Anti-reverse control method, device, system, medium and program product of range extender

Abstract

The present disclosure provides a range extender anti-reverse control method, device, system, medium and program product, relating to the technical field of new energy vehicles. The method comprises: receiving a power generation power request sent by a vehicle controller; determining a speed instruction and a torque instruction according to the power generation power request; sending the speed instruction to an engine controller to control the speed of the engine, and sending the smaller value of the torque in the torque instruction and the engine external characteristic torque corresponding to the speed in the speed instruction to a generator controller to control the torque of the generator; and performing torque limiting control on the generator according to the load percentage of the current speed of the engine fed back by the engine controller.

Description

Technical Field

[0001] This disclosure relates to the field of new energy vehicle technology, and in particular to a method, device, system, medium, and program product for anti-reverse control of a range extender. Background Technology

[0002] Range-extended electric powertrains effectively solve the range anxiety problem of pure electric vehicles, and have become one of the hot topics in the research and development of new energy vehicles. As a key component of range-extended electric vehicles, the range extender mainly consists of an internal combustion engine (engine) and a generator (ISG (Integrated Start-Generator) motor) coaxially connected to it. The core function of the range extender is to start working when the onboard battery is low on power. The engine burns fuel to generate power, which drives the generator to produce electricity. The generated electricity is used to drive the motor that powers the vehicle or to charge the battery.

[0003] The generator used in the range extender has the ability to work in both forward and reverse directions, while the engine generally cannot be reversed. During the reverse process, the engine oil pump cannot form normal oil pressure to supply oil to each rotation amplitude, which can easily cause damage to the engine. Summary of the Invention

[0004] One technical problem this disclosure aims to solve is to provide a range extender anti-reverse control method, device, system, medium, and program product that can reduce the occurrence of catastrophic mechanical failures of the engine.

[0005] According to one aspect of this disclosure, a method for preventing reverse rotation of a range extender is proposed, comprising: receiving a power generation request sent by a vehicle controller; determining a speed command and a torque command based on the power generation request; sending the speed command to an engine controller to control the engine speed, and sending the smaller value between the torque in the torque command and the engine external characteristic torque corresponding to the speed in the speed command to a generator controller to control the generator torque; and performing torque limiting control on the generator based on the load percentage of the engine at the current speed fed back by the engine controller.

[0006] In some embodiments, torque limiting control of the generator based on the load percentage at the current engine speed fed back by the engine controller includes: in response to the load percentage at the current engine speed being greater than the allowable load percentage calibration value at the current speed, sending a torque control command to the generator controller to limit the load percentage at the current engine speed to less than or equal to the allowable load percentage calibration value.

[0007] In some embodiments, torque limiting control of the generator based on the load percentage at the current engine speed fed back by the engine controller further includes: resetting the generator torque to zero when the duration for which the load percentage at the current engine speed is limited to less than or equal to the allowable load percentage calibration value is greater than or equal to a time threshold.

[0008] In some embodiments, an overload flag is established in response to the load percentage at the current engine speed being greater than the allowable load percentage calibration value at the current engine speed.

[0009] In some embodiments, torque limiting control of the generator based on the load percentage at the current engine speed fed back by the engine controller includes: calculating a first speed change rate of the generator and a second speed change rate of the engine in response to the load percentage at the current engine speed being less than or equal to a calibrated allowable load percentage at the current speed; and resetting the torque of the generator to zero in response to at least one of the first speed change rate and the second speed change rate in a series of consecutive cycles being greater than a calibrated maximum speed change rate.

[0010] In some embodiments, the torque limiting control of the generator based on the load percentage at the current engine speed fed back by the engine controller further includes: calculating a first difference between the speed in the speed command and the speed of the generator, and a second difference between the speed in the speed command and the speed of the engine; and resetting the torque of the generator to zero in response to at least one of the first difference and the second difference in a series of consecutive cycles being greater than the maximum speed difference calibration value.

[0011] In some embodiments, a speed runaway flag is established in response to at least one of a first speed change rate and a second speed change rate over a series of consecutive cycles being greater than a maximum speed change rate calibration value, or in response to at least one of a first difference and a second difference over a series of consecutive cycles being greater than a maximum speed difference calibration value.

[0012] In some embodiments, a start command sent by the vehicle controller is received; a start torque is sent to the generator controller; in response to the engine start success count being 0, during the engine start process, a third difference between the generator speed and the engine speed is calculated; in response to the third difference being greater than the speed difference calibration value, or the generator speed being less than the speed threshold, the generator torque is cleared to zero.

[0013] In some embodiments, a reversal flag is set in response to a third difference being greater than the speed difference calibration value, or the generator speed being less than the speed threshold.

[0014] In some embodiments, in response to a third difference being less than or equal to the speed difference calibration value, and the generator speed and the generator rotation speed being within the idle speed range, the number of successful starts is incremented by 1; or, in response to an engine start success count being greater than 0, and the generator speed and the generator rotation speed being within the idle speed range, the number of successful starts is incremented by 1.

[0015] In some embodiments, in response to the engine starting success count being 0, a ramp torque is sent to the generator controller according to a first torque ramp control mode; in response to the engine starting success count being greater than 0, a ramp torque is sent to the generator controller according to a second torque ramp control mode, wherein the first torque ramp control mode includes a first time when the generator torque rises from 0 to a specified torque, a second time when the generator torque rises from the specified torque to a target torque, and the second torque ramp control mode includes a third time when the generator torque rises from 0 to the target torque, and the sum of the first time and the second time is greater than the third time.

