Experiment table for productive range extender

Abstract

The invention belongs to the technical field of new energy automobile power system test equipment, and particularly relates to a productive range extender experiment table. The productive range extender experiment table provided by the invention is high in efficiency and safety. The device comprises a hot test container 1-1, and is characterized in that a feeding and discharging conveying line conversion sliding table 1-12 is arranged at an inlet of the hot test container 1-1, and a storage conveying line 1-3 and a discharging conveying line 1-13 are arranged on the feeding and discharging conveying line conversion sliding table 1-12 in the moving direction of the feeding and discharging conveying line conversion sliding table 1-12; the conveying line conversion sliding table 1-12 is arranged on the sliding table base 10-1; a feeding conveying line 1-4 is arranged on the front side of the conveying line conversion sliding table 1-12, and the conveying direction of the feeding conveying line 1-4 is perpendicular to the moving direction of the conveying line conversion sliding table 1-12. The range extender 100 to be tested is placed on the hot test tray 6-1 of the range extender to be tested on the feeding conveying line 1-4.

Description

Technical Field

[0001] This invention belongs to the technical field of testing equipment for new energy vehicle power systems, and particularly relates to a production range extender test bench. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the range extender, as a key component that can effectively improve the driving range of electric vehicles, directly affects the overall performance of new energy vehicles.

[0003] During the current production and commissioning process of range extenders (which include engines and generators), traditional test benches have significant shortcomings: Firstly, the low level of functional integration and lack of modular design result in high maintenance and upgrade costs. Secondly, the lack of a transport docking structure means that the loading, unloading, and pipeline connection of the range extender rely on manual operation, which is inefficient and poses safety hazards.

[0004] These problems result in long production and debugging cycles and low precision for range extenders, making it difficult to meet the needs of the rapidly developing new energy vehicle industry. Summary of the Invention

[0005] This invention addresses the aforementioned problems by providing a highly efficient and safe production-grade range extender test bench.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: the present invention includes a hot test container 1-1, characterized in that a feed-out conveyor conversion slide 1-12 is provided at the inlet of the hot test container 1-1, and a storage conveyor line 1-3 and an outlet conveyor line 1-13 are provided on the feed-out conveyor conversion slide 1-12 along the moving direction of the feed-out conveyor conversion slide 1-12; the conveyor conversion slide 1-12 is provided on the slide base 10-1; A feeding conveyor line 1-4 is provided on the front side of the conveyor line conversion slide 1-12. The conveying direction of the feeding conveyor line 1-4 is perpendicular to the moving direction of the conveyor line conversion slide 1-12. The range extender 100 to be tested is placed on the hot test tray 6-1 of the range extender to be tested on the feeding conveyor line 1-4. The feeding conveyor line 1-4 is aligned with the storage conveyor line 1-3. The storage conveyor line 1-3 is aligned with the inner conveyor line 1-15 inside the hot test container 1-1. The feeding conveyor line 1-4 transports the hot test tray 6-1 of the range extender to be tested to the storage conveyor line 1-3. The hot test container 1-1 is equipped with an experimental fuel control unit 1-5 and an experimental cooling unit 1-6; The hot test container 1-1 is equipped with an air-cooled unit 1-10 for cooling the heat exchange medium of the cooling section 1-6 and a coolant centralized replenishment and recovery section 1-11 for replenishing and recovering the coolant of the cooling section 1-6.

[0007] As a preferred embodiment, when there is no tested range extender in the hot test container 1-1, the storage conveyor line 1-3 drives the hot test tray 6-1 of the range extender to be tested to directly transport the range extender 100 to the inner conveyor line 1-15 in the hot test container 1-1.

[0008] When the tested range extender is inside the hot test container 1-1, the conveyor conversion slide 1-12 slides, causing the discharge conveyor 1-13 to connect with the inner conveyor 1-15 and the loading conveyor 1-4. The inner conveyor 1-15 drives the tested range extender hot test pallet to transfer the tested range extender to the discharge conveyor 1-13. The discharge conveyor 1-13 then drives the tested range extender hot test pallet to transfer the tested range extender to the loading conveyor 1-4. Afterward, the conveyor conversion slide 1-12 slides, causing the storage conveyor 1-3 to align with the inner conveyor 1-15 inside the hot test container 1-1. The storage conveyor 1-3 drives the range extender to be tested hot test pallet 6-1 to transport the range extender to be tested 100 to the inner conveyor 1-15 inside the hot test container 1-1.

