. The hydraulic valve assembly has a first oil circuit and a second oil circuit. The first oil circuit is connected to the independent pressure oil pipe assembly, and the second oil circuit is connected to the pipeline of the insulated arm of the insulated bucket truck. The hydraulic valve assembly is communicatively connected to the upper control panel and is used to control the opening and closing of the first oil circuit and the second oil circuit.

[0020] According to another aspect of the present invention, a control method for an adaptive hydraulic power generation system for an insulated bucket truck is provided, characterized in that the control method comprises:

[0021] Collect hydraulic oil flow rate and battery status parameters;

[0022] Determine the charging requirements based on the battery status parameters and set the target charging current.

[0023] Adjust the opening of the proportional metering valve according to the target charging current.

[0024] Preferably, adjusting the opening degree of the proportional metering valve according to the target charging current includes:

[0025] Based on the parameters of the hydraulic power generation components and the battery parameters, a hydraulic oil flow-power generation current model is established;

[0026] The hydraulic oil demand flow rate is determined based on the target charging current combined with the hydraulic oil flow rate-generating current model.

[0027] Adjust the opening of the proportional metering valve according to the hydraulic oil flow demand.

[0028] Preferably, the control method further includes:

[0029] When the hydraulic generator is not in operation, the battery voltage is collected and compared with the battery's rated voltage.

[0030] When the battery voltage is lower than the rated voltage, open the proportional metering valve to start the hydraulic generator set.

[0031] Preferably, the control method further includes:

[0032] The charging voltage is collected, and when the charging voltage exceeds 1.2 times the rated voltage, power generation is stopped and an alarm is triggered.

[0033] (III) Beneficial Effects

[0034] The above-described technical solution of the present invention has the following beneficial technical effects:

[0035] 1. The independent pressure oil pipe assembly completely separates the hydraulic power generation oil circuit from the boom movement oil circuit, avoiding interference with boom lifting, slewing and other movements during the charging process, ensuring that boom movement and charging function do not affect each other, and guaranteeing the normal operation and stable power generation of the insulated bucket truck.

[0036] 2. The proportional quantitative valve can dynamically adjust the flow rate through the control module, so that the current output by the hydraulic generator component is always adapted to the current demand of the battery, improving charging efficiency and protecting the hydraulic generator component and the battery. At the same time, the control module uniformly regulates the flow rate and charging and discharging, realizing precise control of system start-up and shutdown, and improving system stability.

[0037] 3. Dynamically adjust the target charging current according to the real-time status of the battery to avoid insufficient flow affecting charging efficiency and excessive flow causing energy loss or structural damage, thereby further ensuring charging efficiency and protecting system stability. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of an adaptive hydraulic power generation system for an insulated bucket truck according to the present invention;

[0039] Figure 2 This is a schematic diagram of a partial position of the hydraulic power generation component and battery provided by the present invention on the insulated boom of an insulated bucket truck.

[0040] Figure 3 This is a connection diagram of an adaptive hydraulic power generation system for an insulated bucket truck according to the present invention;

[0041] Figure 4 This is a flowchart of a control method for an adaptive hydraulic power generation system for an insulated bucket truck according to the present invention;

[0042] Figure 5 This is a flowchart of a control method for an adaptive hydraulic power generation system for an insulated bucket truck according to the present invention;

[0043] Figure 6 This is a flowchart of a control method for an adaptive hydraulic power generation system for an insulated bucket truck according to the present invention.

[0044] Figure label:

[0045] 1. Hydraulic oil tank; 2. Proportional dispensing valve;

[0046] 3. Independent pressure oil pipe assembly; 31. Oil outlet pipe; 32. Oil return pipe;

[0047] 4. Hydraulic generator assembly; 41. Hydraulic motor; 42. Coupling; 43. Generator;

[0048] 5. Storage battery;

[0049] 6. Control module; 61. Charging control unit; 62. Battery management unit; 63. Upper control panel;

[0050] 7. Hydraulic valve assembly; 71. First oil circuit; 72. Second oil circuit. Detailed Implementation

[0051] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and the accompanying drawings. It should be understood that these descriptions are merely exemplary and not intended to limit the scope of the invention. Furthermore, descriptions of well-known structures and techniques are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.