[0016] In some embodiments, it is determined whether the engine is reversing based on signals monitored by the engine's crankshaft position sensor and camshaft position sensor.

[0017] According to another aspect of this disclosure, a range extender anti-reverse control device is also proposed, comprising: a receiving module configured to receive a power generation request sent by a vehicle controller; a determining module configured to determine a speed command and a torque command based on the power generation request; a sending module configured to send the speed command to an engine controller to control the engine speed, and to send the smaller of the torque in the torque command and the engine external characteristic torque corresponding to the speed in the speed command to a generator controller to control the generator torque; and a control module configured to perform torque limiting control on the generator based on the load percentage at the current engine speed fed back by the engine controller.

[0018] According to another aspect of this disclosure, a range extender anti-reverse control device is also proposed, comprising: a memory; and a processor coupled to the memory, the processor being configured to execute the range extender anti-reverse control method as described above based on instructions stored in the memory.

[0019] According to another aspect of this disclosure, a range extender anti-reverse control system is also proposed, comprising: the aforementioned range extender anti-reverse control device; a vehicle controller configured to send a start command or a power generation request to the range extender anti-reverse control device; an engine controller configured to control the engine according to the command of the range extender anti-reverse control device; and a generator controller configured to control the generator according to the command of the range extender anti-reverse control device.

[0020] According to another aspect of this disclosure, a vehicle is also provided, comprising: the aforementioned range extender anti-reverse control device; or the aforementioned range extender anti-reverse control system.

[0021] According to another aspect of this disclosure, a computer-readable storage medium is also proposed, on which computer program instructions are stored, which, when executed by a processor, implement the range extender anti-reverse control method as described above.

[0022] According to another aspect of this disclosure, a computer program product is also proposed, comprising a computer program that, when executed by a processor, implements the above-described range extender anti-reverse control method.

[0023] In this embodiment of the disclosure, dynamic torque limiting is performed based on the engine's external characteristic torque and the allowable load percentage at the current speed, thereby reducing the risk of abnormal engine reversal.

[0024] Other features and advantages of this disclosure will become clear from the following detailed description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description

[0025] The accompanying drawings, which form part of this specification, illustrate embodiments of this disclosure and, together with the specification, serve to explain the principles of this disclosure.

[0026] This disclosure will become clearer with reference to the accompanying drawings and the following detailed description, wherein:

[0027] Figure 1 This is a schematic flowchart of some embodiments of the range extender anti-reverse control method disclosed herein;

[0028] Figure 2 The following are schematic flowcharts of some other embodiments of the range extender anti-reverse control method disclosed herein;

[0029] Figure 3 This is a flowchart illustrating some further embodiments of the range extender anti-reverse control method disclosed herein;

[0030] Figure 4 This is a flowchart illustrating some further embodiments of the range extender anti-reverse control method disclosed herein;

[0031] Figure 5 Block diagrams of some embodiments of the range extender anti-reverse control device disclosed herein;

[0032] Figure 6 Block diagrams of some embodiments of the electronic devices disclosed herein;

[0033] Figure 7 This is a block diagram of some embodiments of the range extender anti-reverse control system disclosed herein. Detailed Implementation

[0034] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. It should be noted that, unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the present disclosure.

[0035] At the same time, it should be understood that, for ease of description, the dimensions of the various parts shown in the accompanying drawings are not drawn according to actual scale.

[0036] The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit this disclosure or its application or use.

[0037] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and equipment should be considered part of the specification.

[0038] In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0039] It should be noted that similar labels and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be discussed further in subsequent figures.

[0040] To make the objectives, technical solutions, and advantages of this disclosure clearer, the following detailed description is provided in conjunction with specific embodiments and the accompanying drawings.

[0041] Engine reversal can be mainly categorized into two types. The first is due to motor and electronic control issues. During the initial calibration testing after generator and engine matching, errors in the zero-position calibration parameters of the resolver in the generator controller can cause the motor to reverse uncontrollably, resulting in a misalignment between the desired torque request direction and the actual torque direction. The second is due to engine-related issues. In this case, the engine may stop injecting fuel or experience performance degradation due to abnormal conditions, causing the load torque to exceed the engine's current maximum output torque capacity. The engine may then be rapidly stopped or even reversed by the generator. Based on these reasons, this disclosure provides a range extender anti-reversal control method that effectively solves engine reversal caused by motor and electronic control issues or engine-related problems, reducing the occurrence of catastrophic mechanical failures of the engine. The solution described below will be introduced with reference to specific embodiments.

[0042] Figure 1This is a flowchart illustrating some embodiments of the range extender anti-reverse control method disclosed herein, which includes steps S11-S14, executed by the RCU (Ranger Controller Unit).

[0043] In step S11, a power generation request sent by the vehicle controller is received.

[0044] The VCU (Vehicle Control Unit) sends a power generation request to the RCU. The VCU and RCU can be connected via CAN (Controller Area Network).

[0045] In step S12, the speed command and torque command are determined based on the power generation request.

[0046] The RCU parses the power generation request to obtain speed and torque commands. For example, mechanical power A = speed * torque * 9550, while power generation P = system efficiency B * mechanical power A. The speed and torque can be obtained from this formula.

[0047] In step S13, the speed command is sent to the engine controller to control the engine speed, and the smaller value between the torque in the torque command and the engine external characteristic torque corresponding to the speed in the speed command is sent to the generator controller to control the generator torque.

