Extended-range power assembly, control method and vehicle

Abstract

The invention provides an extended-range power assembly, a control method and a vehicle. Vibration and noise of the extended-range power assembly can be reduced. The range-extended power assembly comprises a generator, a generator controller and a range-extended engine, and a rotor of the generator is in transmission connection with a crankshaft of the range-extended engine. In the ignition process of the extended-range engine, the generator is actively controlled to output vibration suppression torque opposite to the torque output by the crankshaft to the crankshaft, so that an energy suppression source is externally applied to the extended-range engine, sudden energy increase generated by combustion of the extended-range engine is suppressed, and finally vibration and noise suppression is achieved. According to the range extending type power assembly, vibration and noise can be reduced in the aspect of transmission of the vibration and the noise, so that the vibration and noise suppression effect is not limited by the structure of a range extending type engine any more, and the technical effect of reducing the vibration and the noise is improved to a great extent.

Description

TECHNICAL FIELD

[0001] Embodiments of the present application relate to the technical field of new energy vehicles, in particular to a range-extending power assembly, a control method and a vehicle. BACKGROUND

[0002] The range-extending power assembly is a power assembly combining an engine and a generator. The range-extending engine in the range-extending power assembly needs to be periodically ignited during the working process. In each ignition cycle, the high-voltage current generated by the spark plug first ignites the air-fuel mixture in the cylinder, causing the air-fuel mixture to burn and release energy, which pushes the piston to reciprocate. After the air-fuel mixture is burned, the exhaust valve of the cylinder is opened, and the piston pushes the burned exhaust gas out of the cylinder. Then, when the intake valve of the cylinder is opened, the piston sucks fresh air into the cylinder to form a new air-fuel mixture, and then enters the next ignition cycle. That is, the energy release density of the range-extending engine is uneven at different stages in one ignition cycle, and only when the air-fuel mixture burns, there is a high-density energy release. This uneven energy release causes the range-extending power assembly to generate a large vibration and noise, causing energy consumption and noise, vibration and harshness (NVH) problems, and affecting the user's driving experience.

[0003] Therefore, how to reduce the vibration and noise generated by the range-extending power assembly is a problem to be solved. SUMMARY

[0004] The present application provides a range-extending power assembly, a control method and a vehicle. During the ignition process of the range-extending engine, the generator outputs a vibration suppression torque to the crankshaft, thereby suppressing the torque fluctuation of the crankshaft, and achieving the effect of reducing the vibration and noise of the range-extending power assembly.

[0005] To achieve the above-mentioned purpose, the present application adopts the following technical solutions:

[0006] In a first aspect, a range-extending power assembly is provided, comprising: a generator, a generator controller and a range-extending engine, the rotor of the generator is in driving connection with the crankshaft of the range-extending engine. Wherein, the generator controller is configured to actively control the generator to output a vibration suppression torque to the crankshaft during the ignition process of the range-extending engine, the vibration suppression torque and the torque output by the range-extending engine to the crankshaft are in opposite directions. And, the generator controller is configured to charge the power battery with the current generated by the generator during the process that the rotor of the generator rotates with the rotation of the crankshaft after the ignition of the range-extending engine ends.

[0007] The ignition process of a range extender engine includes the process from the release of high-voltage ignition current from the spark plug to the completion of combustion after the air-fuel mixture is ignited by the high-voltage ignition current. During this process, the air-fuel mixture releases a large amount of energy, pushing the piston to rotate the crankshaft. After the ignition process of the range extender engine ends, the piston continues to push the crankshaft to rotate due to its inertia.

[0008] In this solution, during the ignition of the range extender engine, the generator controller actively controls the generator to output a vibration suppression torque to the crankshaft in the opposite direction to the crankshaft's output torque. This applies energy to the range extender engine to suppress the energy surge caused by combustion during ignition, ultimately suppressing the vibration and noise generated by the range extender powertrain. Furthermore, the range extender powertrain provided in this application can reduce the vibration and noise generated during the ignition of the range extender engine from the generator side. This eliminates the limitation of the range extender engine's own structure on the suppression effect, significantly improving the technical effectiveness of vibration and noise reduction.

[0009] In one possible implementation, the generator controller can also be used to control the amplitude of the vibration suppression torque to increase as the amount of fuel injected during the ignition of the range extender engine increases.

[0010] The greater the ignition fuel injection quantity of the range extender engine, the greater the sudden increase in energy generated by combustion during ignition. In this embodiment, during the ignition process of the range extender engine, the amplitude of the vibration suppression torque is controlled to increase with the increase of the ignition fuel injection quantity. This allows the generator's suppression intensity on the range extender engine to change with the operating conditions of the range extender engine, thereby suppressing vibration and noise through a vibration suppression torque adapted to the range extender engine, thus improving the suppression effect.

[0011] In one possible implementation, the generator controller can also be used to control the amplitude of the vibration suppression torque to vary with the magnitude of the torque output by the range extender engine during the ignition process.

[0012] The energy released by the air-fuel mixture directly affects the torque output to the crankshaft by the range extender engine. In other words, the change in energy generated by combustion during the ignition process of the range extender engine can be reflected by the change in the torque output to the crankshaft. This embodiment improves the adaptability of the vibration suppression torque to the operating conditions of the range extender engine by controlling the amplitude of the vibration suppression torque to vary with the output torque of the range extender engine during the ignition process, thereby enhancing the vibration and noise suppression effect.

[0013] In one possible implementation, the generator controller is specifically used to control the amplitude of the vibration suppression torque to increase as the torque output by the range extender engine increases.

[0014] During the ignition process of the range extender engine, the greater the torque output by the range extender engine, the greater the energy surge generated by combustion. In this embodiment, during the ignition process of the range extender engine, the amplitude of the vibration suppression torque increases with the increase of the torque output by the range extender engine. This allows the generator to more effectively suppress the vibration and noise of the range extender engine, ensuring the effectiveness of vibration and noise suppression.