[0052] The accompanying drawings illustrate a layer structure according to an embodiment of the present invention. These drawings are not to scale, and some details have been enlarged for clarity, and some details may have been omitted. The shapes of the various regions and layers shown in the drawings, as well as their relative sizes and positional relationships, are merely exemplary and may deviate from reality due to manufacturing tolerances or technical limitations. Furthermore, those skilled in the art can design regions / layers with different shapes, sizes, and relative positions as needed.

[0053] Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0054] In the description of this invention, it should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0055] Combination Figures 1 to 3 The first aspect of the present invention provides an adaptive hydraulic power generation system for an insulated bucket truck. The system is installed on the insulated arm of the insulated bucket truck and includes a hydraulic oil tank 1, a proportional metering valve 2, an independent pressure oil pipe assembly 3, a hydraulic power generation assembly 4, a storage battery 5, and a control module 6. The hydraulic oil tank 1 is connected to the hydraulic power generation assembly 4 through the independent pressure oil pipe assembly 3 for supplying oil to the hydraulic power generation assembly 4 independently. The proportional metering valve 2 is installed on the independent pressure oil pipe assembly 3 for controlling the amount of oil entering the hydraulic power generation assembly 4 from the hydraulic oil tank 1. The hydraulic power generation assembly 4 is connected to the storage battery 5. The control module 6 is used to adjust the opening degree of the proportional metering valve 2 in real time and control the charging and discharging process of the storage battery 5.

[0056] Specifically, the hydraulic oil tank 1 provides the oil source for the hydraulic generator; the independent pressure oil pipe assembly 3 connects the hydraulic oil tank 1 and the hydraulic generator assembly 4 separately, forming a dedicated oil circuit; the proportional metering valve 2 is installed on the independent pressure oil pipe assembly 3 to control the flow rate of hydraulic oil flowing into the hydraulic generator assembly 4; the hydraulic generator assembly 4 converts hydraulic energy into electrical energy to charge the battery 5; the control module 6 receives relevant parameters, such as battery status and flow rate, and adjusts the opening of the proportional metering valve 2 in real time, and regulates the charging and discharging process of the battery 5. During system operation, the hydraulic oil in the hydraulic oil tank 1 is delivered to the hydraulic generator assembly 4 through the independent pressure oil pipe assembly 3, and the proportional metering valve 2 adjusts the oil flow rate according to the instructions of the control module 6; the hydraulic generator assembly 4 generates electrical energy under the drive of the hydraulic oil to charge the battery 5; the control module 6 monitors the status of the battery 5 and the oil circuit parameters, and dynamically adjusts the opening of the proportional metering valve 2 to ensure that the charging process meets the needs of the battery 5.

[0057] With this setup, the independent hydraulic piping assembly completely separates the generator hydraulic circuit from the boom hydraulic circuit. Even when operating the boom during charging, such as lifting or slewing, the boom movement remains smooth. For example, when the aerial work platform is being raised and lowered simultaneously with power generation, the platform will not experience sudden changes in lifting speed due to power generation diversion. The independent hydraulic circuit also prevents hydraulic pressure fluctuations caused by boom movement from affecting power generation stability. For instance, the hydraulic pressure shock generated during rapid boom descent will not be transmitted to the generator assembly, ensuring a stable output current from the generator 43. The proportional metering valve 2, combined with the control module 6, dynamically adjusts the flow rate, enabling stepped charging based on the battery 5's status. For example, when the battery level is below 30%, it is charged with a high flow rate and high current for fast charging; from 30% to 80%, it is charged with a medium flow rate; and above 80%, it is charged with a low flow rate. Compared to traditional fixed flow rate charging, this shortens charging time and protects the battery. The entire system is integrated on the insulating arm. Compared with the traditional distributed power generation system, this reduces the length of the oil pipes, reduces the pressure loss of the oil along the pipe, and improves the energy utilization efficiency. The control module 6 uniformly regulates the oil circuit and the electrical circuit, reducing the need for manual intervention. It eliminates the need for manual switching of charging modes, reduces the risk of misoperation, and achieves precise control of system start-up and shutdown, thereby improving system stability and working efficiency.

[0058] It should be noted that the specific structure of the proportional metering valve 2 is not limited here. In the preferred case, the proportional metering valve 2 supports linear adjustment from 1 to 100%, with a response time of less than 50ms and a control accuracy of ±3%. The opening degree is precisely controlled by the control module 6.

