Loader energy consumption test system and method based on energy flow

Abstract

The invention relates to the technical field of loader testing, and particularly discloses a loader energy consumption testing system and method based on energy flow. The system comprises a multi-node electric energy acquisition module used for acquiring electric signals of an electric energy output end and an electric energy input end of the loader; the data calculation and storage module is used for calculating the output power of a power battery of the loader, the input power of each electric component, the energy consumption ratio and the electric energy utilization rate according to the electric signals; and the display and analysis terminal is used for analyzing and displaying the input power, the energy consumption ratio and the electric energy utilization rate. The system solves the problem that the energy consumption of each subsystem cannot be decomposed in the prior art, can adapt to the high-dynamic and high-load operation working conditions of the loader, and provides reliable data support for complete machine energy efficiency evaluation, energy-saving strategy optimization and subsystem matching.

Description

Technical Field

[0001] This application relates to the field of loader testing technology, and more specifically, to a loader energy consumption testing system and method based on energy flow. Background Technology

[0002] As pure electric loaders are gradually adopted in material yards, ports, mines, and other working conditions, their energy source has shifted from traditional diesel to power batteries. The electrical energy discharged from the power battery flows to multiple subsystems in the machine, such as the drive system, hydraulic system motor, and low-voltage accessories. The overall energy consumption of the machine depends on the demand, distribution, and consumption of electrical energy in these subsystems.

[0003] However, the current industry standard uses changes in the state of charge (SOC) of the vehicle's battery management system (BMS) or battery power consumption as an overall energy consumption indicator. This method cannot distinguish the proportion of electrical energy used for the drivetrain, hydraulic pump, and accessory systems. Therefore, relying solely on changes in battery power cannot support energy-saving optimization during the R&D process, nor can it be used for development needs such as subsystem energy efficiency matching, structural adjustments, and verification of energy-saving control strategies. While mature energy flow measurement equipment exists in the pure electric passenger vehicle sector, it focuses on the drive motor and low-voltage accessories, and the testing methods cannot reflect the power consumption characteristics of loaders with multiple operating modes, high loads, and frequent switching, making it difficult to directly replicate in the construction machinery sector. Directly applying passenger vehicle energy flow analysis methods to loaders will encounter significant problems: (1) The power structure of loaders is significantly different: the main power paths of pure electric loaders include drive motor (driving), hydraulic pump motor (operation), low-voltage accessories, etc. Compared with passenger cars, loaders have a large instantaneous current, high load fluctuation frequency, diversified operation, and complex power demand. (2) The loader can only monitor the total power consumption through the current output of the power battery, but there is no direct testing system to support other electrical appliances such as the drive system, hydraulic pump motor, and accessory system, so as to decompose the power consumption ratio of each system; (3) Test equipment based on passenger cars cannot be adapted to the operating conditions of engineering machinery in terms of data acquisition synchronization and installation methods, such as strong vibration, dusty environment and high frequency current dynamic changes.

[0004] To establish a realistic energy consumption evaluation system for pure electric loaders, an energy flow testing system is needed that can accurately measure battery output power and analyze the distribution ratio of electrical energy in the drive system, hydraulic pump motor, and accessory systems. This system must be suitable for high-vibration, high-frequency dynamic architectures. Therefore, this application is submitted. Summary of the Invention

[0005] The purpose of this application is to provide a loader energy consumption testing system and method based on energy flow, which can monitor, synchronously collect, decompose energy and evaluate the overall power consumption process of the loader in real time.

[0006] To achieve the above objectives, this application adopts the following technical solution: In a first aspect, this application provides a loader energy consumption testing system based on energy flow, comprising: The multi-node power acquisition module is used to acquire electrical signals from the power output and power input terminals of the loader. The data calculation and storage module is used to calculate the output power of the loader's power battery, the input power of each electrical component, the energy consumption ratio, and the energy utilization rate based on the electrical signal. The display and analysis terminal is used to analyze and display the input power, energy consumption ratio, and power utilization rate.

[0007] Secondly, this application provides a loader energy consumption testing method based on energy flow, including: Electrical signals are collected from the power output and power input terminals of the loader; Based on the electrical signals, calculate the output power of the loader's power battery, the input power of each electrical component, the energy consumption ratio, and the energy utilization rate. The input power, energy consumption ratio, and power utilization rate are analyzed and displayed.

