Range-extended power systems and their control methods, construction machinery

Abstract

This disclosure provides a range-extended power system and its control method, as well as engineering machinery. The range-extended power system includes: an engine, including a housing and a crankshaft disposed within the housing; a range extender motor, including a first housing and a rotor disposed within the first housing, the first housing being connected to one side of the housing; a clutch, disposed within the housing and located between the crankshaft and the range extender motor, used to realize the power connection or disconnection between the crankshaft and the rotor, the clutch including an output shaft for outputting power to the rotor in the power connection state; and an oil pump, installed on the side of the first housing away from the clutch, the oil pump including an input shaft connected to the rotor; wherein the rotation axes of the crankshaft, output shaft, rotor, and input shaft are collinear.

Description

Technical Field

[0001] This disclosure relates to the field of power system technology, and in particular to a range-extended power system and its control method, as well as engineering machinery. Background Technology

[0002] Against the backdrop of the transformation and upgrading of the construction machinery industry, green and low-carbon technologies are becoming the core direction of technological innovation. Range-extended electric vehicles (REEVs), as an innovative power solution, achieve intelligent synergy between electric drive and fuel replenishment through an integrated power generation auxiliary system. This integrated design not only possesses the environmentally friendly characteristics of pure electric drive but also inherits the range advantage of gasoline power, providing a more feasible technical route for the promotion and application of new energy construction machinery.

[0003] The integration of existing range-extended power systems is not high. Although the range extender motor is connected to the engine, the generator and oil pump are mostly separate and independent devices. The oil pump requires a separate drive unit to drive its rotation, which not only increases equipment costs but also occupies a large amount of space, thus restricting the development of range-extended power systems towards high integration. Summary of the Invention

[0004] This disclosure provides a range-extended power system and its control method, as well as engineering machinery, which can improve the integration of the range-extended power system.

[0005] The first aspect of this disclosure provides a range-extended powertrain system, comprising:

[0006] An engine, including a housing and a crankshaft housed within the housing;

[0007] The range extender motor includes a first housing and a rotor disposed within the first housing, the first housing being connected to one side of the housing;

[0008] The clutch, located within the housing and between the crankshaft and the range extender motor, is used to connect or disconnect power between the crankshaft and the rotor. The clutch includes an output shaft for outputting power to the rotor when power is connected; and

[0009] An oil pump is installed on the side of the first housing away from the clutch. The oil pump includes an input shaft connected to a rotor.

[0010] The rotation axes of the crankshaft, output shaft, rotor, and input shaft are all collinear.

[0011] In some embodiments, the housing is provided with a first partition, which divides the housing into a first cavity and a second cavity.

[0012] At least a portion of the crankshaft is located in the first cavity, the clutch is located in the second cavity, and the crankshaft passes through the first partition and is connected to the clutch.

[0013] In some embodiments, the clutch further includes:

[0014] The flywheel is sleeved on the outside of the output shaft and fixedly installed on the output end of the crankshaft. The output end of the crankshaft is rotatably installed on the first end of the output shaft through the first bearing.

[0015] The pressure plate is fitted outside the output shaft and is located on the side of the flywheel away from the crankshaft;

[0016] The clutch plate is located between the flywheel and the pressure plate; and

[0017] The release bearing, sleeved outside the output shaft and located in the area of ​​the pressure plate away from the flywheel, is configured to drive the pressure plate to move along the axis of rotation so as to contact and separate from the flywheel. In the contact state, the flywheel and the pressure plate are poweredly connected, and in the separated state, the flywheel and the pressure plate are disconnected from the power connection.

[0018] In some embodiments, the rotor end face away from the clutch has a groove, and the range extender motor further includes:

[0019] The intermediate shaft includes a first shaft segment and a second shaft segment that are coaxially connected. The first shaft segment is embedded in a groove, and the end of the second shaft segment away from the clutch is provided with a mounting hole. Fasteners are inserted into the mounting hole to connect the intermediate shaft and the rotor.

[0020] The mounting hole has an internal spline near the opening, and the input shaft has an external spline. The input shaft and the intermediate shaft are connected by the external spline and the internal spline.

[0021] In some embodiments, the range extender motor further includes:

[0022] A flexible coupling is installed between the rotor and the intermediate shaft.

[0023] In some embodiments, the first housing includes:

[0024] The first main housing is connected to the housing and opens towards the end of the oil pump; and

[0025] The first end cap is fastened to the open end of the first main shell. The inner end of the first end cap is provided with a bearing hole, and a second bearing is provided in the bearing hole. The intermediate shaft is supported on the first end cap by the second bearing.

[0026] In some embodiments, the range extender motor further includes a connector mounted on the outside of the first end cover, and the oil pump includes a second housing including a second end cover, the second end cover being detachably mounted on the connector.

[0027] In some embodiments, the range extender motor further includes a stator and a speed detection component, the stator being coaxially arranged with the rotor and configured to detect the speed of the rotor relative to the stator.

[0028] In some embodiments, the range-extended power system further includes an energy storage component for storing electrical energy, and the range extender motor further includes a stator having windings;

[0029] The range extender motor has a motor mode and a generator mode. In motor mode, current is supplied to the windings to control the rotor speed; in generator mode, the current output from the windings is converted into DC power and enters the energy storage component.

[0030] In some embodiments, the range-extended powertrain further includes a controller, wherein the range extender motor has a motor mode and a generator mode, and the controller includes:

[0031] The engine control module is configured to control and monitor the engine's start-up, shutdown, and operating speed;

[0032] The clutch control module is configured to control and monitor the engagement and disengagement of the clutch; and

[0033] The motor control module is configured to control the range extender motor to switch between motor mode and generator mode.