[0059] It should be noted that the specific location of the system on the insulating arm is not limited here, as long as the system is reasonably arranged to charge the battery 5. The specific structure of the hydraulic generator assembly 4 and its arrangement on the insulating arm are also not limited. In a preferred embodiment, the hydraulic generator assembly 4 includes a hydraulic motor 41, a coupling 42, and a generator 43. The hydraulic motor 41 is connected to the independent pressure oil pipe assembly 3, and the coupling 42 connects the hydraulic motor 41 and the generator 43 to drive the generator 43 to generate electricity. The output end of the generator 43 is electrically connected to the battery 5. Specifically, the hydraulic oil supplied by the independent pressure oil pipe assembly 3 drives the hydraulic motor 41 to rotate. The hydraulic motor 41 transmits power to the generator 43 through the coupling 42, driving the generator 43 to generate electrical energy, which is ultimately used to charge the battery 5 through its output end.

[0060] With this configuration, coupling 42 can compensate for axial and radial misalignments between hydraulic motor 41 and generator 43, reducing vibration and noise caused by installation errors. Simultaneously, coupling 42 can absorb the impact load during the start-up and stop of hydraulic motor 41, preventing the impact load from being transmitted to generator 43 and extending the service life of generator 43. Hydraulic motor 41 is directly connected to generator 43 via coupling 42, improving transmission efficiency, reducing energy loss, and saving the overall volume of the hydraulic generator assembly 4, better fitting the limited space of the insulated arm.

[0061] It should be noted that the specific arrangement of the independent oil pipe assembly in the insulating arm is not limited here, nor is the specific arrangement of the hydraulic generator assembly 4 and the battery 5. As long as it is configured in the insulating arm, the independent oil pipe assembly can supply hydraulic oil to the hydraulic motor 41, drive the generator 43 to generate electricity, and transmit the electrical energy to the battery 5 for charging.

[0062] There are no restrictions on the specific connection method between the independent tubing assembly and the proportional metering valve 2.

[0063] In a preferred embodiment, the independent oil pipe assembly includes an outlet pipe 31 and a return pipe 32. Hydraulic oil in the hydraulic oil tank 1 flows along the outlet pipe 31 to the hydraulic generator assembly 4 and along the return pipe 32 back to the hydraulic oil tank 1. Both the outlet pipe 31 and the return pipe 32 are connected to a proportional metering valve 2. Specifically, hydraulic oil flows from the hydraulic oil tank 1 to the hydraulic generator assembly 4 through the outlet pipe 31, drives the hydraulic generator assembly 4 to work, and then flows back to the hydraulic oil tank 1 through the return pipe 32. The proportional metering valve 2 simultaneously controls the inflow rate of the outlet pipe 31 and the return rate of the return pipe 32, achieving bidirectional regulation of the oil flow.

[0064] With this configuration, the oil outlet pipe 31 and the oil return pipe 32 form a closed-loop circuit, ensuring smooth oil return. Furthermore, the diameter of the oil return pipe 32 is larger than that of the oil outlet pipe 31, further improving the oil return efficiency. Both the oil outlet pipe 31 and the oil return pipe 32 are connected to the proportional metering valve 2. During the hydraulic oil circulation process, the oil flows through the proportional metering valve 2, which effectively controls the flow direction of the hydraulic oil and ensures the stability of the hydraulic oil flow process, thereby ensuring that the hydraulic motor 41 stably drives the generator 43.

[0065] In optional cases, a check valve and a one-way bypass valve are also provided on the return oil pipe 32 to further ensure the flow direction of hydraulic oil in the return oil pipe 32 and avoid the stability of the hydraulic generator 43 assembly affected by pressure fluctuations in the main oil circuit.

[0066] In a preferred embodiment, the system further includes a first sensor and a second sensor. The first sensor is communicatively connected to the control module 6 and is used to detect the hydraulic oil flow rate of the independent pressure oil pipe assembly 3. The second sensor is also communicatively connected to the control module 6 and is used to detect the power generation parameters of the hydraulic power generation assembly 4. Specifically, the first sensor collects hydraulic oil flow rate data in real time, and the second sensor collects power generation current, voltage, and other data in real time, and transmits the data to the control module 6. Based on this data, the control module 6 determines the current charging status, such as whether the flow rate matches the current demand, and then adjusts the opening of the proportional metering valve 2.