[0008] Compared with the prior art, the beneficial effects of this application are as follows: This application realizes the visualization of the overall machine's electrical energy decomposition and path. By collecting the electrical energy of multiple key motors, electronic controls, and accessory loads in parallel, it achieves accurate decomposition of battery energy among different systems and clarifies the electrical energy consumption ratio of each system. This application supports the development of the entire machine and the verification of energy-saving strategies, and can provide basic data support for control strategy calibration, overall machine design optimization, motor and electronic control matching, and accessory load management. This application is applicable to high-load and high-dynamic operating conditions of construction machinery. Through high sampling frequency, strong anti-interference design, and synchronous acquisition technology, it can accurately capture changes in electrical energy under drastic fluctuations in operating conditions such as loading, lifting, and transportation, with high testing accuracy. Attached Figure Description

[0009] To more clearly illustrate the technical solutions in the specific embodiments of this application or the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0010] Figure 1 This is a schematic diagram of the structure of a loader energy consumption testing system based on energy flow, provided in an embodiment of this application; Figure 2 This is a flowchart illustrating a loader energy consumption testing method based on energy flow, provided in an embodiment of this application. Detailed Implementation The following description, in conjunction with the accompanying drawings, illustrates exemplary embodiments of this application, including various details to aid understanding. These should be considered merely exemplary. Therefore, those skilled in the art will recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of this application. Similarly, for clarity and brevity, descriptions of well-known functions and structures are omitted in the following description.

[0011] Figure 1 This is a schematic diagram of the structure of a loader energy consumption testing system based on energy flow provided in this application embodiment. This embodiment is applicable to scenarios where the electrical energy of each user component of the loader is collected and statistically analyzed in parallel. Through the synchronous collection of voltage and current data of multiple nodes, real-time analysis and energy consumption decomposition of the loader's overall power consumption process can be realized.

[0012] The overall idea of ​​this application embodiment is to construct a decomposition model of the internal power usage path of the pure electric loader by high-frequency synchronously collecting the voltage and current signals of the power battery output terminal of the loader and the main power-consuming units (including drive motor, hydraulic pump motor, low-voltage accessories, etc.) in the whole machine, so as to realize the real-time distribution, consumption and efficiency analysis of the whole machine's power among various power-consuming systems.

[0013] See Figure 1 The system provided in this embodiment includes: The multi-node power acquisition module is used to acquire electrical signals from the power output and power input terminals of the loader.

[0014] The data calculation and storage module is used to calculate the output power of the loader's power battery, the input power of each electrical component, the energy consumption ratio, and the energy utilization rate based on the electrical signal.

[0015] The display and analysis terminal is used to analyze and display the input power, energy consumption ratio, and power utilization rate.

[0016] Optionally, the multi-node power acquisition module includes: a voltage acquisition unit and a current acquisition unit; the voltage acquisition unit and the current acquisition unit are input to the data calculation and storage module through a multi-channel input port.

[0017] The multi-node power acquisition module is arranged at the following nodes: the total output terminal of the power battery, the input terminal of the drive motor, the input terminal of the hydraulic pump motor, and the high-voltage input terminal of the voltage converter (DCDC); wherein, the low-voltage side of the voltage converter is connected to a low-voltage accessory.

[0018] The voltage acquisition unit uses a high-voltage voltage sensor, which is an electronic device used to accurately measure, safely isolate, and convert the voltage values ​​of high-voltage circuits (typically DC 60V-1500V). It converts dangerous high-voltage signals into low-voltage, safe, and easily processed analog or digital signals.

[0019] The current acquisition unit uses a current sensor. The current sensor can be a Hall effect current sensor, or a precision device suitable for high-frequency, high-current dynamic measurement, such as a shunt combined with an isolated sampling circuit.

[0020] Optionally, the data calculation and storage module includes: an energy model building unit, an energy calculation unit, and an energy efficiency evaluation unit. The functions of each unit are described in detail below.

[0021] The power model building unit is used to decompose power by building a power flow model. The power flow model abstracts the overall power consumption path of the loader into three main power flow directions: (1) power flow of the drive motor, which is used for the machine's driving, acceleration, steering and power output; (2) power flow of the hydraulic pump motor, which is used for loading, lifting and unloading operations (although the hydraulic action occurs in the hydraulic system, this application only analyzes the power input of the motor and does not involve the hydraulic side energy); (3) power flow of the voltage converter and low-voltage accessories, including vehicle-mounted electronic control, lighting, sensors, fans, water pumps, cooling systems, etc. Finally, based on the above three main power flow directions, the power flow model is built as: battery output → power of drive motor + power of hydraulic pump motor + power of low-voltage accessories + power loss.

[0022] The power calculation unit is used to calculate the output power of the power battery, the input power of the drive motor, the input power of the hydraulic pump motor, and the input power of the high-voltage input terminal of the voltage converter based on the electrical signals (i.e., voltage and current) provided by the multi-node power acquisition module.