[0034] A second aspect of this disclosure provides an engineering machine including the range-extended power system of the above embodiments.

[0035] A third aspect of this disclosure provides a control method for a range-extended power system based on the above embodiments. The range-extended power system includes an energy storage component for storing electrical energy, and the control method includes:

[0036] Obtain the electrical status of the energy storage components;

[0037] The operating states of the engine, clutch, and range extender motor are controlled according to the battery status and / or the engine's operating requirements, so that the range extender power system is in different operating modes.

[0038] In some embodiments, the step of controlling the operating requirements of the engine, clutch, and range extender motor according to the battery status and / or engine operating status to put the range-extended power system in different operating modes includes:

[0039] When the energy storage component's charge is lower than the preset charge, the range-extended power system is put into the first operating mode.

[0040] In the first operating mode, the engine is started, the clutch is in a power connection state, and the range extender motor is in generator mode, so that the crankshaft drives the rotor to rotate through the clutch, storing the output electrical energy of the range extender motor into the energy storage component. At the same time, the rotor drives the input shaft to rotate and drive the oil pump to work.

[0041] In some embodiments, the step of controlling the operating states of the engine, clutch, and range extender motor according to the battery status and / or engine operating requirements to place the range-extended power system in different operating modes includes:

[0042] When the energy storage device has electricity and the engine needs to work, the range-extended power system is put into the second operating mode.

[0043] In the second operating mode, the engine is started, the clutch is in a power-connected state, and the range extender motor is in electric motor mode, so that the power of the engine and the range extender motor are jointly transmitted to the input shaft, thereby driving the oil pump to work.

[0044] In some embodiments, the step of controlling the operating states of the engine, clutch, and range extender motor according to the battery status and / or engine operating requirements to place the range-extended power system in different operating modes includes:

[0045] When the energy storage component has a charge level not lower than the preset charge level and the engine does not need to work, the range-extended power system is put into the third working mode.

[0046] In the third operating mode, the engine stops, the clutch is in a power-disconnected state, and the range extender motor is in electric motor mode, so that the electrical energy in the energy storage component is supplied to the range extender motor, which drives the input shaft to rotate and drive the oil pump to work.

[0047] The range-extended power system of this disclosure integrates the engine, clutch, range extender motor and oil pump into a single component, which improves the integration and makes the structure more compact, reducing the space occupied by the power system in the vehicle. The oil pump can be driven by the engine or range extender motor, eliminating the need to install a motor and corresponding accessories for driving the oil pump on the vehicle. This effectively reduces material and maintenance costs, reduces the overall weight of the power system, and improves the ease of installation.

[0048] Moreover, the power output from the engine is directly transmitted to the rotor of the range extender motor and the input shaft of the oil pump via the clutch, without the need for other additional transmission mechanisms. This improves the energy transmission efficiency and conversion rate, enhances the operational reliability of components, and reduces the difficulty of processing and assembly.

[0049] Furthermore, by setting a clutch to control the on / off state of power transmission between the engine and the range extender motor, it is possible to achieve both a working mode where the engine powers the oil pump and a working mode where the range extender motor drives the oil pump, in which case the power transmission does not affect the engine. Thus, the power system has different operating modes, allowing for flexible selection of the appropriate power source to drive the oil pump according to requirements. Attached Figure Description

[0050] To more clearly illustrate the technical solutions in the embodiments of this disclosure or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0051] Figure 1 This is a schematic diagram of the structure of some embodiments of the range-extended power system disclosed herein.

[0052] Figure 2 This is a cross-sectional view of some embodiments of the range-extended power system disclosed herein.

[0053] Figure 3 for Figure 2 Enlarged view of the intermediate shaft connection area.

[0054] Figure 4 This is a schematic diagram of the shaft system connection in the range-extended power system disclosed herein.

[0055] Figure 5 This is a cross-sectional view of the rotor, intermediate shaft, and first end cover of the range extender motor.

[0056] Figure 6 This is a schematic diagram of the stator structure in the range extender motor.

[0057] Figure 7 This is a schematic diagram illustrating the working principle of some embodiments of the range-extended power system disclosed herein.

[0058] Explanation of reference numerals in the attached figures

[0059] 1. Engine; 11. Housing; 12. Crankshaft; 13. First partition; 14. Second partition;

[0060] 2. Range extender motor; 21. First housing; 211. First main housing; 212. First end cover; 213. Bearing hole; 22. Rotor; 221. Disc portion; 222. Cylindrical portion; 223. Protrusion; 224. Groove; 225. Fixing hole; 23. Intermediate shaft; 231. First shaft section; 232. Second shaft section; 233. Mounting hole; 234. Internal spline;

[0061] 24. Second bearing; 25. Connecting seat; 26. Stator; 261. Winding; 262. Three-phase power supply line; 27. Speed ​​detection component; 271. Resolver stator; 272. Resolver rotor; 28. Fastener;

[0062] 3. Clutch; 31. Output shaft; 32. Flywheel disc; 33. Pressure plate; 34. Clutch disc; 35. First bearing; 36. Clutch disc;

[0063] 4. Oil pump; 41. Input shaft; 411. External spline; 42. Second housing; 421. Second end cover; 422. Second main housing;

[0064] 5. Controller; 51. Engine control module; 52. Clutch control module; 53. Motor control module;

[0065] 6. Energy storage components. Detailed Implementation

[0066] The embodiments of this disclosure will be further described in detail below with reference to the accompanying drawings and examples. The following detailed description of the embodiments and the accompanying drawings are used to illustrate the principles of this disclosure by way of example, but should not be used to limit the scope of this disclosure, that is, this disclosure is not limited to the described embodiments.