[0048] In some embodiments, the RCU sends a speed command to the ECU (Engine Control Unit), causing the engine to rotate according to the speed command. The RCU pre-writes an engine external characteristic map (MAP). Based on the engine external characteristic map, it compares the engine external characteristic torque corresponding to the speed in the speed command with the torque in the torque command. The smaller value between the torque in the torque command and the engine external characteristic torque is sent to the GCU (Generator Control Unit), thereby limiting the generator torque to prevent it from becoming too large and thus avoiding the engine being unable to maintain the current speed and being dragged back by the generator.

[0049] The RCU can be connected to the ECU and GCU via CAN respectively.

[0050] In step S14, torque limiting control is performed on the generator based on the load percentage at the current engine speed fed back by the engine controller.

[0051] When the engine malfunctions, its own operating load becomes too high, reducing the torque available for power generation. Maintaining the original generator torque at this point risks engine reversal. The RCU (Regenerative Control Unit) determines whether there is an overload risk based on the load percentage at the current engine speed fed back by the ECU, and then implements torque limiting control for the generator.

[0052] In the above embodiments, dynamic torque limiting is achieved based on the engine's external characteristic torque and the allowable load percentage at the current speed, thereby reducing the risk of abnormal engine reversal.

[0053] In some embodiments, torque limiting control of the generator based on the load percentage at the current engine speed fed back by the engine controller includes: in response to the load percentage at the current engine speed being greater than the allowable load percentage calibration value at the current speed, sending a torque control command to the generator controller to limit the load percentage at the current engine speed to less than or equal to the allowable load percentage calibration value.

[0054] For example, the allowable load percentage calibration value F at the current speed is preset in the RCU. If the load percentage at the current engine speed is greater than the allowable load percentage calibration value F, the RCU needs to request the GCU to limit the torque so that the load percentage at the current engine speed is limited to less than or equal to the allowable load percentage calibration value F.

[0055] In the above embodiments, the torque of the generator is limited by referring to the load percentage at the current engine speed, so as to avoid overload from the source and reduce the probability of the generator dragging the engine in reverse.

[0056] In some embodiments, torque limiting control of the generator based on the load percentage at the current engine speed fed back by the engine controller further includes: resetting the generator torque to zero when the duration for which the load percentage at the current engine speed is limited to less than or equal to the allowable load percentage calibration value is greater than or equal to a time threshold.

[0057] For example, after the RCU requests torque limiting from the GCU, the time accumulator starts counting. If the accumulated time exceeds 300 seconds, it requests the torque to be reset to zero. During this period, the range extender generates a small amount of power to prevent a sudden interruption of power output. By preserving some power, the driver can perform evasive maneuvers, thereby reducing vehicle and personal injury damage.

[0058] In some embodiments, an overload flag is established in response to the load percentage at the current engine speed being greater than the allowable load percentage calibration value at the current engine speed.

[0059] For example, if the load percentage at the current engine speed is greater than the allowable load percentage calibration value F at the current speed, it indicates that the engine is at risk of overload. Therefore, an overload risk sign can be set up and the warning information can be sent to the VCU and displayed on the panel to remind the driver in a timely manner, so that the driver can take some measures to reduce the loss.

[0060] In other embodiments, torque limiting control of the generator based on the load percentage at the current engine speed fed back by the engine controller includes: calculating a first rate of change of the generator speed and a second rate of change of the engine speed in response to the load percentage at the current engine speed being less than or equal to a calibrated allowable load percentage at the current speed; and resetting the generator torque to zero in response to at least one of the first rate of change of the generator speed and the second rate of change of the generator speed being greater than a calibrated maximum rate of change of the generator speed ....

[0061] For example, a maximum speed change rate calibration value R is preset in the RCU. During operation, the RCU calculates the generator speed change rate and engine speed change rate in real time. If the speed change rate is greater than the maximum speed change rate calibration value for three consecutive cycles, it indicates that the engine may be reversing, thus triggering torque zeroing.

[0062] In this embodiment, the reversal trend is quickly predicted by the rate of change of rotational speed. Although the generator and engine are coaxially designed and their rates of change of rotational speed should be the same, this embodiment combines both engine speed signals and generator speed signals to avoid single-point failure.

[0063] In some embodiments, the torque limiting control of the generator based on the load percentage at the current engine speed fed back by the engine controller further includes: calculating a first difference between the speed in the speed command and the speed of the generator, and a second difference between the speed in the speed command and the speed of the engine; and resetting the torque of the generator to zero in response to at least one of the first difference and the second difference in a series of consecutive cycles being greater than the maximum speed difference calibration value.

[0064] For example, the maximum speed difference calibration value N is preset in the RCU. The difference between the speed in the speed command and the generator speed, and the difference between the speed in the speed command and the engine speed are calculated. If the difference is greater than the maximum speed difference calibration value for three consecutive cycles, it indicates that the engine may be reversing, thus triggering torque zeroing.

[0065] In the above embodiments, the reversal trend is quickly predicted by the rate of change of rotational speed, and the redundant protection of the speed difference judgment is increased to avoid protection failure caused by noise interference. At the same time, by combining the engine and generator speed signals, single-point failure can be avoided.

[0066] In some embodiments, a speed runaway flag is established in response to at least one of a first speed change rate and a second speed change rate over a series of consecutive cycles being greater than a maximum speed change rate calibration value, or in response to at least one of a first difference and a second difference over a series of consecutive cycles being greater than a maximum speed difference calibration value.

