Device and method for monitoring and checking components of cooling system of marine range extender

Abstract

The invention relates to the technical field of ship power systems, in particular to a device and method for monitoring and troubleshooting components of a cooling system of a marine range extender, and solves the problems that an existing system is difficult in troubleshooting and low in reliability. According to the method, the high-voltage and fault states of the system are judged by obtaining working parameters after the system is awakened, low-voltage component self-inspection is conducted under specific conditions, the working states of a water pump and a fan are judged by calculating step-down DCDC output power, self-inspection or monitoring is triggered according to the electric control temperature of a motor, and positioning is conducted by means of an indicator lamp when a fault occurs. The device comprises a step-down DCDC, an RCU controller, a man-machine interaction control screen and the like which work cooperatively. Intelligent monitoring and rapid troubleshooting of cooling system components are achieved, the ship operation reliability is improved, the maintenance cost is reduced, and stable operation of the range extender is guaranteed.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ship power systems, in particular to a device and method for monitoring and troubleshooting of a cooling system component of a marine range extender. BACKGROUND

[0002] With the increasing strictness of environmental protection requirements, the ship industry is actively exploring green energy solutions. As a new type of ship power form, the range extender electric ship can effectively optimize fuel efficiency, reduce emissions, and improve energy utilization efficiency through the combination of batteries and generators. However, the current marine range extender still faces many challenges in practical application. On the one hand, the range extender system has not been widely popularized in the new application field of the ship industry, and the technical maturity needs to be further improved. On the other hand, the handling and troubleshooting mechanism for abnormal phenomena and sudden situations is not perfect during the product operation. Once the system fails, it is difficult to quickly and accurately troubleshoot the problem and solve it in time, which greatly reduces the reliability of the ship during operation. Taking the cooling system of the range extender as an example, it is crucial for the stable operation of the range extender. Without sufficient monitoring and intelligent troubleshooting and identification means, the engine is prone to high temperature. This may cause the cooling liquid to vaporize, causing the ship expansion tank to overflow, and thus damaging the engine cylinder components. At the same time, the range extender will be limited in power due to high temperature, which will cause insufficient power of the ship engine, seriously affecting the normal navigation of the ship. In addition, the current low-voltage harness troubleshooting of each component has the problems of long time, high difficulty, and low efficiency, and multiple plugging and unplugging of components not only easily reduces the installation reliability, but also may damage the components, causing potential safety hazards. In summary, developing a technical solution that can effectively monitor the state of the cooling system components of the marine range extender and quickly and accurately troubleshoot faults is of great significance to improve the operation reliability and stability of the range extender electric ship. SUMMARY

[0003] The purpose of the present application is to provide a device and method for monitoring and troubleshooting of the cooling system components of the marine range extender to solve the problems of difficult fault troubleshooting, low reliability, etc. of the cooling system of the marine range extender in the prior art.

[0004] The technical solution of the present application to solve the above technical problems is as follows: The control method for monitoring and troubleshooting of the cooling system components of the marine range extender, the control method comprising: obtaining the working parameters after the system is awakened; if it is determined that the system is under high pressure and there is no range extender fault; the system prompts the self-checking state of the low-voltage component; if it is determined that the manual low-voltage component self-checking mode is entered; The system prompts to start the low-voltage component self-checking; The safety relay of the step-down DCDC is closed, the step-down DCDC is enabled, and the safety relay of the battery is disconnected after normal operation; The RCU enables the water pump and the fan in turn, and targets to pre-prepare the cooling components to work normally at the maximum gear; The working parameters are obtained, including the voltage and current output by the step-down DCDC, the output power of the step-down DCDC is calculated, and the current calculated water pump power and fan power are obtained; If it is determined that the calculated fan power is close to the normal working power threshold of the fan; If it is determined that the calculated water pump power is close to the normal working power threshold of the water pump; The system judges the normal working state of the fan and the normal working state of the water pump; The system prompts that the low-voltage component self-checking is normal; Further solutions also include: The working parameters after the system is woken up are obtained; If it is determined that the system has no high voltage or range extender failure; The system prompts that the high voltage is not turned on or the range extender is in failure state.

[0005] Further solutions also include: If it is determined that the low-voltage component self-checking mode is not manually entered; The system prompts to enter the low-voltage component monitoring state.

[0006] Further solutions also include: If it is determined that the calculated fan power is not close to the normal working power threshold of the fan; The system judges the abnormal working state of the fan.