[0067] In the description of embodiments of this disclosure, the term "multiple" refers to two or more (including two), and similarly, "multiple groups" refers to two or more (including two).

[0068] This disclosure uses terms such as "upper," "lower," "top," "bottom," "front," "back," "inner," and "outer" to indicate orientation or positional relationships. This is only for the convenience of describing this disclosure and is not intended to indicate or imply that the device referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation on the scope of protection of this disclosure.

[0069] Furthermore, the terms "first," "second," and "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. "Vertical" does not mean strictly vertical, but rather within the permissible range of error. "Parallel" does not mean strictly parallel, but rather within the permissible range of error. The directional terms appearing in the following description refer to the directions shown in the figures and are not intended to limit the specific structure of this disclosure.

[0070] In the description of this disclosure, it should also be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this disclosure depending on the specific circumstances.

[0071] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least some of the embodiments disclosed herein. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0072] like Figures 1 to 7 As shown, in some embodiments, the range-extended powertrain of this disclosure includes:

[0073] Engine 1 includes a housing 11 and a crankshaft 12 disposed within the housing 11, the crankshaft 12 having a rotation axis;

[0074] The range extender motor 2 includes a first housing 21 and a rotor 22 disposed within the first housing 21. The first housing 21 is connected to one side of the housing 11 along the rotation axis.

[0075] Clutch 3, located within housing 11 and positioned along the rotation axis between crankshaft 12 and range extender motor 2, is used to connect or disconnect power between crankshaft 12 and rotor 22. Clutch 3 includes output shaft 31, which outputs power to rotor 22 when in the power-connected state; and

[0076] Oil pump 4 is mounted along the rotation axis on the side of the first housing 21 away from the clutch 3. Oil pump 4 includes an input shaft 41, which is connected to the rotor 22. Oil pump 4 is used to provide lubricating oil to the power system.

[0077] The rotation axes of crankshaft 12, output shaft 31, rotor 22 and input shaft 41 are collinear.

[0078] Specifically, such as Figure 1 and Figure 2 As shown, the housing can be a cylindrical structure. The input end of the crankshaft 12 is connected to the piston of the engine 1, and the output end of the crankshaft 12 can be connected to the output shaft 31 of the clutch 3 in a power-on or disengaged manner. Thus, the crankshaft 12 of the engine 1, the output shaft 31 of the clutch 3, the rotor 22 of the range extender motor 2, and the input shaft 41 of the oil pump 4 are connected sequentially along the axis of rotation. When the clutch 3 is in the power-on state, the power of the engine 1 is transmitted to the input shaft 41 of the oil pump 4 sequentially through the crankshaft 12, the output shaft 31, and the rotor 22. When the clutch 3 is in the power-disengaged state, the power transmission path from the engine 1 to the oil pump 4 is cut off, and the input shaft 41 can be driven to rotate by the range extender motor 2 to make the oil pump 4 work.

[0079] The range-extended power system of this embodiment integrates the engine 1, clutch 3, range extender motor 2, and oil pump 4 into a single component, which improves the integration of the power system, making the structure more compact and reducing the space occupied by the power system in the vehicle. The oil pump 4 can be driven by the engine 1 or the range extender motor 2, eliminating the need to install a motor and its corresponding accessories for driving the oil pump on the vehicle. This effectively reduces material and maintenance costs, reduces the overall weight of the power system, and improves the ease of installation.

[0080] Moreover, the power output from engine 1 is directly transmitted to the rotor 22 of range extender motor 2 and the input shaft 41 of oil pump 4 via clutch 3, without the need for other additional transmission mechanisms. This improves the energy transmission efficiency and conversion rate, enhances the operational reliability of components, and reduces the difficulty of processing and assembly.

[0081] Furthermore, by controlling the power transmission between engine 1 and range extender motor 2 via clutch 3, the system can operate in two modes: when clutch 3 is engaged, the engine 1 powers the oil pump 4; when clutch 3 is disengaged, the range extender motor 2 drives the oil pump 4. In either mode, the power transmission does not affect engine 1. Thus, the power system offers different operating modes, allowing for flexible selection of the appropriate power source to drive the oil pump 4 as needed.

[0082] In some embodiments, the housing 11 is provided with a first partition 13, which divides the housing 11 into a first cavity A and a second cavity B; wherein at least a portion of the crankshaft 12 is disposed in the first cavity A, the clutch 3 is disposed in the second cavity B, and the crankshaft 12 passes through the first partition 13 and is connected to the clutch 3.

[0083] Specifically, such as Figure 2 As shown, the first partition 13 is arranged perpendicular to the axis of rotation, and the first partition 13 has a hole through which the output end of the crankshaft 12 passes and is connected to the clutch 3.

[0084] In this embodiment, a clutch 3 is installed inside the housing 11, and a first partition 13 is provided to divide it into two independent areas. The crankshaft 12 and the clutch 3 can operate in different areas, avoiding mutual interference during operation and improving the reliability of the power system. Moreover, the engine 1 and the clutch 3 share the housing 11, which simplifies the structure and provides more stable frame support for the components inside the engine 1 and the clutch 3. The first partition 13 can provide support for the output end of the crankshaft 12, making the rotation of the crankshaft 12 more stable, so as to transmit power more stably to the rear.

[0085] In some embodiments, such as Figure 2 and Figure 4 As shown, clutch 3 also includes:

[0086] The flywheel 32 is sleeved on the outside of the output shaft 31 and fixedly installed on the output end of the crankshaft 12. The output end of the crankshaft 12 is rotatably installed on the first end of the output shaft 31 through the first bearing 35.