[0023] The energy efficiency evaluation unit is used to calculate the energy consumption ratio and power utilization rate based on the output power of the power battery, the input power of the drive motor, the input power of the hydraulic pump motor, and the input power of the high voltage input terminal of the voltage converter.

[0024] The overall system testing process of this application, taking a typical operation scenario (such as loading cycle) as an example, involves setting up a multi-node power acquisition module, starting the data calculation and storage module, establishing a synchronous clock, operating the loader for normal operation, and the system recording the input power of each motor in real time. After the operation is completed, the input power, energy consumption ratio and power utilization rate can be viewed through the display and analysis terminal.

[0025] Optionally, based on the output power of the power battery, the input power of the drive motor, the input power of the hydraulic pump motor, and the input power of the high-voltage input terminal of the voltage converter, the energy consumption ratio and the power utilization rate are calculated, including: The first step is to divide the input power of the drive motor by the output power of the power battery to obtain the energy consumption ratio of the drive motor.

[0026] The output power P_batt of the power battery is obtained by multiplying the collected output current of the power battery by the output voltage. The input power P_drv of the drive motor is obtained by multiplying the collected input current (i.e., three-phase current) of the drive motor by the input voltage (i.e., input DC bus voltage). The energy consumption ratio of the drive motor is obtained by dividing P_drv by P_batt.

[0027] The second step is to divide the input power of the hydraulic pump motor by the output power of the power battery to obtain the energy consumption ratio of the hydraulic pump motor.

[0028] The input current of the hydraulic pump motor is multiplied by the input voltage to obtain the input power P_pump of the drive motor. P_pump is divided by P_batt to obtain the energy consumption ratio of the hydraulic pump motor.

[0029] The third step is to divide the input power of the high-voltage input terminal of the voltage converter by the output power of the power battery to obtain the energy consumption ratio of the low-voltage accessory.

[0030] The input power P_low at the high-voltage input terminal is obtained by multiplying the input current at the high-voltage input terminal of the voltage converter by the input voltage. P_low is then divided by P_batt to obtain the energy consumption ratio of the low-voltage accessory.

[0031] Step 4: Add the input power of the hydraulic pump motor and the input power of the drive motor, then divide by the output power of the power battery to obtain the energy utilization rate. The formula for calculating the energy utilization rate E_drv is as follows: E_drv=(P_drv+P_pump) / P_batt; Optionally, the specific arrangement is as follows: 1) Arrangement at the power battery output end: Connect the voltage acquisition unit to the high-voltage positive and negative terminals of the battery pack using a high-insulation wiring method; connect the current acquisition unit in series on the battery's main positive terminal harness; fix the power acquisition module to the vehicle frame using a vibration damping bracket to prevent signal drift caused by operational vibration. The measurement signals from the voltage and current acquisition units are transmitted to the data calculation and storage module via a dedicated shielded harness. This node obtains the total input power of the entire machine, which is used as a reference for power flow decomposition.

[0032] 2) Arrangement of the drive motor input terminal: The DC bus input terminal of the drive motor controller outputs a voltage signal and connects to the voltage acquisition unit; a current acquisition unit is arranged on the positive terminal of the bus; depending on the space conditions of the loader, the power acquisition module is installed in a vibration-damping area, such as the side of the motor controller bracket; the acquisition harness uses shielding and fixing clamps to reduce swaying during operation. The voltage and current of the drive motor are used to calculate the power of the driving system, i.e., the input power of the drive motor.

[0033] 3) Arrangement of the hydraulic pump motor input terminal: A voltage acquisition line is installed at the input terminal of the hydraulic pump motor controller, connecting to a voltage acquisition unit; a current acquisition unit is arranged on the hydraulic pump motor input harness; since the hydraulic pump motor is often located in areas with stronger vibration, the power acquisition module adopts a dual-point fixation to the vibration damping pad structure; the signal is connected to the data calculation and storage module through a high anti-interference harness. The hydraulic pump motor input power is used to evaluate the power consumption of the loader's operating system (lifting, loading, unloading, etc.).

[0034] 4) Arrangement of the high-voltage input terminal of the DC-DC converter: A power acquisition module is installed at the high-voltage input terminal of the DC-DC converter to collect the voltage and current at the input terminal, thereby calculating the input power of the low-voltage accessories connected to the DC-DC converter. This power acquisition module adopts low-voltage isolation protection to ensure safe data acquisition. The power consumption of the low-voltage system (input power multiplied by power consumption duration) is used to analyze the energy consumption of the auxiliary functions of the entire machine.