[0007] Further solutions also include: If it is determined that the calculated water pump power is not close to the normal working power threshold of the water pump; The system judges the abnormal working state of the water pump.

[0008] Further solutions also include: If it is determined that the motor electronic control temperature abnormally rises or reaches the maximum temperature threshold; The system prompts to start the low-voltage component self-checking; Further solutions also include: If it is determined that the motor electronic control temperature does not abnormally rise and the temperature does not reach the maximum temperature threshold; The system prompts to enter the low-voltage component monitoring state; Further solutions also include: If the system judges the abnormal working state of the fan or the water pump; System automatically turn on or manually press the indicator light switch; When the indicator light switch of the fan or water pump is turned on, the maintenance personnel observe the indicator light state in turn; If it is determined that the indicator lights are all on; Determine that the fan or water pump (body or plug connector, line) is faulty.

[0009] Further solutions also include: If it is determined that the indicator light 01 is not on, it is determined that the RCU is not enabled or the RCU enabling line is faulty; If it is determined that the indicator light 02 is not on, it is determined that the battery power supply is faulty; If it is determined that the indicator light 03 is not on, it is determined that the relay is faulty or the relay ground line is faulty; If it is determined that the indicator light 04 is not on, it is determined that the fuse is faulty.

[0010] Further solutions also include: If it is determined that none of the indicator lights are on, it is determined that the low-voltage power supply or the total positive and negative line is faulty.

[0011] A device for monitoring and troubleshooting components of a cooling system of a marine range extender, the range extender being used in a range-extended electric ship, the cooling system troubleshooting device comprising: A step-down DCDC: reduces the high-voltage power supply of the battery pack to a low-voltage power supply for charging the battery, while monitoring the output voltage and current value; A water jug: guides water through a pipeline to the water jug filler, so that the water jug is used to hold the cooling liquid; An electronic water pump: when the motor electric control needs to be cooled, the electronic pump is used to make the cooling liquid in the water pipe flow, and the higher the speed, the greater the cooling water flow; A cooling fan: when the motor electric control needs to be cooled, the fan is enabled to rotate, so that the cooling liquid in the cooling fins is lowered in temperature.

[0012] An RCU controller: enables the water pump and fan to work through the thermal management function module of the motor electric control, and has a low-voltage component self-checking function, monitors the cooling system and troubleshoots problems.

[0013] A human-computer interaction control screen: used for CAN communication interaction with the RCU controller, displays the current system state, manually confirms the low-voltage component self-checking, and the indicator light switch function, and prompts the system alarm and fault type.

[0014] A fuse relay: integrates the relay with its corresponding fuse, and feeds back the line state through the state of the enabled indicator light.

[0015] Further solutions also include: The insurance relay outputs 5 pin contacts, which are 12V battery positive, RCU enable signal 12V+, 12V battery negative, output component 12V power supply and indicator lamp ground.

[0016] Further schemes further include: The fuse plug in the insurance relay is plug-in and plug-out, facilitating replacement and maintenance, and the fuse corresponding specifications are designed according to the maximum current of the low-voltage line schematic diagram.

[0017] Further schemes further include: The indicator lamp switch can be designed as a manual key or automatic control, so that the insurance relay indicator lamp does not participate in work when the cooling system is normal, and only the abnormal low-voltage system related corresponding insurance relay indicator lamp participates in work when the cooling system is abnormal.

[0018] Further schemes further include a range extender cooling system component monitoring and troubleshooting control device, the range extender cooling system component monitoring and troubleshooting control device comprising: a storage module, a control module, an acquisition module, and a program stored on the storage medium for implementing the range extender cooling system component monitoring and troubleshooting control method; The storage module is used for storing the program of the range extender cooling system component monitoring and troubleshooting control method, characterized in that the storage medium stores the program of the range extender cooling system component monitoring and troubleshooting control method, and the program of the range extender cooling system component monitoring and troubleshooting method is executed by the processor to implement the steps of the range extender cooling system component monitoring and troubleshooting control method; The acquisition module is used for acquiring real-time values and sensor feedback resistance values of the range extender engine cooling system; The control module is used for executing the program of the range extender cooling system component monitoring and troubleshooting control method to implement the steps of the range extender cooling system component monitoring and troubleshooting control method.