[0015] In one possible implementation, the generator controller is specifically used to control the amplitude of the vibration suppression torque to be less than the amplitude of the torque output by the range extender engine.

[0016] The torque output by the range extender engine to the crankshaft generates vibration and noise while also driving the generator to produce electricity. Therefore, in this embodiment, during the ignition process of the range extender engine, the amplitude of the vibration suppression torque output by the generator is controlled to be less than the amplitude of the torque output by the range extender engine. This ensures that while the vibration and noise of the range extender engine are suppressed, the basic function of the range extender engine driving the generator to produce electricity is maintained, thereby guaranteeing the normal operation of the range extender powertrain.

[0017] In one possible implementation, the generator controller is used to control the generator to stop outputting vibration suppression torque after the range extender engine has finished igniting.

[0018] After the ignition process of the range extender engine is completed, the generator rotor will rotate with the crankshaft, ending the energy surge caused by combustion in the range extender engine. Based on this, this embodiment can control the generator to stop outputting vibration suppression torque after the range extender engine ignition is complete, thereby avoiding any obstruction to the normal operation of the range extender engine.

[0019] In one possible implementation, the generator controller is used to control the amplitude of the vibration suppression torque to vary with the crankshaft position during the ignition of the range extender engine.

[0020] The vibration of a range extender engine primarily originates from energy pulses generated by periodic combustion. Since the combustion of the air-fuel mixture is related to the crankshaft position, these energy pulses are essentially a predictable source of interference closely related to the crankshaft position. Therefore, in this embodiment, during the range extender engine ignition process, the amplitude of the vibration suppression torque is controlled to vary with the crankshaft position. This allows the phase and amplitude of energy fluctuations to be predicted and identified by sensing the crankshaft position, thereby enabling the vibration suppression torque output by the generator to effectively counteract these energy fluctuations, thus achieving vibration and noise suppression.

[0021] In one possible implementation, the generator controller is used to control the amplitude of the vibration suppression torque to vary with the camshaft position of the range extender engine during the ignition process.

[0022] The combustion of the air-fuel mixture is also related to the camshaft position of the range extender engine. Therefore, in this embodiment, during the ignition process of the range extender engine, the amplitude of the vibration suppression torque is controlled to change with the camshaft position. This allows the phase and amplitude of energy fluctuations to be predicted and identified by sensing changes in the camshaft position, thereby enabling the vibration suppression torque output by the generator to effectively counteract the energy fluctuations, thus achieving vibration and noise suppression.

[0023] In this embodiment, the change in camshaft position may specifically include a change in camshaft angle.

[0024] In one possible implementation, the generator controller is used to control the amplitude of the vibration suppression torque to increase as the intake air volume of the range extender engine increases during the ignition process.

[0025] The amount of energy released during combustion of the air-fuel mixture in the cylinder of a range extender engine is also affected by the intake manifold air volume. A larger intake manifold air volume results in more complete combustion of the air-fuel mixture and the release of more energy; conversely, a smaller intake manifold air volume leads to less complete combustion and the release of less energy. Therefore, increasing the intake manifold air volume results in higher energy release per combustion cycle during ignition, a stronger torque surge and excitation force, leading to greater vibration and noise.

[0026] In this embodiment, during the ignition process of the range extender engine, the amplitude of the vibration suppression torque increases with the increase of the intake air volume in the intake manifold. By monitoring this key parameter of intake manifold air volume, the trend of increasing vibration can be identified, and the amplitude of the vibration suppression torque can be increased accordingly to achieve precise suppression of greater vibration and noise. This ensures that the vibration suppression torque is always matched with the operating conditions of the range extender engine, avoiding increased vibration due to insufficient suppression force.

[0027] In one possible implementation, the generator controller includes a housing, a power circuit board, an engine control chip, and a generator control chip. The generator control chip controls the power circuit board to drive the generator. The engine control chip controls the operation of the range extender engine.

[0028] The housing surface includes an engine sensor interface and a drive current output interface. The engine control chip is used to receive signals output by the engine sensor through the engine sensor interface. The engine sensor is used to detect the operating status of the range extender engine. The power circuit board is used to output drive current to the generator through the drive current output interface.

[0029] In this embodiment, the generator control chip and the engine control chip are integrated into the generator controller. This allows the vehicle to control both the range extender engine and the generator simultaneously through the generator controller when controlling the generator. Furthermore, the generator controller can transmit the operating status data of the range extender engine to the generator control chip through data exchange within the generator controller. This improves the generator controller's control efficiency and reduces the generator's control delay.

[0030] In one possible implementation, the engine control chip and the generator control chip can be integrated into the same multi-core chip, with data transfer between them via inter-core communication. This can further improve the data interaction speed between the engine controller chip and the generator control chip.

[0031] In one possible implementation, during the ignition process of the range extender engine, the generator control chip is used to receive the operating status of the range extender engine detected by the engine sensors through the engine control chip, and to send control commands to the generator according to the operating status. The control commands indicate the vibration suppression torque output by the generator.

[0032] In this embodiment, during the ignition process of the range extender engine, the generator controller sends control commands to the generator based on the received operating status of the range extender engine to control the vibration suppression torque output by the generator. This enables the generator control to quickly and accurately control the vibration suppression torque output by the generator according to the operating conditions of the range extender engine.

[0033] In one possible implementation, during the ignition process of the range extender engine, before receiving the operating status of the range extender engine, the generator control chip is also used to receive a synchronization signal sent by the engine control chip. This synchronization signal instructs the engine control chip to acquire clock information regarding the operating status.