[0087] The pressure plate 33 is sleeved outside the output shaft 31 and is located on the side of the flywheel 32 away from the crankshaft 12;

[0088] Clutch plate 34 is located between flywheel 32 and pressure plate 33; and

[0089] The release bearing 36 is sleeved on the output shaft 31 and located in the area of ​​the pressure plate 33 away from the flywheel 32. It is configured to drive the pressure plate 33 to move along the rotation axis to achieve contact and separation with the flywheel 32. In the contact state, the flywheel 32 and the pressure plate 33 are poweredly connected. In the separated state, the flywheel 32 and the pressure plate 33 are disengaged from the power connection.

[0090] The crankshaft 12 has a bearing hole on its output end face. The first bearing 35 is installed in the bearing hole. The flywheel 32 is sleeved on the outside of the crankshaft 12 and connected. In order to achieve a stable connection, the outer wall of the output end of the crankshaft 12 is provided with a connecting plate with an increased diameter. The flywheel 32 is further connected to the connecting plate through its end face on the basis of being sleeved on the outside of the output end of the crankshaft 12.

[0091] The first end of the output shaft 31 of the clutch 3 is connected to the inner ring of the first bearing 35, that is, the first bearing 35 is located between the output end of the crankshaft 12 and the first end of the output shaft 31. The clutch disc 34 and the pressure plate 33 are both sleeved on the output shaft 31, and there is a gap between the pressure plate 33 and the output shaft 31. Figure 2 As shown, a second partition 14 can also be provided inside the housing 11. The second partition 14 is spaced apart from the first partition 13 along the axis of rotation and is located on the side of the first partition 13 away from the crankshaft 12. The area between the first partition 13 and the second partition 14 is used to house the clutch 3. The second partition 14 has a hole through which the output shaft 31 can pass and connect to the rotor 22 of the range extender motor 2. To achieve a reliable connection, the output shaft 31 can be T-shaped, with the T-shaped shaft portion passing through the hole and the T-shaped disc portion located on the side of the second partition 14 away from the first partition 13. One end of the housing 11 with an open opening can extend beyond the second partition 14, allowing for easy connection to the first housing 21 of the range extender motor 2.

[0092] The clutch plate 34 can be a friction plate, and the clutch plate 34 can be set to one or more plates.

[0093] The pressure plate 33 includes a pressing part and a sleeve part. The sleeve part is connected to the side of the pressing part away from the flywheel 32. The pressing part is used to contact the flywheel 32. The clutch plate 34 is disposed between the flywheel 32 and the pressing part.

[0094] Specifically, the release bearing 36 is mounted on the output shaft 31 and can reciprocate on the output shaft 31. The rotational motion of the output shaft 31 is independent of the release bearing 36. When the clutch 3 needs to engage to transmit torque, the release bearing 36 moves towards the pressure plate 33, causing the pressure plate 33 to move as well. When the pressure plate 33 contacts the friction plate 34, it drives the friction plate 34 to continue moving. Since there is an initial gap between the friction plate 34 and the flywheel 32, and the friction plate 34 is splined to the shaft 31, the spline allows the friction plate 34 to reciprocate on the shaft 31, simultaneously transmitting torque between the friction plate 34 and the shaft 31. This continues until the pressure plate 33 and the friction plate 34 contact the flywheel 32. At this point, the torque transmission path is: crankshaft 12—flywheel 32—friction plate 34—spline—output shaft 31.

[0095] Furthermore, such as Figure 4 As shown, a spring and connecting rod mechanism is provided between the pressure plate 33 and the release bearing 36 to reset the release bearing 36 and the pressure plate 33. In the reset state, the clutch 3 is disengaged.

[0096] The clutch 3 in this embodiment has a simple structure, is easy to control, and can reliably realize the power connection and disengagement of the clutch 3.

[0097] In some embodiments, such as Figures 2 to 5 The rotor 22 has a groove 224 on its end face away from the clutch 3, and the range extender motor 2 also includes:

[0098] The intermediate shaft 23 includes a first shaft segment 231 and a second shaft segment 232 coaxially connected. The first shaft segment 231 is embedded in a groove 224. The end of the second shaft segment 232 away from the clutch 3 is provided with a mounting hole 233. Fasteners 28 pass through the mounting hole 233 to connect the intermediate shaft 23 and the rotor 22.

[0099] The mounting hole 233 has an internal spline 234 near the opening, and the input shaft 41 has an external spline 411. The input shaft 41 and the intermediate shaft 23 are connected by the cooperation of the external spline 411 and the internal spline 234.

[0100] Specifically, such as Figure 4 As shown, the rotor 22 includes a disc portion 221 and a cylindrical portion 222. The diameter of the cylindrical portion 222 is smaller than the diameter of the disc portion 221. The disc portion 221 has a protrusion 223 in the central region of the side away from the clutch 3. The end face of the protrusion 223 away from the clutch 3 has a groove 224. The bottom surface of the groove 224 has a through fixing hole 225. The disc portion 221 has a recess in the central region of the side near the clutch 3.

[0101] The second shaft segment 232 has a mounting hole 233 at its end away from the clutch 3. The bottom of the mounting hole 233 has a through hole that passes through the first shaft segment 231. A fastener 28 enters through the mounting hole 233, passes through the through hole and the mounting hole 233 in sequence, and extends into a recessed portion. A nut can be used to secure the fastener within the recessed portion, thereby connecting the intermediate shaft 23 and the rotor 22. The disc portion 221 of the rotor 22 is connected to the disc portion of the output shaft 31.