[0019] The present application has the following advantages: The control method of the present application can quickly and accurately judge the working state of key components such as water pumps and fans in the range extender cooling system of a ship, and when a system fault occurs, the fault point can be quickly located, greatly shortening the fault troubleshooting time and improving the reliability of ship operation. By setting the voltage reducing DCDC, RCU controller, man-machine interaction control screen and insurance relay and other devices, comprehensive monitoring and intelligent control of the cooling system are realized, the performance of the system is optimized, and the maintenance cost is reduced. The special design of the fuse relay, such as the pluggable fuse connector and the indicator light state feedback circuit, facilitates the maintenance and troubleshooting of the low-voltage line by maintenance personnel, improves work efficiency, and reduces the risk of damage caused by repeated plugging and unplugging of components. The design of the indicator light switch is flexible, and manual or automatic control mode can be selected according to actual needs, which does not affect work when the system is normal, and can accurately indicate the fault position in time when the system is abnormal, thereby improving the operability and safety of the system. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 The flowchart of the control method of the present application.

[0021] Figure 2 The logic block diagram of the fault judgment of the present application.

[0022] Figure 3 The energy flow diagram of the cooling system in the monitoring and troubleshooting device.

[0023] Figure 4 The control structure diagram of the cooling fan in the monitoring and troubleshooting device.

[0024] Figure 5 The circuit connection diagram of the indicator light in the monitoring and troubleshooting device. DETAILED DESCRIPTION

[0025] The principles and characteristics of the present application are described below in conjunction with the accompanying drawings, and the examples are used to explain the present application and are not intended to limit the scope of the present application.

[0026] (1) Specific implementation steps of the control method System wake-up and parameter acquisition: When the marine range extender cooling system is awakened, the acquisition module in the system will immediately start working and begin to collect real-time values of the range extender engine cooling system and sensor feedback resistance values. These real-time values include but are not limited to the voltage and current of the step-down DCDC output, the temperature of the motor electric control, the speed of the water pump, the speed of the fan, and the temperature of the cooling liquid, etc.; the sensor feedback resistance values come from the state monitoring sensors of each key component, such as current sensors and temperature sensors for detecting the working state of the water pump and the fan. After preliminary processing of the collected data, the acquisition module transmits the data to the control module as the basis for subsequent judgment and control of the system.

[0027] High voltage and fault state judgment: After the control module receives the data transmitted by the acquisition module, it first judges whether the system is on high voltage and has no range extender fault. The judgment logic is as follows: by monitoring the output voltage of the step-down DCDC, if the voltage value is in the preset high voltage normal range (for example, 380V-420V), it is considered that the system is on high voltage; at the same time, the system will detect the state of each key component (such as engine, generator, etc.) of the range extender, and if no fault signal is output from each component, it is determined that the system has no range extender fault. If the condition is met, the system prompts the low-voltage component self-checking state through the human-computer interaction control screen, and informs the operator that the current system can perform low-voltage component self-checking operation.

[0028] Low-voltage component self-checking start: if the operator manually selects to enter the low-voltage component self-checking mode, the human-computer interaction control screen further prompts to start the low-voltage component self-checking. At this time, the system starts to execute the self-checking operation process: first, close the fuse relay of the step-down DCDC to enable the step-down DCDC, and the step-down DCDC starts to work to reduce the high-voltage power supply of the battery pack to a low-voltage power supply for charging the battery, and the step-down DCDC starts to monitor the voltage and current values of its output. After the step-down DCDC works normally (generally, the output voltage and current of the step-down DCDC are stabilized in the preset range, for example, the voltage is stabilized at 12V±0.5V, the current fluctuation does not exceed 10% of the rated value, and the duration reaches 5 seconds as the judgment basis), the fuse relay of the battery is disconnected to cut off the direct connection between the battery and the system, so as to avoid interference of the battery to the system during the self-checking process.

[0029] Cooling component working and power calculation: then, the RCU controller enables the water pump and the fan in turn to make the cooling components work normally at the maximum gear. During the operation of the water pump and the fan, the system continuously obtains the voltage and current output by the step-down DCDC, and calculates the output power of the step-down DCDC according to the power calculation formula (wherein P is the power, V is the voltage, I is the current). Since the power consumed by the water pump and the fan working at the maximum gear occupies a major part in the whole system, and the output power of the step-down DCDC is mainly used to drive the water pump and the fan, the current calculated water pump power and fan power can be calculated by analyzing the output power of the step-down DCDC, combined with the rated power and efficiency of the water pump and the fan, etc. For example, it is known that the rated power of the water pump is P1, the efficiency is , the rated power of the fan is P2, and the efficiency is , by measuring and calculating the output power P3 of the step-down DCDC, combined with the circuit connection and power distribution relationship of the system, the water pump power P4 and the fan power P4 can be estimated.