[0009] As another preferred embodiment, the lower side of the hot test tray 6-1 of the present invention adopts a flat plate structure, and the conveyor bodies on the feeding conveyor line 1-4 and the storage conveyor line 1-3 adopt a roller structure to transport the hot test tray 6-1.

[0010] As another preferred embodiment, the slide base 10-1 of the present invention is provided with a drive cylinder 10-6 for driving the conveyor line conversion slide 1-12 to slide.

[0011] As another preferred embodiment, a cantilever crane 1-2 is provided on the side of the conveyor line conversion slide 1-12 of the present invention, and an electric hoist 1-7 is provided on the cantilever crane 1-2.

[0012] As another preferred embodiment, the cooling section 1-6 of the present invention includes a profile frame 2-1, within which a range extender engine cooling section 2-3 and a range extender motor cooling section 2-2 are disposed.

[0013] As another preferred embodiment, the range extender engine cooling section 2-3 of the present invention includes a second liquid reservoir 2-11, a first circulating pump 2-12, a first tubular heat exchanger 2-13, a first high-level water tank 2-14, a first replenishment pump 2-15, and a first three-way temperature regulating valve 2-21. The replenishment port of the second liquid reservoir 2-11 is connected to the water inlet of the range extender through the first replenishment pump 2-15; the first port of the first three-way temperature regulating valve 2-21 is connected to the water inlet of the range extender, and the second port of the first three-way temperature regulating valve 2-21 is connected to the water outlet of the heating tank. The third port of the temperature regulating valve 2-21 is connected to one end of the first channel of the first tubular heat exchanger 2-13; the other end of the first channel of the first tubular heat exchanger 2-13 is connected to the return water port of the range extender and the water supply port of the first high-level water tank 2-14 respectively through the first circulating pump 2-12; the cooling water inlet of the first tubular heat exchanger 2-13 is connected to the outlet of the air-cooled unit 1-10, the cooling water outlet of the first tubular heat exchanger 2-13 is connected to the inlet of the air-cooled unit 1-10, and the water supply port and drain port of the second liquid storage tank 2-11 are connected to the coolant centralized supply and recovery section 1-11.

[0014] As another preferred embodiment, the range extender motor cooling section 2-2 of the present invention includes a first liquid storage tank 2-10, a second circulating pump 2-17, a second high-level water tank 2-18, a second tubular heat exchanger 2-19, a second replenishment pump 2-16, and a second three-way temperature regulating valve 2-22. The outlet of the first liquid storage tank 2-10 is connected sequentially to the cooling water inlet of the range extender motor, one end of the DJ-BB solenoid valve, and one end of the DJ-EE solenoid valve via the second replenishment pump 2-16 and the DJ-CC solenoid valve, respectively. The other end of the DJ-BB solenoid valve is connected to the return port of the first liquid storage tank 2-10, and the other end of the DJ-EE solenoid valve is connected to the first port of the second three-way temperature regulating valve 2-22. The second port of the second three-way temperature regulating valve 2-22 is connected to the first port of the second tubular heat exchanger 2-19. At one end of the channel, the other end of the first channel of the second tubular heat exchanger 2-19 is connected to the third port of the second three-way temperature regulating valve 2-22 and the outlet of the second circulating pump 2-17, respectively. The inlet of the second circulating pump 2-17 is connected to the medium inlet of the intercooler and the water inlet of the second high-level water tank 2-18, respectively. The exhaust port of the second high-level water tank 2-18 is connected to the medium outlet of the intercooler through the DJ-FF solenoid valve. The water inlet of the intercooler is connected to the cooling water inlet of the range extender motor. The cooling water inlet of the second tubular heat exchanger 2-19 is connected to the outlet of the air-cooled unit 1-10, and the cooling water outlet of the second tubular heat exchanger 2-19 is connected to the inlet of the air-cooled unit 1-10. The liquid inlet and outlet of the first liquid storage tank 2-10 are connected to the coolant centralized supply and recovery section 1-11.