[0102] like Figure 3 and Figure 5 As shown, the mounting hole 233 has an internal spline 234 near the opening, and the input shaft 41 has an external spline 411. The input shaft 41 and the intermediate shaft 23 are connected by the cooperation of the external spline 411 and the internal spline 234, so that power can be transmitted from the intermediate shaft 23 to the input shaft 41.

[0103] Optionally, the crankshaft 12 and flywheel 32 can be machined as a single unit; the output shaft 31 and rotor 22 can be machined as a single unit; the rotor 22 and intermediate shaft 23 can also be fixedly connected in other ways, or machined as a single unit.

[0104] This embodiment, by setting an intermediate shaft 23, can transmit the power of the rotor 22 to the input shaft 41 of the oil pump 4, which can shorten the axial length of the rotor 22 and reduce the machining difficulty of the rotor 22. For example, in the structure of the rotor 22 including a disc portion 221 and a cylindrical portion 222, since the diameter of the disc portion 221 is large, by shortening the length of the cylindrical portion 222, materials are saved during machining and machining is easier. Furthermore, the first end of the intermediate shaft 23 is connected to the rotor 22 by a fastener 28, and the intermediate shaft 23 is fixed to the rotor 22 in advance. The second end of the intermediate shaft 23 is connected to the input shaft 41 by a spline, which facilitates assembly and can transmit power stably and reliably.

[0105] In some embodiments, the range extender motor 2 further includes a flexible coupling disposed between the rotor 22 and the intermediate shaft 23, which can reduce the torsional vibration transmitted from the engine 1 to the input shaft 41 of the oil pump 4 and improve the stability of power transmission.

[0106] In some embodiments, such as Figure 2 and Figure 5 As shown, the first housing 21 includes:

[0107] The first main housing 211 is connected to the housing 11, and the first main housing 211 is open towards the end of the oil pump 4; and

[0108] The first end cover 212 is fastened to the open end of the first main shell 211. The inner end of the first end cover 212 is provided with a bearing hole 213, and a second bearing 24 is provided in the bearing hole 213. The intermediate shaft 23 is supported on the first end cover 212 through the second bearing 24.

[0109] Among them, such as Figure 3 As shown, the inner surface of the first end cap 212 is thickened by a protrusion, and the inner end face of the protrusion is provided with a bearing hole 213, in which the second bearing 24 is disposed. The first housing 21 and the box body 11 can be connected by fasteners or the like.

[0110] This embodiment, by providing a first end cover 212, facilitates the installation of internal structural components of the range extender motor 2 and also provides a good seal, preventing oil leaking from the oil pump 4 from entering the range extender motor 2 and reducing the risk of operation risks. Furthermore, the first end cover 212 serves as a bearing housing, allowing the installation of a second bearing 24 to support the intermediate shaft 23. This effectively improves the coaxiality of the connection between the intermediate shaft 23 and the rotor 22, increases the dynamic stiffness of the intermediate shaft 23, and suppresses vibration noise generated by high-speed operation of the shaft system, thereby improving the stability of power transmission.

[0111] The crankshaft 12 of engine 1, the output shaft 31 of clutch 3, the rotor 22 of range extender motor 2 and the input shaft 41 of oil pump 4 are collinear. The output shaft 31 is supported by the first bearing 35 and the intermediate shaft 23 is supported by the second bearing 24, which can improve the installation rigidity of the shaft system.

[0112] In some embodiments, such as Figure 2 As shown, the range extender motor 2 also includes a connecting seat 25, which is installed on the outside of the first end cover 212. The oil pump 4 includes a second housing 42, which includes a second end cover 421, which is detachably installed on the connecting seat 25.

[0113] The connecting seat 25 is located on the outside of the second end cover 421 and can be connected by bolts or other fasteners. The second end cover 421 of the second housing 42 of the oil pump 4 can be connected to the second end cover 421 by bolts or other fasteners. This structure, by additionally setting the connecting seat 25 on the outside of the second end cover 421, allows the connecting seat 25 to match the mounting interface of the second housing 42 of the oil pump 4, improves installation accuracy, reduces the structural impact on the large area of ​​the first end cover 212 of the range extender motor 2, and makes the disassembly and assembly of the oil pump 4 more convenient.

[0114] In some embodiments, such as Figure 2 As shown, the range extender motor 2 also includes a stator 26 and a speed detection component 27. The stator 26 is coaxially arranged with the rotor 22 and is configured to detect the speed of the rotor 22 relative to the stator 26.

[0115] Specifically, such as Figure 3As shown, the speed detection component 27 includes a resolver stator 271 and a resolver rotor 272. The resolver stator 271 can be installed in the opening on the side of the first end cover 212 where the connecting seat 25 is located. The resolver rotor 272 is installed on the second end of the intermediate shaft 23 to rotate with the intermediate shaft 23. The resolver rotor 272 is directly opposite the resolver stator 271.

[0116] This embodiment, by setting a speed detection component 27, can detect the operating speed of the range extender motor 2, thereby facilitating feedback control of the rotor 22 speed and improving the speed control accuracy of the range extender motor 2 during operation.

[0117] In some embodiments, such as Figure 5 and Figure 6 As shown, the range-extended power system also includes an energy storage component 6 for storing electrical energy, and the range extender motor 2 also includes a stator 26, which includes a winding 261, for example, the winding 261 is a copper wire winding, and the lead-out end of the winding 261 is provided with a three-phase power line 262.