[0030] Component working state judgment: the system compares the calculated fan power with the fan normal working power threshold value, and compares the calculated pump power with the pump normal working power threshold value. The fan normal working power threshold value and the pump normal working power threshold value are determined through a large number of experiments and tests in the system design stage, considering the normal working power range of the fan and the pump under different working conditions and a certain safety margin. If the calculated fan power is within ± 15% of the fan normal working power threshold value, and the calculated pump power is within ± 15% of the pump normal working power threshold value, the system judges that the fan and the pump are in normal working state, and prompts the low pressure component self-check normal state through the man-machine interactive control screen.

[0031] Abnormal state judgment and prompt: if the system judges that there is no high pressure or range extender failure, it prompts the non-high pressure or range extender failure state through the man-machine interactive control screen, reminding the operator that the system has high pressure or range extender related problems, which need to be further checked and repaired. If the low pressure component self-check mode is not manually entered, the system prompts to enter the low pressure component monitoring state, at which time the system continuously monitors the working state of the low pressure component in real time, and takes corresponding measures to handle the abnormal situation as soon as possible.

[0032] Abnormal working state judgment: if the calculated fan power is not close to the fan normal working power threshold value (i.e. exceeds the above ± 15% range), the system judges that the fan is in abnormal working state; similarly, if the calculated pump power is not close to the pump normal working power threshold value, the system judges that the pump is in abnormal working state. When the system judges that the fan or the pump is in abnormal working state, it will immediately display the corresponding fault prompt information on the man-machine interactive control screen, telling the operator which component is abnormal.

[0033] Temperature triggered self-check and monitoring: when the system monitors that the motor control temperature abnormally rises (for example, the temperature rise rate exceeds 5℃ per minute) or the temperature reaches the maximum temperature threshold value (such as 120℃), the system automatically prompts to start the low pressure component self-check, without the need for manual operation by the operator. The system will immediately perform self-check according to the above low pressure component self-check process to quickly check whether the cooling system has a fault causing the motor control temperature to be too high. Conversely, if the motor control temperature does not abnormally rise and the temperature does not reach the maximum temperature threshold value, the system prompts to enter the low pressure component monitoring state, and continues to monitor the system in real time.

[0034] Fault location and troubleshooting: If the system judges that the fan or water pump is in an abnormal working state, the system automatically starts or the operator manually presses the indicator light switch. After the fan or water pump indicator light switch is turned on, the maintenance personnel observe the indicator light state in turn. If all the indicator lights are on, it is judged that the fan or water pump (body or plug connector, line) is faulty; if indicator light 01 does not light up, it is judged that the RCU is not enabled or the RCU enable line is faulty; if indicator light 02 does not light up, it is judged that the battery power supply is faulty; if indicator light 03 does not light up, it is judged that the relay is faulty or the relay ground line is faulty; if indicator light 04 does not light up, it is judged that the fuse is faulty; if none of the indicator lights are on, it is judged that the low-voltage power supply or the total positive and negative line is faulty. Maintenance personnel can quickly locate the fault point and carry out targeted maintenance and processing according to the status prompt of the indicator light.

[0035] Normal ship navigation scenario: During normal ship navigation, the step-down DCDC continuously reduces the high-voltage power supply of the battery pack to a low-voltage power supply for charging the battery, and monitors the output voltage and current values in real time. The step-down DCDC will automatically adjust the output voltage and current according to the charging state of the battery and the power demand of the system, to ensure that the battery is always in good charging condition, and to provide stable power supply for other low-voltage components in the system. For example, when the battery power is low, the step-down DCDC will appropriately increase the output current to speed up the charging speed; when the battery is close to full, the step-down DCDC will reduce the output current to prevent overcharging.