[0015] As another preferred embodiment, the fuel control section 1-5 of the present invention includes a frame 3-2, on which a fuel consumption meter 3-1 is mounted. A dual-fuel fuel tank 3-3, a dual-fuel fuel supply pump 3-4, a dual-fuel fuel recovery pump 3-5, and a fuel overflow valve 3-6 are disposed within the frame 3-2. One end of the fuel consumption meter 3-1 is connected to the fuel inlet of the engine and the inlet of the dual-fuel fuel recovery pump 3-5, respectively. The other end of the fuel consumption meter 3-1 is connected to the outlet of the dual-fuel fuel supply pump 3-4 and one end of the fuel overflow valve 3-6 via a fuel switching valve 3-13. The inlet of the dual-fuel fuel supply pump 3-4 is connected to the outlet of the dual-fuel fuel tank 3-3, and the other end of the fuel overflow valve 3-6 is connected to the inlet of the dual-fuel fuel tank 3-3 and the outlet of the dual-fuel fuel recovery pump 3-5, respectively.

[0016] As another preferred embodiment, the main control computer of this invention is connected to a CAN card via USB. The DB9 interface of the CAN card is connected to the ECU and GCU of the range extender engine via a cable. The main control computer first sends a command to the GCU to control the speed, and at the same time triggers the fuel cut-off command of the ECU. The range extender motor rises to 1500 rpm, the engine is driven, the ignition conditions are met, the fuel cut-off command is canceled, the engine starts, torque control is performed, and the test conditions are entered to test the performance of the range extender engine at different speeds and torques.

[0017] As another preferred embodiment, the main control computer of the present invention is connected to a DC power supply via a USB to 232 cable. The main control computer controls the voltage and current settings of the linear DC power supply to meet the testing requirements of the range extender. The power output port of the linear DC power supply is connected to the GCU and ECU of the range extender and is responsible for supplying low-voltage DC power.

[0018] As another preferred embodiment, the power output port of the dual-phase DC power supply of the present invention is connected to the high-voltage DC power supply port of the range extender motor, which is responsible for the high-voltage DC supply during the start-up phase and the reverse power feedback during power generation.

[0019] As another preferred embodiment, the power analyzer of the present invention measures the power generation of the range extender engine. The PLC sets the engine inlet water temperature, generator inlet water temperature, and water blowing time of the range extender engine through the formula issued by the main control computer. At the same time, it specifies the voltage, current, and power settings of the dual-phase DC power supply to the range extender engine.

[0020] As another preferred embodiment, the fuel output port of the fuel consumption meter 3-1 of the present invention can be connected to the fuel inlet of the engine via a quick-connect fitting.

[0021] As another preferred embodiment, the hot test tray 6-1 of the present invention includes a base plate 11-1, which is connected to the upper tray support plate 11-3 through a shock-absorbing block 11-2. The hot test tray 6-1 is provided with a tray cooling pipe docking component 6-3 and a tray exhaust docking component 6-2. The upper tray support plate 11-3 is provided with an engine positioning column 6-9 and a motor support structure 6-10.

[0022] Secondly, the motor support structure 6-10 described in this invention is made of polyoxymethylene.

[0023] In addition, the hot test container 1-1 of the present invention is provided with a hot test stand 1-8. The hot test stand 1-8 includes a stand base 6-8. A docking slide 6-6 and a docking cylinder 6-7 are provided on the stand base 6-8. The docking cylinder 6-7 drives the docking slide 6-6. A stand exhaust docking component 6-4 and a stand cooling pipe docking component 6-5 are provided on the docking slide 6-6.

[0024] The beneficial effects of this invention.

[0025] This invention enables the automatic entry and exit of the range extender into the hot test container through the combined use of a conversion slide, conveyor line, and hot test tray; it is highly efficient and safe.

[0026] The present invention integrates experimental fuel control unit 1-5, experimental cooling unit 1-6, air-cooled unit 1-10 and coolant centralized replenishment and recovery unit 1-11 in the hot test container, which has a high degree of functional integration, is easy to maintain and reduces costs.

[0027] The range extender motor cooling module of this invention integrates both liquid cooling and air cooling modes. Attached Figure Description

[0028] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. The scope of protection of the present invention is not limited to the following description.