[0118] The range extender motor 2 has a motor mode and a generator mode. In motor mode, the winding 261 is supplied with current to control the running speed of the rotor 22. In generator mode, the current output from the winding 261 is converted into DC power and enters the energy storage unit 6.

[0119] In this embodiment, the range extender motor 2 has both motor mode and generator mode. By controlling parameters such as the direction and frequency of the current in the three-phase power line 262, the range extender motor 2 can switch between motor mode and generator mode. In conjunction with the clutch 3, it can operate in a mode where the engine 1 powers the oil pump 4 when the clutch 3 is engaged, and in a mode where the range extender motor 2 drives the oil pump 4 when the clutch 3 is disengaged. In this mode, power transmission does not affect the engine 1. Therefore, the power system has different operating modes, allowing for flexible selection of a suitable power source to drive the oil pump 4 according to requirements.

[0120] In some embodiments, the range-extended power system further includes a controller 5, the range extender motor 2 having a motor mode and a generator mode, and the controller 5 includes:

[0121] Engine control module 51 is configured to control and monitor the start-up, shutdown, and operating speed of engine 1;

[0122] Clutch control module 52 is configured to control and monitor the on / off state of clutch 3; and

[0123] The motor control module 53 is configured to control the range extender motor 2 to switch between motor mode and generator mode.

[0124] In generator mode, the power from engine 1 is transmitted to the rotor 22 of range extender motor 2 via a clutch, and the current output from the three-phase power line 262 is converted into direct current and enters the energy storage unit 6. In motor mode, external three-phase alternating current is input to the three-phase power line 262, and the operating speed of rotor 22 is controlled by controlling the frequency and magnitude of the input current.

[0125] In this embodiment, the controller 5 is designed as multiple different modules to control the engine 1, clutch 3 and range extender motor 2 respectively, which can increase control reliability and make the control of each component in the power system relatively independent.

[0126] Secondly, this disclosure provides a type of construction machinery, which in some embodiments includes the range-extended power system described above. For example, the construction machinery is a new energy construction machinery.

[0127] This type of range-extended power system has a high degree of integration, which can reduce the space occupied by the power system in the whole vehicle. The oil pump 4 can be driven by the engine 1 or the range extender motor 2, eliminating the need to install a motor and its corresponding accessories for driving the oil pump on the whole vehicle. This effectively reduces material and maintenance costs, reduces the overall weight of the vehicle, and improves the ease of installation.

[0128] Moreover, the power output by engine 1 is directly transmitted to the rotor 22 of range extender motor 2 and the input shaft 41 of oil pump 4 via clutch 3, without the need for other additional transmission mechanisms. This improves the energy transmission efficiency and conversion rate, as well as the operational reliability of components, thereby enhancing the reliability of the engineering machinery.

[0129] Furthermore, by controlling the power transmission between engine 1 and range extender motor 2 via clutch 3, the system can operate in two modes: when clutch 3 is engaged, the engine 1 powers the oil pump 4; when clutch 3 is disengaged, the range extender motor 2 drives the oil pump 4. In either mode, the power transmission does not affect engine 1. Thus, the power system offers different operating modes, allowing for flexible selection of the appropriate power source to drive the oil pump 4 according to the needs of the construction machinery.

[0130] Finally, this disclosure provides a control method for a range-extended power system based on the above embodiments. In some embodiments, the range-extended power system includes an energy storage component 6 for storing electrical energy, and the control method includes:

[0131] Obtain the power status of energy storage component 6;

[0132] Based on the battery status and / or the operating requirements of engine 1, control the operating status of engine 1, clutch 3 and range extender motor 2 to put the range extender power system in different operating modes.

[0133] This embodiment can flexibly select a suitable operating mode for the power system based on the power status of the energy storage component 6 and / or whether the engine 1 needs to work. By setting up the energy storage component 6, the energy storage component 6 can be charged and discharged during the operation of the power system, which can enable the engine fuel drive and electric drive to work together, thus having both the range advantage of fuel power and the environmental protection characteristics of electric drive.

[0134] In some embodiments, such as Figure 7 As shown, the steps for controlling the operation of engine 1, clutch 3, and range extender motor 2 according to the battery status and / or the operating status of engine 1, so as to put the range extender power system in different operating modes, include:

[0135] When the energy storage component 6 has a lower charge than the preset charge, the range-extended power system is put into the first working mode.

[0136] In the first working mode, the engine 1 is started, the clutch 3 is in the power connection state, and the range extender motor 2 is in the generator mode, so that the crankshaft 12 drives the rotor 22 to rotate through the clutch 3, and stores the output electrical energy of the range extender motor 2 into the energy storage component 6. At the same time, the rotor 22 drives the input shaft 41 to rotate and drive the oil pump 4 to work.

[0137] This embodiment enables the clutch control module 52 to engage the clutch 3 when the energy storage component 6 is in a low-battery mode, the engine control module 51 to start the engine 1, the crankshaft 12 to drive the rotor 22 to rotate via the clutch 3, and the motor control module 53 to control the range extender motor 2 to enter generator mode, storing the output electrical energy of the range extender motor 2 in the energy storage component 6. Simultaneously, the rotor 22 drives the input shaft 41 of the oil pump 4 to rotate via the intermediate shaft 23, thereby driving the oil pump 4 to operate. This operating mode, when the engine 1 is running, provides power to the oil pump 4 and replenishes the low-battery energy storage component 6, so that when the engine 1 is not running, the energy storage component 6 can provide electrical energy to the range extender motor 2 to drive the oil pump 4.

[0138] In this direct-drive power connection method where the engine 1 directly drives the oil pump 4, the power output of the engine 1 is used to drive the rotor 22 of the range extender motor 2, while also directly driving the oil pump 4. This reduces power loss during power transmission and improves energy utilization.