[0067] With this setup, the first sensor can provide real-time feedback on changes in oil flow, offering precise adjustment data for the control module 6. The second sensor monitors the power generation parameters of the hydraulic power generation component 4 in real time. Based on the hydraulic oil flow data detected by the first sensor and the power generation parameters detected by the second sensor, the control module 6 determines whether the current hydraulic oil flow and power generation parameters are within the normal operating range and whether they meet the current charging requirements of the battery 5 or the system's power consumption requirements. This allows it to adjust the opening of the proportional metering valve 2, achieving efficient and precise control of the hydraulic power generation component 4.

[0068] It should be noted that the specific placement of the first and second sensors is not limited here, as long as they can monitor and transmit their respective information to the control module 6.

[0069] In a preferred embodiment, the control module 6 includes a charging control unit 61, a battery management unit 62, and an upper control panel 63. The charging control unit 61 and the battery management unit 62 are communicatively connected to the upper control panel 63. The first sensor and the second sensor are also communicatively connected to the upper control panel 63. The hydraulic generator assembly 4 is connected to the battery 5 via the charging control unit 61, which controls the hydraulic generator assembly 4 to charge the battery 5. The battery management unit 62 is connected to the battery 5 and controls the discharge parameters of the battery 5. Specifically, the charging control unit 61 controls the hydraulic generator assembly 4 to charge the battery 5 according to the instructions from the upper control panel 63, such as starting and stopping power generation and adjusting the charging power. The battery management unit 62 monitors the status of the battery 5, such as its charge level and temperature, and transmits the data to the upper control panel 63. The upper control panel 63 integrates the sensor data and battery status data to generate adjustment instructions for the proportional metering valve 2, realizing full-process control from data acquisition to decision-making to execution.

[0070] With this setup, the charging control unit 61 and the battery management unit 62 interact via the upper control panel 63. For example, the battery management unit 62 sends battery SOC (state of charge) and temperature data to the upper control panel 63 in real time. When the battery temperature exceeds a preset limit, such as 45°C, the upper control panel 63 controls the charging control unit 61 to reduce the charging current, for example, from 10A to 5A, to prevent the battery from overheating. The upper control panel 63 uses a touchscreen design, integrating data display of flow rate, current, voltage, and battery SOC, and supports manual input of the target charging current, realizing automatic and manual dual-mode control. This improves the adaptability of the upper control panel 63 to various usage scenarios. The specific placement of the upper control panel 63 is not limited here; it only needs to be convenient to operate during the operation of the insulated bucket truck's boom, such as in the operator's cab or on the side of the vehicle, where control, data display, and transmission can be achieved.

[0071] It should be noted that the specific structure of the hydraulic oil tank 1 and its specific location on the insulated boom truck are not limited here. It can be set up separately from the oil tank used when the boom of the insulated boom truck is running, or the two can share a single oil tank. In the preferred embodiment, the hydraulic oil tank 1 and the insulated boom truck share a single oil tank. The hydraulic oil tank 1 is connected to a hydraulic valve assembly 7, which has a first oil passage 71 and a second oil passage 72. The first oil passage 71 is connected to an independent pressure oil pipe assembly 3, and the second oil passage 72 is connected to the pipeline of the insulated boom of the insulated boom truck. The hydraulic valve assembly 7 is communicatively connected to the upper control panel 63 to control the opening and closing of the first oil passage 71 and the second oil passage 72. Specifically, the hydraulic oil tank 1 is shared by the insulated boom truck; the hydraulic valve assembly 7 has a first oil passage 71 and a second oil passage 72, and is communicatively connected to the upper control panel 63. When the insulated boom truck is running, the hydraulic valve assembly 7 draws oil from the shared hydraulic oil tank 1. The upper control panel 63 controls the opening and closing of the first oil circuit 71 and the second oil circuit 72 by controlling the hydraulic valve assembly 7. For example, when starting power generation, the first oil circuit 71 is opened and the second oil circuit 72 is closed; when operating the boom, the second oil circuit 72 is opened and the first oil circuit 71 is closed, or both can be opened as needed. Furthermore, the pressure in the hydraulic pipeline can be detected, for example, by installing a pressure sensor in the first oil circuit 71. Based on the pressure in the pipeline, the opening and closing scale of the two oil circuits can be adjusted, thereby ensuring that the first oil circuit 71 provides a hydraulic oil flow that meets the power generation requirements while satisfying the operation of the insulated boom.