[0034] To control the vibration suppression torque, the generator control chip needs to exchange operating status data with the engine control chip. There may be a delay between the time the generator control chip receives the operating status data and the time the engine control chip acquires the operating status data of the range extender engine. In this embodiment, during the range extender engine ignition process, before receiving the range extender engine's operating status data, a synchronization signal sent by the engine control chip is used to synchronize the clocks between the generator control chip and the engine control chip, helping to ensure precise control of the generator's output vibration suppression torque.

[0035] Secondly, a control method for a range-extended powertrain is provided. The range-extended powertrain includes a generator, a generator controller, and a range-extending engine, wherein the rotor of the generator is connected to the crankshaft of the range-extending engine via a drive transmission. The method includes:

[0036] During the ignition process of the range extender engine, the generator is actively controlled to output vibration suppression torque to the crankshaft. The vibration suppression torque is opposite in direction to the torque output by the range extender engine to the crankshaft. After the range extender engine ignition ends, the generator receives the current generated by the generator to charge the power battery as the generator rotor rotates with the crankshaft.

[0037] In one possible implementation, the method further includes: during the ignition process of the range extender engine, controlling the amplitude of the vibration suppression torque to increase as the amount of fuel injected during ignition of the range extender engine increases.

[0038] In one possible implementation, the method further includes: during the ignition process of the range extender engine, controlling the amplitude of the vibration suppression torque to vary with the magnitude of the torque output by the range extender engine.

[0039] In one possible implementation, the method further includes controlling the amplitude of the vibration suppression torque to increase as the torque output by the range extender engine increases.

[0040] In one possible implementation, the method further includes controlling the amplitude of the vibration suppression torque to be less than the amplitude of the torque output by the range extender engine.

[0041] In one possible implementation, the method further includes controlling the generator to stop outputting vibration suppression torque after the range extender engine has finished igniting.

[0042] In one possible implementation, the method further includes: during the ignition of the range extender engine, controlling the amplitude of the vibration suppression torque to vary with the crankshaft position.

[0043] In one possible implementation, the method further includes: during the ignition process of the range extender engine, controlling the amplitude of the vibration suppression torque to vary with the position of the camshaft of the range extender engine.

[0044] In one possible implementation, the method further includes: during the ignition process of the range extender engine, controlling the amplitude of the vibration suppression torque to increase as the intake volume of the range extender engine's intake manifold increases.

[0045] In one possible implementation, the method further includes: during the ignition process of the range extender engine, sending a control command to the generator according to the operating status of the range extender engine, the control command indicating the vibration suppression torque output by the generator.

[0046] In one possible implementation, the method further includes: during the ignition process of the range extender engine, before receiving the operating status of the range extender engine, receiving a synchronization signal sent by the engine control chip. The synchronization signal instructs the engine control chip to acquire clock information of the operating status.

[0047] Thirdly, a vehicle is provided, including a power battery, a vehicle controller, and a range-extended powertrain according to the first aspect of this application. The vehicle controller is used to: when the power battery charge is lower than or equal to a charging threshold, control the range-extending engine to output torque to the rotor of the generator to drive the rotor to rotate and charge the power battery. Attached Figure Description

[0048] Figure 1 A diagram showing the relationship between the torque output of a four-cylinder engine and the crankshaft position is provided for embodiments of this application.

[0049] Figure 2 A schematic diagram of a vehicle architecture provided for an embodiment of this application;

[0050] Figure 3 This is a schematic diagram of the structure of a generator controller provided in an embodiment of this application;

[0051] Figure 4 This application provides a schematic diagram of the control process of a generator.

[0052] Figure 5 This is a schematic diagram of the control process of another generator provided in an embodiment of this application;

[0053] Figure 6 A schematic diagram illustrating the steps of a control method for a range-extended powertrain provided in this application embodiment;

[0054] Figure 7 A control timing diagram for a range-extended powertrain provided in this application embodiment;

[0055] Figure 8 This is a schematic diagram of the steps of a generator control method provided in an embodiment of this application. Detailed Implementation

[0056] The technical solutions in this application will now be described in conjunction with the accompanying drawings. The detailed descriptions and drawings of the following embodiments are used to exemplarily illustrate the principles of this application, but should not be used to limit the scope of this application; that is, this application is not limited to the described embodiments.

[0057] Range-extended electric vehicles (REEVs) address the range anxiety of pure electric vehicles by adding an engine to the vehicle's structure. Compared to traditional vehicles, REEVs more frequently start and stop the engine to generate electricity based on the vehicle's operating conditions and the battery's state of charge (SOC) characteristics, thereby reducing fuel consumption and emissions.

[0058] Figure 1 This is a diagram showing the relationship between the torque output of a four-cylinder engine and the crankshaft position. (Example:) Figure 1 As shown, in one power cycle of a range-extender engine, the crankshaft rotates twice, and each cylinder in a four-cylinder range-extender engine ignites once. During each cylinder's ignition cycle, the high-voltage current generated by the spark plug ignites the air-fuel mixture in the cylinder, causing it to burn and release energy, pushing the piston in reciprocating motion. After the air-fuel mixture has burned completely, the exhaust valve opens, and the piston expels the combusted exhaust gas from the cylinder. Then, when the intake valve opens, the piston draws in fresh air, forming a new air-fuel mixture, thus entering the next ignition cycle. In other words, the energy release density of a range-extender engine is uneven at different stages of an ignition cycle, with high-density energy release only occurring during the combustion of the air-fuel mixture. This uneven energy release causes the torque output of the range-extender engine to vary as shown in Figure 1, resulting in significant vibration and noise in the range-extender powertrain, which is transmitted through the vehicle body to the cabin, affecting the user's driving experience.

[0059] One possible implementation is to increase the number of spark plug discharge points to improve the uniformity of air-fuel mixture combustion at various locations within the cylinder, thereby reducing the peak energy release height and the fluctuation range of the range extender engine's output torque, ultimately achieving the technical effect of reducing vibration and noise. However, this approach improves upon the source of vibration and noise, and its effectiveness in reducing vibration and noise is limited by the inherent structure of the range extender engine itself.