[0139] In some embodiments, such as Figure 7 As shown, the steps for controlling the operating states of engine 1, clutch 3, and range extender motor 2 according to the battery status and / or the operating requirements of engine 1, so that the range extender power system is in different operating modes, include:

[0140] When the energy storage component 6 has electrical charge and the engine 1 needs to work, the range-extended power system is put into the second operating mode.

[0141] In the second operating mode, the engine 1 is started, the clutch 3 is in a power connection state, and the range extender motor 2 is in electric motor mode, so that the power of the engine 1 and the range extender motor 2 are jointly transmitted to the input shaft 41, thereby driving the oil pump 4 to work.

[0142] Specifically, the power of engine 1 is transmitted sequentially to input shaft 41 via crankshaft 12, clutch 3, and rotor 22, while the power of range extender motor 2 is transmitted to input shaft 41 via rotor 22.

[0143] This embodiment enables the clutch control module 52 to control the clutch 3 to be in a powered engagement state when the engine 1 needs to operate and the energy storage component 6 has power. The engine control module 51 controls the engine 1 to start, inputting torque to the oil pump 4. The motor control module 53 controls the range extender motor 2 to enter electric motor mode, simultaneously outputting or inputting torque to the oil pump 4. At this time, the engine 1 and the range extender motor 2 jointly transmit power to the input shaft 41 of the oil pump 4. As long as the energy storage component 6 has power, it can enter the second mode without considering the power level, providing greater torque to the oil pump 4 to adapt to heavy-load conditions.

[0144] In some embodiments, the step of controlling the operating states of engine 1, clutch 3, and range extender motor 2 according to the battery status and / or the operating requirements of engine 1, so that the range extender power system is in different operating modes, includes:

[0145] When the energy storage component 6 has a charge level not lower than the preset charge level and the engine 1 does not need to work, the range-extended power system is put into the third working mode.

[0146] In the third working mode, the engine 1 stops working, the clutch 3 is in a power disconnected state, and the range extender motor 2 is in electric motor mode so that the electrical energy in the energy storage component 6 is supplied to the range extender motor 2, which drives the input shaft 41 to rotate through the rotor 22 to drive the oil pump 4 to work.

[0147] In this embodiment, when the energy storage component 6 has a high charge level, the energy storage component 6 controls the range extender motor 2 to enter motor mode, inputting the electrical energy in the energy storage component 6 as current into the three-phase power lines 262 of the winding 261 of the range extender motor 2, thereby driving the rotor 22 to rotate. Simultaneously, the clutch control module 52 controls the clutch 3 to be in a power disengaged state, and the clutch control module 52 controls the engine 1 to stop, thereby disconnecting the power transmission between the crankshaft 12 and the rotor 22. In this mode, the rotor 22 drives the input shaft 41 of the oil pump 4 to rotate via the intermediate shaft 23, thereby driving the oil pump 4 to operate.

[0148] In some embodiments, such as Figure 7 As shown, the range-extended power system simultaneously has a first operating mode, a second operating mode, and a third operating mode, allowing selection of one mode according to requirements. The controller 5 controls the operating status of the engine 1, clutch 3, and range extender motor 2, enabling multiple operating modes using different power sources to drive the oil pump 4, thus solving the problem of a single drive mode in traditional power systems.

[0149] Taking a new energy excavator as an example, the oil pump 4 is an important working device of the excavator. When the working environment is not convenient for replenishing the energy storage component 6, the first working mode can be used; when the excavator encounters extreme heavy-load conditions, such as excavating extremely hard rock, the second working mode can be used; when the excavator's energy storage component 6 has sufficient power and is operating for short distances, the third working mode can be used. Under normal circumstances, these three working modes are used alternately.

[0150] While this disclosure has been described with reference to preferred embodiments, various modifications can be made thereto and components can be replaced with equivalents without departing from the scope of this disclosure. In particular, the technical features mentioned in the various embodiments can be combined in any manner, provided there is no structural conflict. This disclosure is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A range extended powertrain, characterized in that, include: The engine (1) includes a housing (11) and a crankshaft (12) disposed within the housing (11). The range extender motor (2) includes a first housing (21) and a rotor (22) disposed in the first housing (21), the first housing (21) being connected to one side of the housing (11); A clutch (3), disposed within the housing (11) and located between the crankshaft (12) and the range extender motor (2), is used to achieve power connection or disconnection between the crankshaft (12) and the rotor (22). The clutch (3) includes an output shaft (31) for outputting power to the rotor (22) in the power connection state. An oil pump (4) is installed on the side of the first housing (21) away from the clutch (3), the oil pump (4) includes an input shaft (41) connected to the rotor (22); The rotation axes of the crankshaft (12), the output shaft (31), the rotor (22), and the input shaft (41) are collinear. The clutch (3) further includes: a flywheel disc (32), which is sleeved on the output shaft (31) and fixedly installed on the output end of the crankshaft (12), wherein the output end of the crankshaft (12) is rotatably installed on the first end of the output shaft (31) through a first bearing (35); and a pressure plate (33), which is sleeved on the output shaft (31) and located on the side of the flywheel disc (32) away from the crankshaft (12). A clutch plate (34) is disposed between the flywheel disc (32) and the pressure plate (33); and a release bearing (36) is sleeved outside the output shaft (31) and disposed in the area of ​​the pressure plate (33) away from the flywheel disc (32). It is configured to drive the pressure plate (33) to move along the axis of rotation so as to contact and separate from the flywheel disc (32). In the contact state, the flywheel disc (32) is poweredly connected to the pressure plate (33). In the separated state, the flywheel disc (32) is disengaged from the pressure plate (33).