[0067] For example, if the rate of change of speed exceeds the set maximum rate of change of speed calibration value R for three consecutive cycles, or if the difference between the commanded speed and the motor / engine speed exceeds the set maximum speed difference calibration value N, a speed stall indicator will be set up, and a warning message will be sent to the VCU and displayed on the panel to promptly remind the driver so that the driver can take some measures to reduce losses.

[0068] The following section provides a detailed introduction to the anti-reverse control method for range extenders during the power generation process. For example... Figure 2 As shown, Figure 2 The following is a flowchart illustrating some other embodiments of the range extender anti-reverse control method disclosed herein, including steps S21-S29.

[0069] In step S21, the VCU sends a power generation request to the RCU.

[0070] In step S22, the RCU parses the power generation request and obtains the speed command and torque command.

[0071] In step S23, it is determined whether the torque in the torque command is less than the engine external characteristic torque corresponding to the speed in the speed command. If so, step S241 is executed; otherwise, step S242 is executed.

[0072] In step S241, the RCU sends the torque from the torque command to the GCU, and then proceeds to step S25.

[0073] In step S242, the RCU sends the engine external characteristic torque to the GCU, and then proceeds to step S25.

[0074] In step S25, it is determined whether the load percentage at the current engine speed is less than or equal to the allowable load percentage calibration value F at the current speed. If not, step S261 is executed; if so, step S271 is executed.

[0075] In step S261, an overload flag is set.

[0076] In step S262, the torque is limited to the allowable load percentage calibration value F at the current speed.

[0077] If the cumulative time is greater than 300 seconds in step S263, then step S28 is executed.

[0078] In step S271, the generator speed change, the engine speed change rate, the difference between the speed in the speed command and the generator speed, and the difference between the speed and the engine speed are calculated.

[0079] In step S272, it is determined whether the rate of change of rotational speed within three consecutive cycles is greater than the maximum rate of change of rotational speed calibration value R, or whether the speed difference is greater than the maximum speed difference calibration value N. If so, step S273 is executed; otherwise, step S274 is executed.

[0080] In step S273, a speed control failure flag is set, and then step S28 is executed.

[0081] In step S274, the requested torque is executed.

[0082] In step S28, the torque is reset to zero.

[0083] In step S29, the warning information is sent to the VCU, and the range extender stops generating electricity.

[0084] In the above embodiments, the control strategy adopts hierarchical control. Steps S21-S263 belong to the basic layer, and steps S271-S29 belong to the protection layer. The basic layer dynamically limits the load percentage based on the engine's external characteristic torque and the current speed, preventing overload from the source. The protection layer monitors the speed gradient during power generation to ensure rapid prevention and blocking in case of faults, and also sets up redundant protection for speed difference judgment. Dual speed detection of the engine and generator can avoid the impact of single-point failure. This control method can solve the problem of engine reversal caused by motor control issues or engine problems, avoiding the occurrence of catastrophic mechanical failure of the engine.

[0085] Figure 3 This is a flowchart illustrating further embodiments of the range extender anti-reverse control method disclosed herein, which includes steps S31-S34.

[0086] In step S31, a start command sent by the vehicle controller is received.

[0087] The VCU sends a boot command to the RCU. This boot command can be either the first boot command or a non-first boot command.

[0088] In step S32, the starting torque is sent to the generator controller.

[0089] After receiving the command, the RCU sends the starting torque to the GCU. The GCU responds with the torque, causing the engine to rotate. During startup, the generator drives the engine to rotate; the generator responds with the starting torque, which in turn drives the engine to rotate, thus starting the engine.

[0090] In step S33, in response to the engine starting success count being 0, during the engine starting process, a third difference between the generator speed and the engine speed is calculated.

[0091] For example, the RCU contains a storeable start success count signal A. During the first start, the success count A is 0. The generator's speed fluctuates during operation, resulting in a speed difference during reversal. During startup, the speed difference value fed back by the GCU and ECU is compared in real-time with the speed difference calibration value D.

[0092] In step S34, in response to the third difference being greater than the speed difference calibration value, or the generator speed being less than the speed threshold, the generator torque is reset to zero.

[0093] If the third difference is greater than the speed difference calibration value, it indicates that the engine is about to reverse, and the generator torque needs to be reset to zero. Ensure the generator speed is not negative; when the generator speed is less than -10 rpm, the generator torque should also be reset to zero. This speed threshold is less than 0 to prevent false triggering. When the speed is close to zero (e.g., -1 to -5 rpm), the motor may misinterpret the instantaneous reverse signal due to mechanical vibration or measurement noise. Therefore, the speed threshold can be set lower, such as -10 rpm.

[0094] In the above embodiments, during the start-up process of the range extender, given that the engine speed only has a positive characteristic, the speed difference between the generator and the engine can be used to quickly and effectively determine the occurrence of reverse rotation during the start-up process, and timely measures can be taken to reduce the probability of engine reverse rotation, thereby reducing vehicle malfunctions.

[0095] In some embodiments, a reversal flag is set in response to a third difference being greater than the speed difference calibration value, or the generator speed being less than the speed threshold.

[0096] For example, a fault warning can be established and sent to the VCU. When a fault warning is established, the RCU does not respond to the VCU's startup command, thereby reducing the occurrence of subsequent faults.

[0097] In some embodiments, in response to a third difference being less than or equal to the speed difference calibration value, and the generator speed and the generator rotation speed being within the idle speed range, the number of successful starts is incremented by 1; or, in response to an engine start success count being greater than 0, and the generator speed and the generator rotation speed being within the idle speed range, the number of successful starts is incremented by 1.