[0072] This configuration reduces space occupation and improves structural compactness by sharing the hydraulic oil tank 1. The hydraulic valve group 7 adopts an integrated design, integrating the control valve cores of the first oil circuit 71 and the second oil circuit 72 into the same valve group, further improving space utilization. The opening and closing actions of the hydraulic valve group 7 are controlled via the upper operating panel 63, enabling rapid switching between power generation and insulated arm operation states and precise control of the oil circuit, thus improving overall work efficiency. Furthermore, the shared hydraulic oil tank 1 ensures the rational use of hydraulic oil, avoiding waste and saving costs.

[0073] It should be noted that the specific number of the first oil line 71 and the second oil line 72 is not limited here. The number can be adaptively configured according to the specific structure of the insulated bucket truck and the system requirements. Figure 1 The system is configured with a first hydraulic circuit 71 for power generation and three second hydraulic circuits 72 for the operation of the insulating arm. In addition, the hydraulic valve assembly 7 is equipped with a control valve core, which is connected to the upper control panel 63. The upper control panel 63 controls the opening and closing of the first hydraulic circuit 71 and the second hydraulic circuits 72 via the control valve core.

[0074] Combination Figures 4 to 6 According to another aspect of the present invention, a control method for an adaptive hydraulic power generation system of an insulated bucket truck is provided, characterized in that the control method includes:

[0075] Collect hydraulic oil flow rate and battery status parameters;

[0076] Determine the charging requirements based on the battery's 5 state parameters and set the target charging current.

[0077] Adjust the opening of the proportional metering valve 2 according to the target charging current.

[0078] Specifically, during system operation, the system first collects hydraulic oil flow and battery 5 status parameters through sensors. The hydraulic oil flow reflects the current power generation capacity, and the battery 5 status parameters include charge, voltage, and temperature, which can reflect charging needs. Based on the battery 5 status parameters, the charging needs are determined. For example, when the charge is low, a high current fast charge is required, and when it is close to full charge, a low current slow charge is required. The target charging current is set. The opening of the proportional quantitative valve 2 is adjusted according to the target charging current. If the target charging current is large, the opening of the proportional quantitative valve 2 is increased to increase the flow rate, and if the target current is small, the opening of the proportional quantitative valve 2 is decreased to reduce the flow rate.

[0079] This control method dynamically adjusts the target charging current based on the real-time status of battery 5, avoiding insufficient flow from affecting charging efficiency and excessive flow from causing energy loss or structural damage, thus ensuring charging efficiency and protecting system stability.

[0080] It should be noted that the adjustment of the opening of the proportional quantitative valve 2 based on the target charging current can be obtained experimentally based on the system's own structure and stored in the control module 6, or the relationship between the target charging current and the opening of the proportional quantitative valve 2 can be established through parameters in the system. In a preferred embodiment, adjusting the opening of the proportional quantitative valve 2 based on the target charging current includes:

[0081] Based on the 4 parameters of the hydraulic power generation component and the 5 parameters of the battery, a hydraulic oil flow-power generation current model is established;

[0082] The hydraulic oil demand flow rate is determined based on the target charging current combined with the hydraulic oil flow rate-generating current model.

[0083] Adjust the opening degree of the proportional metering valve 2 according to the hydraulic oil flow demand.

[0084] Specifically, the system first collects power generation current data under different hydraulic oil flow rates through experiments. Then, it combines the parameters of the hydraulic power generation component 4 (such as the relationship between motor speed and flow rate) and the parameters of the battery 5 (such as the relationship between internal resistance and current) to build a hydraulic oil flow rate-power generation current model (such as the linear or nonlinear correspondence between flow rate and current). During system operation, after determining the target charging current, it substitutes the hydraulic oil flow rate-power generation current model to deduce the required hydraulic oil flow rate. The control module 6 then adjusts the opening of the proportional quantitative valve 2 according to the required flow rate to complete the adaptation and adjustment of the power generation current.