[0036] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A control method for marine range extender cooling system component monitoring and troubleshooting, characterized in that, The device comprises: a step-down DCDC for reducing the high-voltage power supply of a battery pack to a low-voltage power supply for charging a storage battery and monitoring the output voltage and current value; an RCU controller for enabling the water pump and fan to work through the thermal management function module of the motor electronic control and having a low-voltage component self-checking function to monitor the cooling system and troubleshoot problems; a man-machine interactive control screen for CAN communication with the RCU controller, displaying the system state, manually confirming the low-voltage component self-checking and the indicator light switch function, and prompting the system alarm and fault type; and a safety relay for integrating the relay and its corresponding fuse to feedback the line state through the state of the indicator light. The device further comprises: obtaining the working parameters after the system wakes up, and if it is determined that the system has high pressure and no range extender fault, the system prompts the low-voltage component self-checking state; if the low-voltage component self-checking mode is manually entered, the system prompts the start of the low-voltage component self-checking, the safety relay of the step-down DCDC is closed to enable the step-down DCDC, and after the step-down DCDC works normally, the safety relay of the storage battery is disconnected, the RCU enables the water pump and fan in turn to work normally at the maximum gear, the working parameters are obtained to calculate the output power of the step-down DCDC, the water pump power and the fan power are obtained, and if the calculated fan power is close to the normal working power threshold of the fan and the calculated water pump power is close to the normal working power threshold of the water pump, the system judges that the fan and the water pump are in the normal working state, and prompts the low-voltage component self-checking normal state.

2. The control method for marine range extender cooling system components monitoring and troubleshooting according to claim 1, characterized in that, The device further comprises: obtaining the working parameters after the system wakes up, and if it is determined that the system has no high pressure or range extender fault, the system prompts the state of no high pressure or range extender fault. The device further comprises: if it is determined that the low-voltage component self-checking mode is not manually entered, the system prompts the low-voltage component monitoring state.

3. The control method for marine range extender cooling system component monitoring and troubleshooting according to claim 1, characterized in that, The device further comprises: if it is determined that the calculated fan power is not close to the normal working power threshold of the fan, the system judges that the fan is in an abnormal working state. The device further comprises: if it is determined that the calculated water pump power is not close to the normal working power threshold of the water pump, the system judges that the water pump is in an abnormal working state.

4. The control method for marine range extender cooling system component monitoring and troubleshooting of claim 1, wherein, The device further comprises: if it is determined that the temperature of the motor electronic control abnormally rises or reaches the maximum temperature threshold, the system prompts the start of the low-voltage component self-checking. The device further comprises: if it is determined that the temperature of the motor electronic control does not abnormally rise and does not reach the maximum temperature threshold, the system prompts the low-voltage component monitoring state.

5. The control method for marine range extender cooling system components monitoring and troubleshooting according to claim 1, characterized in that, The device further comprises: if the system judges that the fan or the water pump is in an abnormal working state, the system automatically turns on or manually presses the indicator light switch, and after the indicator light switch is turned on, the maintenance personnel observes the state of the indicator light; if all the indicator lights are on, it is judged that the fan or the water pump body, the plug connector, the joint or the line is faulty. The device comprises: a step-down DCDC for reducing the high-voltage power supply of a battery pack to a low-voltage power supply for charging a storage battery and monitoring the output voltage and current value; an RCU controller for enabling the water pump and fan to work through the thermal management function module of the motor electronic control and having a low-voltage component self-checking function to monitor the cooling system and troubleshoot problems; a man-machine interactive control screen for CAN communication with the RCU controller, displaying the system state, manually confirming the low-voltage component self-checking and the indicator light switch function, and prompting the system alarm and fault type; and a safety relay for integrating the relay and its corresponding fuse to feedback the line state through the state of the indicator light.

6. The control method for marine range extender cooling system components monitoring and troubleshooting according to claim 3, characterized in that, The safety relay outputs five pin contacts, which are 12V storage battery positive, RCU enable signal 12V+, 12V storage battery negative, output component 12V power supply and indicator light ground respectively; and the fuse connector is plug-in, and its specification is designed according to the maximum current of the low-voltage line schematic diagram; the indicator light switch is a manual key or automatic control, the safety relay indicator light does not work when the cooling system is normal, and only the abnormal low-voltage system related safety relay indicator light works when the cooling system is abnormal. ​ 7. The control method for marine range extender cooling system components monitoring and troubleshooting according to claim 3, characterized in that, ​ ​ 8. The control method for marine range extender cooling system component monitoring and troubleshooting of claim 1, wherein, ​ ​ 9. A marine range extender cooling system component monitoring and troubleshooting device for performing the control method of any one of claims 1-8, characterized in that, ​ 10. The marine range extender cooling system component monitoring and troubleshooting device of claim 9, wherein, ​

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