[0098] For example, if the engine speed and generator speed are within ±20 rpm of the idle speed, the number of successful starts is incremented by 1. This makes it easier for the RCU to determine the number of successful starts when it receives the start command from the VCU for the next time.

[0099] In some embodiments, in response to the engine starting success count being 0, a ramp torque is sent to the generator controller according to a first torque ramp control mode; in response to the engine starting success count being greater than 0, a ramp torque is sent to the generator controller according to a second torque ramp control mode, wherein the first torque ramp control mode includes a first time when the generator torque rises from 0 to a specified torque, a second time when the generator torque rises from the specified torque to a target torque, and the second torque ramp control mode includes a third time when the generator torque rises from 0 to the target torque, and the sum of the first time and the second time is greater than the third time.

[0100] For example, the starting torque is generated by the ramp generator, and the RCU sends the ramp torque to the GCU according to the message transmission cycle. When the number of successes A is 0, the ramp generator is in mode 1; when the number of successes A is greater than 0, the ramp generator is in mode 2. When the ramp generator is in mode 1, for example, the ramp time for the first 100 N·m is t1, and the ramp time from 100 N·m to the starting target torque is t2. When the ramp generator is in mode 2, the ramp time from 0 to the starting target torque is t2, and t1 + t2 > t3, where t can be set to a larger value.

[0101] When the number of successful attempts is 0, corresponding to the first start, there is a risk of engine reversal. The engine is started in two stages. The first stage is equivalent to low torque revving; the speed is not too high, allowing for timely detection of engine reversal and preventing serious mechanical damage. If no reversal occurs, the engine is started with normal high torque in the second stage. Compared to a success count greater than 0, when the number of successful attempts is 0, i.e., the first start, the time from 0 to the target starting torque is longer, meaning the loading process is slower. However, this allows for timely detection of engine reversal, thus reducing the risk of reversal.

[0102] In the above embodiments, the torque ramp control mode is selected based on the number of successful starts, and a two-stage start method is adopted when the engine is started for the first time. This can promptly detect whether the engine is reversing, thereby facilitating timely measures to reduce vehicle malfunctions.

[0103] In some embodiments, it is determined whether the engine is reversing based on signals monitored by the engine's crankshaft position sensor and camshaft position sensor.

[0104] For example, the phase relationship can be determined by combining signals monitored by the crankshaft position sensor and the camshaft position sensor. The crankshaft position sensor generates a Ne signal (crankshaft angle signal) by detecting changes in the missing / convex teeth of the crankshaft gear or flywheel. When the engine reverses, the direction of rotation of the gear changes, causing the phase sequence of the Ne signal to reverse. The G signal (top dead center reference signal) of the camshaft position sensor is tied to the position of the camshaft gear. When the engine reverses, the timing relationship between the trigger edge of the G signal and the Ne signal will be logically reversed.

[0105] In the above embodiments, on the one hand, the engine reverses direction based on the speed difference, and on the other hand, the engine reverses direction based on the signals monitored by the crankshaft position sensor and camshaft position sensor. Through redundant judgment, the accuracy of the judgment can be improved.

[0106] The following is combined with Figure 4 The engine start-up process will be described. Figure 4 This is a flowchart illustrating some further embodiments of the range extender anti-reverse control method disclosed herein, which includes steps S41-S492.

[0107] In step S41, the VCU sends a start command to the RCU.

[0108] In step S42, the RCU sends the starting torque to the GCU.

[0109] In step S43, determine whether the number of successful startups is greater than 0. If yes, proceed to step S441; otherwise, proceed to step S451.

[0110] In step S441, the ramp generator adopts mode 2, and then step S47 is executed.

[0111] In step S451, the ramp generator adopts mode 1.

[0112] In step S452, it is determined whether the speed difference between the generator and the engine is greater than the maximum speed difference calibration value N, or whether the generator speed is less than -10 rpm. If yes, step S461 is executed; otherwise, step S47 is executed.

[0113] In step S461, a reversal flag is set.

[0114] In step S462, the starting torque is reset to zero.

[0115] In step S463, the warning information is sent to the VCU.

[0116] In step S47, ramp torque is sent to GCU.

[0117] In step S48, it is determined whether the engine speed and generator speed are within the idle speed range. If so, step S491 is executed; otherwise, step S492 is executed.

[0118] In step S491, the number of successful startups is incremented by 1.

[0119] In step S492, the startup failure count is incremented by 1.

[0120] In this embodiment, during engine startup, the torque ramp control mode is selected based on the number of successful starts. Since the engine speed has only a positive characteristic, the difference between the generator and engine speeds is used to quickly and effectively determine the occurrence of a reversal during the startup process.

[0121] The above embodiments represent the range extender anti-reverse control strategy disclosed herein. The control strategy employs layered control, consisting of a basic layer and a protection layer. The basic layer dynamically limits the load percentage based on the engine's external characteristic torque and the current speed, preventing overload at the source. The protection layer uses soft-start control with torque ramp control during startup; if the speed difference between the generator and engine exceeds the calibrated value, startup is stopped. During power generation, the protection layer monitors the speed gradient to ensure rapid prevention and interruption of faults, while also providing redundant protection for speed difference judgment. Dual speed detection of the engine and generator avoids the impact of single-point failures. This control strategy effectively solves engine reversal caused by motor / electronic control issues or engine problems, preventing catastrophic mechanical engine failures.

[0122] The range extender anti-reverse control device of the present disclosure, such as an RCU, will now be described with reference to the accompanying drawings.