[0085] By establishing a hydraulic oil flow-generator current model through this control method, the opening accuracy of the proportional quantitative valve 2 can be ensured, thereby making the charging current control more precise. For example, when the target current is 10A, by precisely controlling the opening of the proportional quantitative valve 2, the charging current fluctuation range can be kept within ±3%, and the actual current fluctuation range can be controlled within ±0.3A. This ensures both charging efficiency and reasonable control of the charging temperature, thus protecting the hydraulic generator assembly 4 and the battery 5.

[0086] In addition, when establishing the hydraulic oil flow-generator current model, the influence of oil temperature on hydraulic oil viscosity can be considered. Through temperature compensation, the hydraulic oil flow-generator current model can be corrected to ensure the stability of the generator current under different hydraulic oil temperatures.

[0087] In a preferred embodiment, the control method further includes:

[0088] When the hydraulic generator assembly 4 is not in operation, the voltage of the battery 5 is collected and compared with the rated voltage of the battery 5;

[0089] When the voltage of battery 5 is lower than the rated voltage, the proportional metering valve 2 is opened, and the hydraulic generator assembly 4 is started.

[0090] Specifically, when the hydraulic generator set 43 is not running, the battery 5 can be in a power supply state or a dormant state. By detecting the voltage of the battery 5, when the voltage of the battery 5 is lower than the rated voltage, it indicates that the battery 5 is in a power supply state. The proportional quantitative valve 2 is opened, the hydraulic generator set 4 is started, and the battery 5 is charged.

[0091] This control method allows for the determination of whether the battery 5 is under power when the hydraulic generator assembly 4 is not running, as the battery 5 may be in a state of power depletion. By collecting the battery 5 voltage and comparing it with the rated voltage, the system can determine whether the battery 5 is under power depletion, thus preventing deep discharge and damage to the battery 5 and extending its service life. Simultaneously, collecting the battery 5 voltage and comparing it with the rated voltage enables the hydraulic generator assembly 4 to start automatically, eliminating the need for manual monitoring and startup operations, resulting in smoother system operation.

[0092] In a preferred embodiment, the control method also includes automatic sleep control. For example, when the insulated bucket truck stops running, or if there are no operation commands within 30 minutes, the system automatically enters a sleep state. At this time, the proportional metering valve 2 closes, the hydraulic generator assembly 4 stops generating electricity, and the control module 6 enters sleep mode, with the system's static power consumption being less than 1W. When operation is required, the system is woken up by the insulated bucket truck operator's cab, the upper control panel 63 of the control module 6, and the lower voltage limit. This control method avoids prolonged full-load operation of the system, saving energy and reducing costs.

[0093] In a preferred embodiment, the control method further includes: acquiring the charging voltage; when the charging voltage exceeds 1.2 times the rated voltage, stopping power generation and triggering an alarm. Specifically, during charging, the voltage at which the hydraulic generator assembly 4 charges the battery 5 is acquired in real time and compared with a safe charging voltage threshold, such as 1.2 times the rated voltage; the acquired voltage is compared with 1.2 times the rated voltage of the battery 5; if the charging voltage exceeds the threshold, the control module 6 immediately instructs the hydraulic generator assembly 4 to stop power generation, such as by closing the proportional metering valve 2, stopping the operation of the hydraulic generator assembly 4, and triggering an alarm, such as an audible and visual alarm or a human-machine interface prompt.

[0094] With this control method, the overvoltage protection threshold is set to 1.2 times the rated voltage, such as 14.4V for a 12V battery. When the charging voltage reaches 14.4V, the power generation circuit is cut off to prevent overcharging of the battery. In addition, after the overvoltage protection is triggered, the system enters a self-locking state, requiring manual inspection and restart to prevent the system from self-starting and causing damage to the battery and the system.

[0095] It should be noted that data such as the charging current and battery temperature can be collected and corresponding thresholds can be set to further improve the safety performance of battery 5. The control method is similar to that of overvoltage protection and will not be elaborated upon here.

[0096] It should be understood that the specific embodiments described above are merely illustrative or explanatory of the principles of the invention and do not constitute a limitation thereof. Therefore, any modifications, equivalent substitutions, improvements, etc., made without departing from the spirit and scope of the invention should be included within the protection scope of the invention. Furthermore, the appended claims are intended to cover all variations and modifications falling within the scope and boundaries of the appended claims, or equivalent forms of such scope and boundaries.