[0060] To address the aforementioned problems, this application provides a range-extended powertrain, a control method, and a vehicle. During the ignition process of the range-extended engine, the generator is actively controlled to output a vibration-suppressing torque to the crankshaft in the opposite direction to the crankshaft's output torque. This applies an external energy suppression source to the range-extended engine, suppressing the energy surge caused by combustion and ultimately achieving vibration and noise suppression. The range-extended powertrain described in this application can reduce vibration and noise propagation, thus freeing the suppression effect from the limitations of the range-extended engine's own structure and significantly improving the technical effect of vibration and noise reduction.

[0061] Figure 2 This is a schematic diagram of the architecture of a vehicle provided in an embodiment of this application.

[0062] like Figure 2 As shown, vehicle 10 includes range-extended powertrain 20, vehicle controller 70, and power battery 80.

[0063] The vehicle 10 can be a range-extended electric vehicle, and the range-extended powertrain 20 includes a generator 30, a range-extending engine 40, a generator controller 50, and a fuel tank (not shown in the figure).

[0064] refer to Figure 3 The diagram shows a generator controller 50, which includes a housing 51, a power circuit board 52, an engine control chip 53, and a generator control chip 54. The generator control chip 54 controls the power circuit board 52 to drive the generator 30. The engine control chip 53 controls the operation of the range extender engine 40, such as controlling its ignition or shutdown.

[0065] The housing 51 includes an engine sensor interface 56 and a drive current output interface 55. The engine control chip 53 is used to receive signals output by the engine sensor 60 through the engine sensor interface 56. The engine sensor 60 is used to detect the operating status of the range extender engine 40. The power circuit board 52 is used to output drive current to the generator 30 through the drive current output interface 55.

[0066] This application integrates the generator control chip 54 and the engine control chip 53 into the generator controller 50, so that when the vehicle controls the generator 30, data can be exchanged through the internal bus of the generator controller 50, thereby improving the control efficiency of the generator 30 and reducing the control delay of the generator 30.

[0067] In one possible implementation, in order to further improve the data interaction speed between the engine control chip 53 and the generator control chip 54, the engine control chip 53 and the generator control chip 54 can be integrated into the same multi-core chip, and the engine control chip 53 and the generator control chip 54 can transfer data through inter-core communication.

[0068] The range-extended powertrain 20, also known as a range extender, is used to charge the power battery 80.

[0069] The generator controller 50 controls the operation of the generator 30. It connects to the vehicle controller 70 and controls the generator 30 according to the instructions from the vehicle controller 70. The generator 30 can output AC power to the generator controller 50, which then integrates this AC power and outputs current to the power battery 80 for charging. The generator controller 50 can also output current to the generator 30 to control the output torque of the generator 30.

[0070] The generator 30 is coaxially connected to the range extender engine 40 via the drive shaft 31. Alternatively, the generator 30 is connected via a reducer 32. When the generator 30 is coaxially connected to the range extender engine 40 via the drive shaft 31, the generator 30 and the range extender engine 40 rotate at the same speed. When the generator 30 is connected to the range extender engine 40 via the reducer 32, the speeds of the generator 30 and the range extender engine 40 are in a fixed ratio. This fixed ratio is equal to the reduction ratio of the reducer 32.

[0071] A torque sensor 33 is installed on the drive shaft 31. The torque sensor 33 is used to collect the torque signal carrying the generated torque output by the range extender engine 40.

[0072] The range extender engine 40 may include multiple cylinders and multiple pistons. Each piston reciprocates within each cylinder. The pistons are connected to the crankshaft via connecting rods, and the crankshaft converts the reciprocating motion of the pistons into rotational motion at its shaft end, thereby outputting torque. At any given time, the positions of the multiple pistons within the cylinders may not be exactly the same, but the relative positions between the multiple pistons are fixed.

[0073] In one embodiment, the generator controller 50 is connected to a resolver sensor via a signal interface. The resolver sensor is used to detect the rotational speed of the generator 30 controlled by the generator controller 50. The generator controller 50 is used to receive the rotational speed signal from the resolver sensor, and the rotational speed signal indicates the rotational speed of the generator 30.

[0074] The vehicle controller 70 can control the generator 30 to operate in power generation mode, converting the mechanical energy of the range extender engine 40 into electrical energy to charge the power battery 80, achieving online energy replenishment. As the control center of the electric vehicle, the vehicle controller 70 monitors the SOC information of the power battery 80 and user driving information in real time, and controls the start / stop and power output of the range extender powertrain 20 after comprehensive judgment to maintain the charge balance of the power battery 80. The vehicle 10 determines whether to start or stop the range extender powertrain 20 based on the state of charge of the power battery 80 and the vehicle's state. When the range extender powertrain 20 is working, i.e., the range extender engine 40 is running, after the range extender engine 40 is ignited, it outputs generating torque to the drive shaft 31, driving the drive shaft 31 to rotate. The drive shaft 31 then drives the rotor of the generator 30, which in turn generates current. This current is transmitted to the power battery 80 of the vehicle 10 through an inverter circuit, thus converting the engine-side kinetic energy into electrical energy to charge the power battery 80. The generating torque can be adjusted according to the charging power requirements.

[0075] The vehicle controller 70 controls the range extender engine 40 to switch from a stopped state to an operating state so that the range extender powertrain 20 can charge the power battery 80 when the charge level of the power battery 80 is lower than or equal to the charging threshold. When the charge level of the power battery 80 is higher than the charging threshold, the controller controls the range extender engine 40 to switch from an operating state to a stopped state.

[0076] When the range extender engine 40 is in a stopped state, the piston of the range extender engine 40 stops moving and the rotor of the generator 30 stops moving.