[0123] Figure 5 This is a block diagram of some embodiments of the range extender anti-reverse control device disclosed herein, which includes a processing module 51 and a control module 52.

[0124] The processing module 51 is configured to receive a power generation request sent by the vehicle controller, and determine the speed command and torque command based on the power generation request. The control module 52 is configured to send the speed command to the engine controller to control the engine speed, and send the smaller value between the torque in the torque command and the engine external characteristic torque corresponding to the speed in the speed command to the generator controller to control the generator torque, and perform torque limiting control on the generator based on the load percentage of the engine at the current speed fed back by the engine controller.

[0125] In the above embodiments, dynamic torque limiting is achieved based on the engine's external characteristic torque and the allowable load percentage at the current speed, thereby suppressing the risk of abnormal engine reversal.

[0126] In some embodiments, the control module 52 is configured to send a torque control command to the generator controller in response to the load percentage at the current engine speed being greater than the allowable load percentage calibration value at the current engine speed, so as to limit the load percentage at the current engine speed to be less than or equal to the allowable load percentage calibration value.

[0127] In the above embodiments, the torque of the generator is limited by referring to the load percentage at the current engine speed, so as to avoid overload from the source and reduce the probability of the generator dragging the engine in reverse.

[0128] In some embodiments, the control module 52 is configured to zero the generator torque when the duration of limiting the load percentage at the current engine speed to less than or equal to the allowable load percentage calibration value is greater than or equal to a time threshold.

[0129] In this embodiment, after torque limiting is applied, the time accumulator begins counting. During this period, the range extender generates a small amount of power to prevent a sudden interruption of power output. By preserving some power, the driver can perform evasive maneuvers, thereby reducing vehicle and personal injury losses.

[0130] In some embodiments, the control module 52 is configured to establish an overload flag in response to the engine's current load percentage exceeding a permissible load percentage calibration value at the current speed. In this embodiment, the driver is promptly alerted, enabling them to take measures to minimize potential damage.

[0131] In some embodiments, the control module 52 is configured to calculate a first rate of change of generator speed and a second rate of change of generator speed in response to a load percentage at the current engine speed being less than or equal to a calibrated allowable load percentage at the current engine speed; and to reset the torque of the generator to zero in response to at least one of the first rate of change of generator speed and the second rate of change of generator speed being greater than a calibrated maximum rate of change of generator speed in a series of consecutive cycles.

[0132] In this embodiment, the reversal trend is quickly predicted by the rate of change of rotational speed. Although the generator and engine are coaxially designed and their rates of change of rotational speed should be the same, this embodiment combines both engine speed signals and generator speed signals to avoid single-point failure.

[0133] In some embodiments, the control module 52 is configured to calculate a first difference between the speed in the speed command and the speed of the generator, and a second difference between the speed in the speed command and the speed of the engine; in response to at least one of the first difference and the second difference in a series of consecutive cycles being greater than the maximum speed difference calibration value, the torque of the generator is reset to zero.

[0134] In the above embodiments, the reversal trend is quickly predicted by the rate of change of rotational speed, and the redundant protection of the speed difference judgment is increased to avoid protection failure caused by noise interference. At the same time, by combining the engine and generator speed signals, single-point failure can be avoided.

[0135] In some embodiments, the control module 52 is further configured to establish a speed runaway flag in response to at least one of a first speed change rate and a second speed change rate over multiple consecutive cycles being greater than a maximum speed change rate calibration value, or in response to at least one of a first difference and a second difference over multiple consecutive cycles being greater than a maximum speed difference calibration value. This embodiment provides timely reminders to the driver, enabling the driver to take measures to reduce potential losses.

[0136] In other embodiments, the processing module 51 is further configured to receive a start command sent by the vehicle controller; the control module 52 is further configured to send a start torque to the generator controller, and in response to the engine start success count being 0, calculate a third difference between the generator speed and the engine speed during the engine start process; and in response to the third difference being greater than the speed difference calibration value, or the generator speed being less than the speed threshold, clear the generator torque to zero.

[0137] In the above embodiments, during the start-up process of the range extender, given that the engine speed only has a positive characteristic, the speed difference between the generator and the engine can be used to quickly and effectively determine the occurrence of reverse rotation during the start-up process, and timely measures can be taken to reduce the probability of engine reverse rotation, thereby reducing vehicle malfunctions.

[0138] In some embodiments, the control module 52 is configured to establish a reversal flag in response to a third difference value being greater than a speed difference calibration value, or the generator speed being less than a speed threshold. This embodiment helps the driver to promptly detect abnormalities and reduces the occurrence of subsequent vehicle malfunctions by providing timely reminders.

[0139] In some embodiments, the control module 52 is configured to increment the start success count by 1 in response to a third difference value being less than or equal to a speed difference calibration value, and the generator speed and generator rotation speed being within the idle speed range; or, in response to an engine start success count being greater than 0, and the generator speed and generator rotation speed being within the idle speed range, increment the start success count by 1. This facilitates the RCU's determination of the start success count when it receives the VCU start command again.

[0140] In some embodiments, the control module 52 is further configured to send ramp torque to the generator controller in accordance with a first torque ramp control mode in response to a successful engine start count of 0; and to send ramp torque to the generator controller in accordance with a second torque ramp control mode in response to a successful engine start count of greater than 0. The first torque ramp control mode includes a first time when the generator torque rises from 0 to a specified torque, a second time when the generator torque rises from the specified torque to a target torque, and a third time when the generator torque rises from 0 to the target torque. The sum of the first time and the second time is greater than the third time.