Claims

1. An adaptive hydraulic power generation system for an insulated bucket truck, characterized in that, The system is installed on the insulated boom of the insulated bucket truck. The system includes a hydraulic oil tank (1), a proportional metering valve (2), an independent pressure oil pipe assembly (3), a hydraulic power generation assembly (4), a storage battery (5), and a control module (6). The hydraulic oil tank (1) is connected to the hydraulic power generation component (4) through the independent pressure oil pipe assembly (3) for supplying oil to the hydraulic power generation component (4) separately. The proportional metering valve (2) is installed on the independent pressure oil pipe assembly (3) for controlling the amount of oil entering the hydraulic power generation component (4) from the hydraulic oil tank (1). The hydraulic power generation component (4) is connected to the storage battery (5). The control module (6) is used to adjust the opening of the proportional metering valve (2) in real time and control the charging and discharging process of the battery (5).

2. The system according to claim 1, characterized in that, The hydraulic power generation assembly (4) includes a hydraulic motor (41), a coupling (42), and a generator (43). The hydraulic motor (41) is connected to the independent pressure oil pipe assembly (3). The coupling (42) connects the hydraulic motor (41) and the generator (43) to drive the generator (43) to generate electricity. The output end of the generator (43) is electrically connected to the battery (5).

3. The system according to claim 1, characterized in that, The independent oil pipe assembly includes an oil outlet pipe (31) and an oil return pipe (32). The hydraulic oil in the hydraulic oil tank (1) flows along the oil outlet pipe (31) to the hydraulic power generation assembly (4) and along the oil return pipe (32) to the hydraulic oil tank (1). Both the oil outlet pipe (31) and the oil return pipe (32) are connected to the proportional metering valve (2).

4. The system according to claim 1, characterized in that, The system also includes a first sensor and a second sensor. The first sensor is communicatively connected to the control module (6) and is used to detect the hydraulic oil flow of the independent pressure oil pipe assembly (3). The second sensor is communicatively connected to the control module (6) and is used to detect the power generation parameters of the hydraulic power generation assembly (4).

5. The system according to claim 4, characterized in that, The control module (6) includes a charging control unit (61), a battery management unit (62), and an upper operating console (63). The charging control unit (61) and the battery management unit (62) are communicatively connected to the upper operating console (63). The first sensor and the second sensor are communicatively connected to the upper operating console (63). The hydraulic power generation component (4) is connected to the storage battery (5) through the charging control unit (61) and is used to control the hydraulic power generation component (4) to charge the storage battery (5); The battery management unit (62) is linked to the battery (5) and is used to control the discharge parameters of the battery (5).

6. The system according to claim 5, characterized in that, The hydraulic oil tank (1) and the insulated bucket truck share one oil tank. The hydraulic oil tank (1) is connected to a hydraulic valve group (7). The hydraulic valve group (7) is provided with a first oil circuit (71) and a second oil circuit (72). The first oil circuit (71) is connected to the independent pressure oil pipe assembly (3), and the second oil circuit (72) is connected to the pipeline of the insulated arm of the insulated bucket truck. The hydraulic valve group (7) is communicatively connected to the upper operating platform (63) and is used to control the opening and closing of the first oil circuit (71) and the second oil circuit (72).

7. A control method for an adaptive hydraulic power generation system for an insulated bucket truck as described in any one of claims 1-6, characterized in that, The control method includes: Collect hydraulic oil flow rate and battery status parameters; Determine the charging requirements based on the battery status parameters and set the target charging current. Adjust the opening of the proportional metering valve according to the target charging current.

8. The control method according to claim 7, characterized in that, The step of adjusting the opening degree of the proportional quantitative valve according to the target charging current includes: Based on the parameters of the hydraulic power generation components and the battery parameters, a hydraulic oil flow-power generation current model is established; The hydraulic oil demand flow rate is determined based on the target charging current combined with the hydraulic oil flow rate-generating current model. Adjust the opening of the proportional metering valve according to the hydraulic oil flow demand.

9. The control method according to claim 7, characterized in that, The control method further includes: When the hydraulic generator is not in operation, the battery voltage is collected and compared with the battery's rated voltage. When the battery voltage is lower than the rated voltage, open the proportional metering valve to start the hydraulic generator set.

10. The control method according to claim 9, characterized in that, The control method further includes: The charging voltage is collected, and when the charging voltage exceeds 1.2 times the rated voltage, power generation is stopped and an alarm is triggered.

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