[0035] Optionally, ideally, the total battery energy can be decomposed into: P_batt=P_drv+P_pump+P_low+P_loss; Where: P_drv is the input power of the drive motor; P_pump is the input power of the hydraulic pump motor; P_low is the input power of the high-voltage input terminal of the voltage converter; P_loss is the power loss, including wiring harness loss, electrical control loss, conversion loss, etc., and is an empirical value. If the difference between the value of P_drv + P_pump + P_low + P_loss and P_batt in the above formula is greater than the set threshold, an acquisition anomaly or sensor drift is indicated.

[0036] Integrating the input power yields the specific energy consumption of each electrical component.

[0037] The overall system testing process of this application, taking a typical operation scenario (such as loading cycle) as an example, involves setting up a multi-node power acquisition module, starting the data calculation and storage module, establishing a synchronous clock, operating the loader for normal operation, recording the input power of each motor in real time, and viewing the energy consumption ratio through the display and analysis terminal after the operation is completed.

[0038] This application also provides a loader energy consumption testing method based on energy flow, including the following operations: S110. Collect electrical signals from the power output and power input terminals of the loader; S120. Based on the electrical signal, calculate the output power of the loader's power battery, the input power of each electrical component, the energy consumption ratio, and the energy utilization rate. S130. Analyze and display the input power, energy consumption ratio and power utilization rate.

[0039] The method provided in this embodiment is executed by the above-mentioned energy flow-based loader energy consumption testing system and has corresponding technical effects, which will not be elaborated here.

[0040] It should be understood that the various forms of processes shown above can be used to rearrange, add, or delete steps. For example, the steps described in this application can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution disclosed in this application can be achieved, and this is not limited herein.

[0041] The specific embodiments described above do not constitute a limitation on the scope of protection of this application. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A loader energy consumption testing system based on energy flow, characterized in that, include: The multi-node power acquisition module is used to acquire electrical signals from the power output and power input terminals of the loader. The data calculation and storage module is used to calculate the output power of the loader's power battery, the input power of each electrical component, the energy consumption ratio, and the energy utilization rate based on the electrical signal. The display and analysis terminal is used to analyze and display the input power, energy consumption ratio, and power utilization rate.

2. The system according to claim 1, characterized in that, A multi-node power acquisition module includes a voltage acquisition unit and a current acquisition unit; the voltage acquisition unit and the current acquisition unit are input to the data calculation and storage module through a multi-channel input port.

3. The system according to claim 2, characterized in that, The multi-node power acquisition module is deployed at the following nodes: The power battery output terminal, drive motor input terminal, hydraulic pump motor input terminal, and high voltage input terminal of the voltage converter; The low-voltage side of the voltage converter is connected to a low-voltage accessory.

4. The system according to claim 3, characterized in that, The data computing and storage module includes: The power model building unit is used to decompose power by building a power flow model. The power flow model abstracts the overall power consumption path of the loader into three main power flow directions: power flow of the drive motor, power flow of the hydraulic pump motor, and power flow of the voltage converter and low-voltage accessories. The power calculation unit is used to calculate the output power of the power battery, the input power of the drive motor, the input power of the hydraulic pump motor, and the input power of the high-voltage input terminal of the voltage converter based on the electrical signals provided by the multi-node power acquisition module. The energy efficiency evaluation unit is used to calculate the energy consumption ratio and power utilization rate based on the output power of the power battery, the input power of the drive motor, the input power of the hydraulic pump motor, and the input power of the high voltage input terminal of the voltage converter.

5. The system according to claim 4, characterized in that, Based on the output power of the power battery, the input power of the drive motor, the input power of the hydraulic pump motor, and the input power of the high-voltage input terminal of the voltage converter, the energy consumption ratio and energy utilization rate are calculated, including: Divide the input power of the drive motor by the output power of the power battery to obtain the energy consumption ratio of the drive motor. Divide the input power of the hydraulic pump motor by the output power of the power battery to obtain the energy consumption ratio of the hydraulic pump motor. Divide the input power at the high-voltage input terminal of the voltage converter by the output power of the power battery to obtain the energy consumption ratio of the low-voltage accessory. The energy utilization rate is obtained by adding the input power of the hydraulic pump motor and the input power of the drive motor, and then dividing by the output power of the power battery.

6. The system according to claim 5, characterized in that, The low-voltage accessories include: vehicle electronic control, lighting, sensors, fans, water pumps, and cooling systems.

7. A method for testing the energy consumption of a loader based on energy flow, characterized in that, include: Electrical signals are collected from the power output and power input terminals of the loader; Based on the electrical signals, calculate the output power of the loader's power battery, the input power of each electrical component, the energy consumption ratio, and the energy utilization rate. The input power, energy consumption ratio, and power utilization rate are analyzed and displayed.

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