[0077] When the range extender engine 40 is running, the reciprocating motion of the piston of the range extender engine 40 drives the drive shaft 31 to rotate, thereby driving the rotor of the generator 30 to move, so that the range extender powertrain 20 charges the power battery 80.

[0078] The following combination Figure 2 The vehicle architecture shown, taking one working cycle of the range extender engine 40 as an example, details the range extender powertrain, control method, and vehicle provided in this application.

[0079] During vehicle operation, when the vehicle controller 70 detects that the power battery 80's charge level is below the charging threshold, the vehicle controller 70 sends a start signal to the generator controller 50. In response to the start signal, the generator controller 50 controls the generator 30 to drive the crankshaft of the range extender engine 40 to begin rotating via the drive shaft. As the generator 30 drives the crankshaft to rotate, the starting torque output by the generator 30 to the crankshaft gradually increases, causing the crankshaft speed to gradually increase to the ignition speed.

[0080] When the engine control chip 53 detects that the crankshaft speed is greater than the ignition speed, it controls the spark plugs of the range extender engine 40 to start ignition (this can be called the first ignition). This causes the range extender engine 40 to switch from being driven by the generator 30 to driving the generator 30, thus completing the start-up and entering a stable operating condition. Under stable operating conditions, the range extender engine 40 performs periodic ignition.

[0081] During the initial ignition of the range extender engine 40 or each ignition cycle of periodic ignition under stable operating conditions, the generator controller 50 actively controls the generator 30 to output vibration suppression torque to the crankshaft during the ignition process of the range extender engine 40. This vibration suppression torque is opposite in direction to the torque output by the range extender engine 40 to the crankshaft. Furthermore, after the ignition of the range extender engine 40 has ended, the generator controller 50 receives the current generated by the generator 30 to charge the power battery 80 as the rotor of the generator 30 rotates with the crankshaft.

[0082] In one embodiment, the above-described control process may be specifically executed by the generator control chip 54 in the generator controller 50. Furthermore, the control described below, which may be partially or entirely executed by the generator controller 50, may also be specifically executed by the generator control chip 54 in the generator controller 50.

[0083] The ignition process of the range extender engine 40 includes the process from the release of high-voltage ignition current from the spark plug of the range extender engine 40 to the completion of combustion after the air-fuel mixture is ignited by the high-voltage ignition current. During this process, the air-fuel mixture releases a large amount of energy, pushing the piston to drive the crankshaft to rotate. After the ignition process of the range extender engine 40 ends, the piston continues to drive the crankshaft to rotate under the action of motion inertia.

[0084] The ignition cycle includes the time elapsed between the first release of high-voltage ignition current from the spark plug and the next release of high-voltage ignition current by the range extender engine 40. In an optional embodiment, since the release of high-voltage ignition current from the spark plug is triggered by an ignition signal from the engine control chip 53, the time range of the ignition cycle can also be determined by the interval between two adjacent ignition signals issued by the engine control chip 53. In some embodiments, the faster the crankshaft of the range extender engine 40 rotates, the shorter the ignition cycle; the slower the crankshaft of the range extender engine 40 rotates, the longer the ignition cycle.

[0085] The vibration suppression torque is opposite in direction to the torque output by the range extender engine 40 to the crankshaft. Specifically, when the torque output by the range extender engine 40 to the crankshaft is clockwise, the vibration suppression torque is counterclockwise, or when the torque output by the range extender engine 40 to the crankshaft is counterclockwise, the vibration suppression torque is clockwise.

[0086] In one implementation, to further improve the effect of vibration and noise suppression, the generator controller 50 can also be used to control the amplitude of the vibration suppression torque to increase with the increase of the ignition fuel injection quantity of the range extender engine 40 during the ignition process of the range extender engine 40.

[0087] Based on the analysis above, the fundamental reason for the vibration and noise generated by the range-extended powertrain 20 is that the range-extended engine 40 releases energy unevenly at different stages of the ignition cycle. A large amount of energy is released during the ignition process, while no energy is released after the ignition process ends. Therefore, the fluctuation range of energy released by the range-extended engine 40 during the ignition cycle mainly depends on the amount of energy released during the ignition process.

[0088] Considering that the energy released by the range extender engine 40 during ignition comes entirely from the combustion of the air-fuel mixture, the amount of energy released by the combustion of the air-fuel mixture can be determined by the ignition fuel injection quantity of the range extender engine 40, thereby controlling the vibration suppression torque to change with the ignition fuel injection quantity. In one specific embodiment, the engine control chip 53 can calculate the ignition fuel injection quantity for the current ignition cycle based on the operating parameters of the range extender engine 40, and then send the calculated ignition fuel injection quantity to the generator control chip 54. The generator control chip 54 determines the vibration suppression torque based on the ignition fuel injection quantity sent by the engine control chip 53, so that the vibration suppression torque increases with the increase of the ignition fuel injection quantity.

[0089] In this embodiment, the amplitude of the vibration suppression torque is increased as the fuel injection quantity of the range extender engine 40 increases during the ignition process. This allows the suppression strength of the generator 30 on the range extender engine 40 to change with the operating conditions of the range extender engine 40, thereby suppressing vibration and noise with a vibration suppression torque adapted to the range extender engine 40, thus improving the suppression effect.

[0090] In one implementation, the generator controller 50 is used to control the amplitude of the vibration suppression torque to vary with the crankshaft position during the ignition of the range extender engine 40.

[0091] As analyzed above, the vibration of the range extender engine 40 mainly originates from energy pulses generated by periodic combustion. Since the combustion of the air-fuel mixture is related to the crankshaft position, these energy pulses are essentially a predictable source of interference closely related to the crankshaft position. Therefore, the generator controller 50, by accurately sensing the crankshaft position, can predict and identify the phase and amplitude of energy fluctuations, thereby ensuring that the vibration suppression torque output by the generator 30 precisely counteracts these energy fluctuations, thus achieving vibration and noise suppression. The change in crankshaft position can be a change in crankshaft angle.