[0141] In the above embodiments, the torque ramp control mode is selected based on the number of successful starts, and a two-stage start method is adopted when the engine is started for the first time. This can promptly detect whether the engine is reversing, thereby facilitating timely measures to reduce vehicle malfunctions.

[0142] In some embodiments, the control module 52 is configured to determine whether the engine is reversing based on signals monitored by the engine's crankshaft position sensor and camshaft position sensor.

[0143] In the above embodiments, on the one hand, the engine reverses direction based on the speed difference, and on the other hand, the engine reverses direction based on the signals monitored by the crankshaft position sensor and camshaft position sensor. Through redundant judgment, the accuracy of the judgment can be improved.

[0144] It should be noted that the above modules are logical modules divided according to their specific functions, and are not used to restrict the specific implementation method. For example, they can be implemented in software, hardware, or a combination of software and hardware. In actual implementation, the above modules can be implemented as independent physical entities, or they can be implemented by a single entity (e.g., a processor (CPU or DSP, etc.), integrated circuit, etc.).

[0145] The range extender anti-reverse control device can be an electronic device, such as... Figure 6 As shown, Figure 6 This is a block diagram of some embodiments of the electronic device disclosed herein. The electronic device 6 includes a memory 61 and a processor 62. The memory 61 may be a disk, flash memory, or any other non-volatile storage medium. The memory is used to store instructions as described in the above embodiments. The processor 62 is coupled to the memory 61 and may be implemented as one or more integrated circuits, such as a microprocessor or microcontroller. The processor 62 is used to execute the instructions stored in the memory.

[0146] In some embodiments, the processor 62 is coupled to the memory 61 via a BUS bus 63. The electronic device can also be connected to an external storage device 66 via a storage interface 64 to access external data, and can also be connected to a network or another computer system (not shown) via a network interface 66. Further details are omitted here.

[0147] In this embodiment, by storing data instructions in a memory and then processing the instructions by a processor, the occurrence of catastrophic mechanical failures of the engine can be reduced.

[0148] Figure 7 This is a block diagram of some embodiments of the range extender anti-reverse control system disclosed herein. The range extender anti-reverse control system includes a range extender anti-reverse control device 71, a vehicle controller 72, an engine controller 73, and a generator controller 74.

[0149] The range extender anti-reverse control device 71 is, for example, a range extender controller; the vehicle controller 72 is configured to send a start command or a power generation request to the range extender anti-reverse control device; the engine controller 73 is configured to control the engine 75 according to the command of the range extender anti-reverse control device; and the generator controller 74 is configured to control the generator 76 according to the command of the range extender anti-reverse control device.

[0150] The engine 75 is electrically connected to the engine controller 73, the generator 76 is electrically connected to the generator controller 74, and the range extender anti-reverse control device 71 is connected to the engine controller 73, the generator controller 74, and the vehicle controller 72 via the CAN bus.

[0151] The range extender anti-reverse control system disclosed herein can reduce the occurrence of catastrophic mechanical failures of the engine.

[0152] In other embodiments of this disclosure, a vehicle is also protected that includes the range extender anti-reverse control system or range extender anti-reverse control device described in the above embodiments.

[0153] The vehicle is, for example, a range-extended vehicle.

[0154] In other embodiments, a computer-readable storage medium stores computer program instructions that, when executed by a processor, implement the steps of the methods described above. Those skilled in the art will understand that embodiments of this disclosure can be provided as methods, apparatus, or computer program products. Therefore, this disclosure can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this disclosure can take the form of a computer program product embodied on one or more computer-usable non-transitory storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0155] In some embodiments, a computer program product is protected, comprising a computer program or instructions that, when executed by a processor, implement the methods described above. The computer program product includes a computer program carried on a computer-readable medium, the computer program containing program code for performing the methods shown in the flowchart. In such embodiments, the computer program can be downloaded and installed from a network via a communication device, or installed from a storage device, or installed from ROM. When the computer program is executed by a CPU, it performs the functions defined in the methods of embodiments of this disclosure.

[0156] This disclosure is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this disclosure. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create a machine for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0157] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0158] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0159] This concludes the detailed description of the present disclosure. To avoid obscuring the concept of the disclosure, some details known in the art have not been described. Those skilled in the art will fully understand how to implement the technical solutions disclosed herein based on the above description.

[0160] The methods and apparatus of this disclosure may be implemented in many ways. For example, they may be implemented by software, hardware, firmware, or any combination of software, hardware, and firmware. The above-described order of steps for the methods is for illustrative purposes only, and the steps of the methods of this disclosure are not limited to the order specifically described above unless otherwise specifically stated. Furthermore, in some embodiments, this disclosure may also be implemented as a program recorded on a recording medium, the program including machine-readable instructions for implementing the methods according to this disclosure. Thus, this disclosure also covers recording media storing programs for performing the methods according to this disclosure.

[0161] While specific embodiments of this disclosure have been described in detail by way of example, those skilled in the art should understand that the examples are for illustrative purposes only and not intended to limit the scope of this disclosure. Those skilled in the art should understand that modifications can be made to the above embodiments without departing from the scope and spirit of this disclosure. The scope of this disclosure is defined by the appended claims.

Claims

1. A method for preventing reverse rotation of a range extender, comprising: Receive the power generation request sent by the vehicle controller; Based on the power generation request, determine the speed command and torque command; The speed command is sent to the engine controller to control the engine speed, and the smaller value between the torque in the torque command and the engine external characteristic torque corresponding to the speed in the speed command is sent to the generator controller to control the generator torque. Based on the load percentage of the engine at the current speed fed back by the engine controller, the generator is subjected to torque limiting control. In response to the load percentage of the engine at the current speed being greater than the allowable load percentage calibration value at the current speed, a torque control command is sent to the generator controller to limit the load percentage of the engine at the current speed to less than or equal to the allowable load percentage calibration value.