2. The range extended powertrain of claim 1, wherein, The box (11) is provided with a first partition (13), which divides the box (11) into a first cavity (A) and a second cavity (B). At least a portion of the crankshaft (12) is disposed in the first cavity (A), the clutch (3) is disposed in the second cavity (B), and the crankshaft (12) passes through the first partition (13) and is connected to the clutch (3).

3. The range extended powertrain of claim 1, wherein, The rotor (22) has a groove (224) on its end face away from the clutch (3), and the range extender motor (2) further includes: The intermediate shaft (23) includes a first shaft segment (231) and a second shaft segment (232) coaxially connected. The first shaft segment (231) is embedded in the groove (224), and the second shaft segment (232) has a mounting hole (233) at the end away from the clutch (3). Fasteners (28) pass through the mounting hole (233) to connect the intermediate shaft (23) and the rotor (22). The mounting hole (233) is provided with an internal spline (234) near the opening, and the input shaft (41) is provided with an external spline (411). The input shaft (41) and the intermediate shaft (23) are connected by the external spline (411) and the internal spline (234).

4. The range extended powertrain of claim 3, wherein, The range extender motor (2) also includes: A flexible coupling is provided between the rotor (22) and the intermediate shaft (23).

5. The range extended power system of claim 3, wherein, The first housing (21) includes: A first main housing (211) is connected to the housing (11), and the first main housing (211) is open toward the end of the oil pump (4); and The first end cap (212) is fastened to the open end of the first main shell (211). The inner end of the first end cap (212) is provided with a bearing hole (213). A second bearing (24) is provided in the bearing hole (213). The intermediate shaft (23) is supported on the first end cap (212) through the second bearing (24).

6. The range extended power system of claim 5, wherein, The range extender motor (2) also includes a connecting seat (25), which is installed on the outside of the first end cover (212). The oil pump (4) includes a second housing (42), which includes a second end cover (421), which is detachably installed on the connecting seat (25).

7. The range extended powertrain system of claim 1, wherein, The range extender motor (2) also includes a stator (26) and a speed detection component (27), the stator (26) being coaxially arranged with the rotor (22) and configured to detect the speed of the rotor (22) relative to the stator (26).

8. The range-extended power system according to any one of claims 1 to 7, characterized in that, It also includes an energy storage component (6) for storing electrical energy, and the range extender motor (2) also includes a stator (26) including windings (261). The range extender motor (2) has a motor mode and a generator mode. In the motor mode, the winding (261) is supplied with current to control the running speed of the rotor (22). In the generator mode, the current output by the winding (261) is converted into DC power and enters the energy storage component (6).

9. The range-extended power system according to any one of claims 1 to 7, characterized in that, It also includes a controller (5), the range extender motor (2) having a motor mode and a generator mode, the controller (5) including: The engine control module (51) is configured to control and monitor the start-stop and operating speed of the engine (1); The clutch control module (52) is configured to control and monitor the on / off state of the clutch (3); and The motor control module (53) is configured to control the range extender motor (2) to switch between the motor mode and the generator mode.

10. An engineering machinery, characterized in that, include: The range-extended power system according to any one of claims 1 to 9.

11. A control method for a range-extended powertrain system according to any one of claims 1 to 9, characterized in that, The range-extended power system includes an energy storage component (6) for storing electrical energy, and the control method includes: Obtain the electrical state of the energy storage component (6); Based on the battery status and / or the operating requirements of the engine (1), control the operating states of the engine (1), the clutch (3), and the range extender motor (2) so that the range extender power system is in different operating modes.

12. The control method according to claim 11, characterized in that, The steps of controlling the operating requirements of the engine (1), the clutch (3), and the range extender motor (2) to put the range-extended power system into different operating modes according to the battery status and / or the operating status of the engine (1) include: When the power of the energy storage component (6) is lower than the preset power, the range-extended power system is put into the first working mode. In the first working mode, the engine (1) is started, the clutch (3) is in a power connection state, and the range extender motor (2) is in generator mode, so that the crankshaft (12) drives the rotor (22) to rotate through the clutch (3), and stores the output electrical energy of the range extender motor (2) into the energy storage component (6). At the same time, the rotor (22) drives the input shaft (41) to rotate and drive the oil pump (4) to work.

13. The control method according to claim 11, characterized in that, The steps of controlling the operating states of the engine (1), the clutch (3), and the range extender motor (2) according to the battery status and / or the operating requirements of the engine (1) to put the range-extended power system in different operating modes include: When the energy storage component (6) has electrical charge and the engine (1) needs to operate, the range-extended power system is put into a second operating mode. In the second working mode, the engine (1) is started, the clutch (3) is in a power connection state, and the range extender motor (2) is in motor mode, so that the power of the engine (1) and the range extender motor (2) is transmitted to the input shaft (41) together, thereby driving the oil pump (4) to work.

14. The control method according to claim 11, characterized in that, The steps of controlling the operating states of the engine (1), the clutch (3), and the range extender motor (2) according to the battery status and / or the operating requirements of the engine (1) to put the range-extended power system in different operating modes include: When the power of the energy storage component (6) is not lower than the preset power and the engine (1) does not need to work, the range-extended power system is put into the third working mode. In the third working mode, the engine (1) stops working, the clutch (3) is in a power disconnected state, and the range extender motor (2) is in motor mode so that the electrical energy in the energy storage component (6) is provided to the range extender motor (2), and the input shaft (41) is rotated by the rotor (22) to drive the oil pump (4) to work.

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