[0092] In one implementation, the generator controller 50 is used to control the amplitude of the vibration suppression torque to vary with the camshaft position of the range extender engine during the ignition process of the range extender engine 40. The change in camshaft position in this embodiment may include a change in camshaft angle.

[0093] Similarly, considering that the combustion of the air-fuel mixture is also related to the crankshaft position, the generator controller 50 can also predict and identify the phase and amplitude of energy fluctuations by sensing changes in the camshaft position, so that the vibration suppression torque output by the generator 30 can just offset the energy fluctuations, thereby achieving vibration and noise suppression.

[0094] In one implementation, the generator controller 50 is used to control the amplitude of the vibration suppression torque to increase as the intake volume of the range extender engine's intake manifold increases during the ignition process of the range extender engine 40.

[0095] The amount of energy released during combustion of the air-fuel mixture in the cylinder of the range extender engine 40 is also affected by the intake manifold air volume. A larger intake manifold air volume results in more complete combustion of the air-fuel mixture and the release of more energy; conversely, a smaller intake manifold air volume leads to less complete combustion and the release of less energy. Therefore, increasing the intake manifold air volume results in higher energy release per combustion cycle during ignition, a stronger torque surge and excitation force, leading to greater vibration and noise. In this embodiment, during the ignition process of the range extender engine 40, the amplitude of the vibration suppression torque is controlled to increase with the increase of the intake manifold air volume. By monitoring this key parameter, the trend of increasing vibration can be identified, and the amplitude of the vibration suppression torque can be increased accordingly to achieve precise suppression of greater vibration and noise. This ensures that the vibration suppression torque remains matched to the operating conditions of the range extender engine, avoiding increased vibration due to insufficient suppression force.

[0096] In one possible implementation, in order to improve the suppression of vibration and noise, the generator controller 50 can also be used to control the amplitude of the vibration suppression torque to vary with the magnitude of the torque output by the range extender engine 40 during the ignition process of the range extender engine 40.

[0097] In one embodiment, the range-extended powertrain 20 may include a torque sensor for detecting the torque output by the range-extended engine to the crankshaft.

[0098] In one optional embodiment, the vibration suppression torque output by the generator 30 can be synthesized from the control torque and the compensation torque. When the output speed of the generator 30 remains stable, the control torque is a constant value. Therefore, in this embodiment, the magnitude of the control compensation torque varies with the output torque of the range extender engine 40, allowing the vibration suppression torque to change accordingly.

[0099] For details, please refer to Figure 4 The diagram illustrates a control process for a generator. The vibration suppression torque varies with the output torque of the range extender engine 40. This can be achieved through the following control process: First, the generator controller 50 obtains the crankshaft torque from the torque sensor. Then, based on the crankshaft torque, the generator controller 50 determines a compensation torque and adds it to the control torque determined by the speed control to obtain the vibration suppression torque. Finally, the generator controller 50 sends the determined vibration suppression torque to the generator 30, so that the vibration suppression torque varies with the crankshaft torque.

[0100] In addition, considering the signal transmission lag between the torque sensor and the generator controller 50, when the generator controller 50 receives the crankshaft torque collected by the torque sensor, it can first perform phase calibration on the crankshaft torque collected by the torque sensor according to the crankshaft position and camshaft position of the range extender engine 40, and then determine the compensation torque according to the crankshaft torque collected by the torque sensor.

[0101] Considering that the energy released by the air-fuel mixture directly affects the torque output to the crankshaft by the range extender engine 40, this embodiment can also improve the adaptability of the vibration suppression torque to the operating conditions of the range extender engine 40 by controlling the amplitude of the vibration suppression torque to vary with the magnitude of the torque output by the range extender engine 40, thereby improving the effect of vibration and noise suppression.

[0102] In one implementation, the generator controller 50 is specifically used to control the amplitude of the vibration suppression torque to increase as the torque output by the range extender engine 40 increases.

[0103] In this embodiment, the vibration suppression amplitude is controlled to increase as the torque output by the range extender engine 40 increases, so that the generator 30 can more effectively suppress the vibration and noise of the range extender engine 40, thus ensuring the suppression effect.

[0104] In one implementation, the generator controller 50 is specifically used to control the amplitude of the vibration suppression torque to be less than the amplitude of the torque output by the range extender engine 40.

[0105] Considering the torque output by the range extender engine 40 to the crankshaft, it will generate vibration and noise while also driving the generator 30 to generate electricity. Therefore, in order to ensure the basic function of the range extender engine 40 driving the generator 30 to generate electricity, the amplitude of the vibration suppression torque output by the generator 30 should be less than the amplitude of the torque output by the range extender engine 40, so as to suppress the vibration and noise of the range extender engine 40 while ensuring the normal operation of the range extender powertrain 20.

[0106] In one implementation, the generator controller 50 is used to control the generator 30 to stop outputting vibration suppression torque after the range extender engine 40 has finished igniting.

[0107] After the ignition process of the range extender engine 40 is completed, the rotor of the generator 30 will rotate with the crankshaft. At this time, the range extender engine 40 is at the lowest point of energy output, so the generator 30 can stop outputting vibration suppression torque, thereby avoiding any obstruction to the normal operation of the range extender engine 40. In an optional embodiment, the generator controller 50 can determine whether the ignition of the range extender engine 40 has ended by using a preset duration characterizing the time required for the ignition process. Specifically, after a preset duration has elapsed since the spark plugs have emitted high-voltage ignition current, the generator controller 50 can confirm that the ignition of the range extender engine 40 has ended, and then control the generator 30 to stop outputting vibration suppression torque.