2. The range extender anti-reverse control method according to claim 1, wherein, The torque limiting control of the generator based on the load percentage at the current engine speed fed back by the engine controller further includes: The torque of the generator is reset to zero when the load percentage at the current engine speed is limited to a duration less than or equal to the allowable load percentage calibration value and greater than or equal to a time threshold.

3. The range extender anti-reverse control method according to claim 1 further includes: An overload flag is established in response to the fact that the load percentage at the current engine speed is greater than the allowable load percentage calibration value at the current engine speed.

4. The range extender anti-reverse control method according to claim 1, wherein, Based on the load percentage at the current engine speed fed back by the engine controller, torque limiting control of the generator includes: In response to the fact that the load percentage at the current engine speed is less than or equal to the allowable load percentage calibration value at the current engine speed, the first speed change rate of the generator and the second speed change rate of the engine are calculated; In response to at least one of the first speed change rate and the second speed change rate being greater than the maximum speed change rate calibrated value for multiple consecutive cycles, the torque of the generator is reset to zero.

5. The range extender anti-reverse control method according to claim 4, wherein, The torque limiting control of the generator based on the load percentage at the current engine speed fed back by the engine controller further includes: Calculate the first difference between the speed in the speed command and the speed of the generator, and the second difference between the speed in the speed command and the speed of the engine; In response to at least one of the first difference and the second difference being greater than the maximum speed difference calibration value for a consecutive multiple cycles, the torque of the generator is reset to zero.

6. The range extender anti-reverse control method according to claim 5 further includes: In response to at least one of the first speed change rate and the second speed change rate being greater than the maximum speed change rate calibration value for multiple consecutive cycles, or in response to at least one of the first difference and the second difference being greater than the maximum speed difference calibration value for multiple consecutive cycles, a speed runaway flag is established.

7. The range extender anti-reverse control method according to any one of claims 1 to 6 further includes: Receive the start command sent by the vehicle controller; Send starting torque to the generator controller; In response to the engine's successful start count being 0, during the engine start-up process, a third difference between the generator's rotational speed and the engine's rotational speed is calculated. In response to the third difference being greater than the speed difference calibration value, or the generator speed being less than the speed threshold, the torque of the generator is reset to zero.

8. The range extender anti-reverse control method according to claim 7 further includes: In response to the third difference being greater than the speed difference calibration value, or the generator speed being less than the speed threshold, a reversal flag is established.

9. The range extender anti-reverse control method according to claim 7 further includes: In response to the third difference being less than or equal to the speed difference calibration value, and the engine speed and the generator speed being within the idle speed range, the number of successful starts is incremented by 1; or, In response to the engine having a successful start count greater than 0, and the engine speed and the generator speed being within the idle range, the successful start count is incremented by 1.

10. The range extender anti-reverse control method according to claim 7, further comprising: In response to the engine's successful start count being 0, a ramp torque is sent to the generator controller according to the first torque ramp control mode; In response to the engine's successful start count being greater than 0, a ramp torque is sent to the generator controller according to the second torque ramp control mode, wherein... The first torque ramp control mode includes a first time when the generator torque rises from 0 to a specified torque, a second time when the generator torque rises from the specified torque to a target torque, and a third time when the generator torque rises from 0 to the target torque. The sum of the first time and the second time is greater than the third time.

11. The range extender anti-reverse control method according to claim 7, further comprising: Based on the signals monitored by the crankshaft position sensor and camshaft position sensor of the engine, it is determined whether the engine is reversing.

12. A range extender anti-reverse control device, comprising: The processing module is configured to receive a power generation request sent by the vehicle controller, and determine the speed command and torque command based on the power generation request; The control module is configured to send the speed command to the engine controller to control the engine speed, and to send the smaller of the torque in the torque command and the engine external characteristic torque corresponding to the speed in the speed command to the generator controller to control the generator torque. Based on the load percentage of the engine at the current speed fed back by the engine controller, the module performs torque limiting control on the generator. Specifically, in response to the load percentage of the engine at the current speed being greater than the allowable load percentage calibration value at the current speed, the module sends a torque control command to the generator controller to limit the load percentage of the engine at the current speed to less than or equal to the allowable load percentage calibration value.

13. A range extender anti-reverse control device, comprising: Memory; as well as A processor coupled to the memory, the processor being configured to execute the range extender anti-reverse control method as described in any one of claims 1 to 11 based on instructions stored in the memory.

14. A range extender anti-reverse control system, comprising: The range extender anti-reverse control device as described in claim 12 or 13; The vehicle controller is configured to send a start command or a power generation request to the range extender anti-reverse control device; The engine controller is configured to control the engine according to the instructions of the range extender anti-reverse control device; The generator controller is configured to control the generator according to the instructions of the range extender anti-reverse control device.

15. A vehicle comprising: The range extender anti-reverse control device as described in claim 12 or 13; or The range extender anti-reverse control system as described in claim 14.

16. A computer-readable storage medium having stored thereon computer program instructions that, when executed by a processor, implement the range extender anti-reverse control method as described in any one of claims 1 to 11.

17. A computer program product comprising a computer program that, when executed by a processor, implements the range extender anti-reverse control method according to any one of claims 1 to 11.

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