[0108] In one implementation, during the ignition process of the range extender engine 40, the generator controller is used to receive the operating status of the range extender engine 40 and control the vibration suppression torque output to the generator according to the operating status of the range extender engine 40.

[0109] In one optional embodiment, during the ignition process of the range extender engine 40, the generator control chip 54 is used to receive the operating status of the range extender engine 40 detected by the engine sensor 60 through the engine control chip 53, and send control commands to the generator 30 according to the operating status. The control commands indicate the vibration suppression torque output by the generator 30.

[0110] refer to Figure 5The diagram illustrates another control process for a generator. The generator control chip 54 can also send control commands to the generator 30 based on the operating status of the range extender engine 40. Specifically, the generator control chip 54 can first determine the torque output by the range extender engine 40 to the crankshaft based on the operating status of the range extender engine 40. Then, based on the torque output by the range extender engine 40 to the crankshaft, it generates a control command to indicate the vibration suppression torque and sends it to the generator 30. Specifically, the process by which the generator control chip 54 generates the control command to indicate the vibration suppression torque based on the torque output by the range extender engine 40 to the crankshaft can be as follows: the generator control chip 54 determines the compensation torque based on the torque transmitted to the crankshaft, adds the compensation torque to the control torque determined by the speed control, obtains the vibration suppression torque, and then generates the control command.

[0111] The operating status of the range extender engine 40 can be specifically characterized by operating information such as the ignition fuel injection quantity, crankshaft position, camshaft position, intake manifold intake volume, coolant temperature, and speed of the range extender engine 40.

[0112] In this embodiment, control commands are sent to the generator 30 by the operating status of the range extender engine 40, which can reduce the types of sensors required for the range extender engine 40, thereby reducing the manufacturing cost of the range extender powertrain 20.

[0113] In one possible implementation, during the ignition process of the range extender engine 40, before receiving the operating status of the range extender engine 40, the generator control chip 54 is also used to receive a synchronization signal sent by the engine control chip 53. The synchronization signal instructs the engine control chip 53 to acquire clock information regarding the operating status.

[0114] The synchronization signal can specifically be a square wave pulse signal. The clock information indicated by the synchronization signal can be understood as a time coordinate system. The engine control chip 53 sends the synchronization signal to the generator control chip 54 via the bus between the engine control chip 53 and the generator control chip 54. After receiving the synchronization signal, the generator control chip 54 can determine the time coordinate system in which the engine control chip 53 acquired the operating status based on the clock information indicated by the synchronization signal. It then adjusts its own time coordinate system to align with the time coordinate system of the engine control chip 53, thereby completing the clock synchronization between the generator control chip 54 and the engine control chip 53.

[0115] In this embodiment, considering that the generator control chip 54 needs to transmit data with the engine control chip 53 in order to achieve the control of vibration suppression torque, in order to ensure smooth and accurate control, before receiving the operating status of the range extender engine 40, the generator control chip 54 and the engine control chip 53 should first synchronize their clocks through the synchronization signal sent by the engine control chip 53.

[0116] Next, with Figure 6 The diagram shown illustrates a control method for a range-extended powertrain, with reference to... Figure 7 The control timing diagram of a range-extended powertrain 20 shown illustrates the control method provided in the embodiments of this application.

[0117] Step S101: During the ignition process of the range extender engine 40, the generator 30 is actively controlled to output vibration suppression torque to the crankshaft.

[0118] Among them, the vibration suppression torque and the torque output to the crankshaft by the range extender engine 40 are in opposite directions.

[0119] In step S102, after the range extender engine 40 is ignited, the generator 30 receives current generated by the generator 30 to charge the power battery 80 as the rotor of the generator 30 rotates with the crankshaft.

[0120] Based on the above control methods, and referring to Figure 8 The diagram shows a step-by-step control method for a generator 30. Step S101 may specifically include the following steps:

[0121] Step S101-1: During the ignition process of the range extender engine 40, the operating status of the range extender engine 40 is received by the engine sensor 60.

[0122] Step S101-2: Based on the operating status of the range extender engine 40, a control command is sent to the generator 30 so that the generator 30 outputs a vibration suppression torque that is opposite to the torque output by the crankshaft under the instruction of the control command.

[0123] Specifically, step S101-2 can be implemented by looking up a table. For example, after receiving the operating status of the range extender engine 40, the generator controller 50 looks up the operating status of the range extender engine 40 in a preset mapping table, determines the torque corresponding to the operating status of the range extender engine 40 in the preset mapping table as the vibration suppression torque of the generator 30, and sends a control command to the generator 30 according to the vibration suppression torque. The preset mapping table can be compiled from test data of the test bench.

[0124] In one possible implementation, where steps S101-1 and S101-2 are executed by the generator control chip 54 in the generator controller 50, and the operating status of the range extender engine 40 is sent by the engine control chip 53 in the generator controller 50, the control method may further include the following before step S101-1:

[0125] Step S103: Receive a synchronization signal sent by the engine control chip 53. The synchronization signal instructs the engine control chip 53 to acquire clock information indicating the operating status.

[0126] Furthermore, during the ignition process of the range-extender engine 40, the control method of the range-extender powertrain of this application may also include one or more of the following steps:

[0127] The amplitude of the vibration suppression torque increases with the increase of the ignition fuel injection quantity of the range extender engine 40.

[0128] The amplitude of the vibration suppression torque varies with the magnitude of the torque output by the range extender engine 40. Specifically, the amplitude of the vibration suppression torque increases as the torque output by the range extender engine 40 increases.

[0129] The amplitude of the vibration suppression torque is less than the amplitude of the torque output by the range extender engine 40.

[0130] The amplitude of the vibration suppression torque varies with the crankshaft position.

[0131] The amplitude of the vibration suppression torque varies with the position of the camshaft of the range extender engine 40.

[0132] The amplitude of the vibration suppression torque increases with the increase of the intake air volume of the intake manifold of the range extender engine 40.

[0133] After the range extender engine 40 finishes ignition, the control method of the range extender powertrain can also control the generator 30 to stop outputting vibration suppression torque.

[0134] In the embodiments of this application, the words "exemplary," "for example," etc., are used to indicate that they are examples, illustrations, or descriptions. Any embodiment or design that is described as "exemplary" in this application should not be construed as being more preferred or advantageous than other embodiments or design options. Specifically, the use of the term "exemplary" is intended to present the concept in a concrete manner.

[0135] It should be understood that the term "embodiment" used throughout this specification means that a specific feature, structure, or characteristic related to an embodiment is included in at least one embodiment of this application. Therefore, various embodiments throughout this specification do not necessarily refer to the same embodiment. Furthermore, these specific features, structures, or characteristics can be combined in any suitable manner in one or more embodiments.

[0136] It should also be understood that in this application, "when," "if," "in the circumstances of," and "if" all refer to a situation where a corresponding action will be taken under certain objective circumstances, and are not time-limited. They do not require the device to perform a judgment action, nor do they imply any other limitations. Furthermore, in this application, the descriptions of conditions such as "when," "if," "in the circumstances of," and "if" can be understood as necessary conditions, without limiting whether the condition is a sufficient condition or a necessary and sufficient condition. For example, "in the case of A, execute B" can be understood as "if at least A is satisfied, execute B."

[0137] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A range-extended powertrain, characterized in that, The range-extended powertrain includes a generator, a generator controller, and a range-extending engine, wherein the rotor of the generator is connected to the crankshaft of the range-extending engine via a drive connection. The generator controller is used for: During the ignition process of the range extender engine, the generator is actively controlled to output a vibration suppression torque to the crankshaft, and the vibration suppression torque is opposite in direction to the torque output by the range extender engine to the crankshaft. After the range extender engine finishes ignition, the generator rotor receives current generated by the generator to charge the power battery as the generator rotor rotates with the crankshaft.

2. The range-extended powertrain according to claim 1, characterized in that, The generator controller is used for: During the ignition process of the range extender engine, the amplitude of the vibration suppression torque increases with the increase of the ignition fuel injection quantity of the range extender engine.

3. The range-extended powertrain according to claim 1, characterized in that, The generator controller is used for: During the ignition process of the range extender engine, the amplitude of the vibration suppression torque varies with the magnitude of the torque output by the range extender engine.

4. The range-extended powertrain according to claim 3, characterized in that, The generator controller is specifically used for: The amplitude of the vibration suppression torque increases as the torque output by the range extender engine increases.

5. The range-extended powertrain according to claim 3, characterized in that, The generator controller is specifically used for: The amplitude of the vibration suppression torque is controlled to be less than the amplitude of the torque output by the range extender engine.

6. The range-extended powertrain according to claim 1, characterized in that, The generator controller is used for: After the range extender engine finishes ignition, the generator is controlled to stop outputting the vibration suppression torque.

7. The range-extended powertrain according to any one of claims 1-6, characterized in that, The generator controller is used for: During the ignition process of the range extender engine, the amplitude of the vibration suppression torque varies with the position of the crankshaft.

8. The range-extended powertrain according to any one of claims 1-7, characterized in that, The generator controller is used for: During the ignition process of the range extender engine, the amplitude of the vibration suppression torque varies with the position of the camshaft of the range extender engine.

9. The range-extended powertrain according to any one of claims 1-8, characterized in that, The generator controller is used for: During the ignition process of the range extender engine, the amplitude of the vibration suppression torque increases as the intake volume of the range extender engine's intake manifold increases.

10. The range-extended powertrain according to claim 1, characterized in that, The generator controller includes a housing, a power circuit board, an engine control chip, and a generator control chip. The generator control chip is used to control the power circuit board to drive the generator, and the engine control chip is used to control the operation of the range extender engine. The housing surface includes an engine sensor interface and a drive current output interface. The engine control chip is used to receive signals output by the engine sensor through the engine sensor interface. The engine sensor is used to detect the operating status of the range extender engine. The power circuit board is used to output drive current to the generator through the drive current output interface.

11. The range-extended powertrain according to claim 10, characterized in that, The engine control chip and the generator control chip are integrated into the same multi-core chip, and the engine control chip and the generator control chip transmit data through inter-core communication.

12. The range-extended powertrain according to claim 11, characterized in that, During the ignition process of the range extender engine, the generator control chip is used to receive the operating status of the range extender engine detected by the engine sensors through the engine control chip; The generator control chip is used to send control commands to the generator according to the operating status, and the control commands indicate the vibration suppression torque output by the generator.

13. The range-extended powertrain according to claim 12, characterized in that, During the ignition process of the range extender engine, before receiving the operating status of the range extender engine, the generator control chip is also used to receive a synchronization signal sent by the engine control chip. The synchronization signal instructs the engine control chip to acquire the clock information of the operating status.

14. A control method for a range-extended powertrain, characterized in that, The range-extended powertrain includes a generator, a generator controller, and a range-extending engine, wherein the rotor of the generator is connected to the crankshaft of the range-extending engine via a drive connection. The method includes: During the ignition process of the range extender engine, the generator is actively controlled to output a vibration suppression torque to the crankshaft, and the vibration suppression torque is opposite in direction to the torque output by the range extender engine to the crankshaft. After the range extender engine finishes ignition, the generator rotor receives current generated by the generator to charge the power battery as the generator rotor rotates with the crankshaft.

15. A vehicle, characterized in that, The vehicle includes a power battery, a vehicle controller, and a range-extended powertrain as described in any one of claims 1-13, wherein the vehicle controller is used for: When the charge of the power battery is lower than or equal to the charging threshold, the range extender engine is controlled to output torque to the rotor of the generator to drive the rotor to rotate and charge the power battery.

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