[0029] Figure 1 , 2 3: Overall layout diagram of the experimental platform.

[0030] Figure 4 , 5 : Structure diagram of the cooling section.

[0031] Figure 6 , 7 : Structural diagram of the fuel control section.

[0032] Figure 8 : Electronic control system architecture diagram.

[0033] Figure 9 : Structure diagram of docking components.

[0034] Figure 10 : Structural diagram of the conveyor line conversion slide.

[0035] Figure 11 : Structural diagram of the hot test tray.

[0036] Figure 12 Circuit diagram of the engine cooling section of the range extender.

[0037] Figure 13 Circuit diagram of the range extender motor cooling section.

[0038] Figure 14 Fuel control section route diagram.

[0039] The reference numerals in the attached figures are explained as follows: 1-1 Hot test container, 1-2 cantilever crane, 1-3 storage conveyor line, 1-4 loading conveyor line, 1-5 experimental fuel control section, 1-6 experimental cooling section, 1-7 electric hoist, 1-8 hot test bench, 1-10 air-cooled unit, 1-11 centralized coolant replenishment and recovery, 2-1 profile frame, 2-2 range extender motor cooling section, 2-3 range extender engine cooling section, 2-10 first reservoir, 2-11 second reservoir, 2-12 first circulating pump, 2-13 first tubular heat exchanger, 2-14 first high-level water tank, 2-15 first replenishment pump, 2-16 second replenishment pump 2-17 Liquid pump, 2-18 Second circulation pump, 2-19 Second high-level water tank, 2-19 Second tubular heat exchanger, 2-21 First three-way temperature regulating valve, 2-22 Second three-way temperature regulating valve, 3-1 Fuel consumption meter, 3-2 Frame, 3-3 Dual-fuel fuel tank, 3-4 Dual-fuel fuel supply pump, 3-5 Dual-fuel fuel recovery pump, 3-6 Fuel overflow valve, 6-1 Hot test tray, 6-2 Tray exhaust docking component, 6-3 Tray cooling pipe docking component, 6-4 Stand exhaust docking component, 6-5 Stand cooling pipe docking component, 6-6 Docking slide, 6-7 Docking cylinder, 6-8 Stand base. Detailed Implementation

[0040] As shown in the figure, the present invention includes a hot test container 1-1, a conveyor line conversion slide 1-12 is provided at the inlet of the hot test container 1-1, and a storage conveyor line 1-3 and a discharge conveyor line 1-13 are provided on the inlet and outlet conveyor line conversion slide 1-12 along the movement direction of the inlet and outlet conveyor line conversion slide 1-12; the conveyor line conversion slide 1-12 is provided on the slide base 10-1; A feeding conveyor line 1-4 is provided on the front side of the conveyor line conversion slide 1-12. The conveying direction of the feeding conveyor line 1-4 is perpendicular to the moving direction of the conveyor line conversion slide 1-12. The range extender 100 to be tested is placed on the hot test tray 6-1 of the range extender to be tested on the feeding conveyor line 1-4. The feeding conveyor line 1-4 is aligned with the storage conveyor line 1-3. The storage conveyor line 1-3 is aligned with the inner conveyor line 1-15 inside the hot test container 1-1. The feeding conveyor line 1-4 transports the hot test tray 6-1 of the range extender to be tested to the storage conveyor line 1-3. The hot test container 1-1 is equipped with an experimental fuel control unit 1-5 and an experimental cooling unit 1-6; The hot test container 1-1 is equipped with an air-cooled unit 1-10 for cooling the heat exchange medium of the cooling section 1-6 and a coolant centralized replenishment and recovery section 1-11 for replenishing and recovering the coolant of the cooling section 1-6.

[0041] When there is no tested range extender in the hot test container 1-1, the storage conveyor line 1-3 drives the hot test tray 6-1 of the range extender to be tested to directly transport the range extender 100 to the inner conveyor line 1-15 in the hot test container 1-1.

[0042] When the tested range extender is inside the hot test container 1-1, the conveyor conversion slide 1-12 slides, causing the discharge conveyor 1-13 to connect with the inner conveyor 1-15 and the loading conveyor 1-4. The inner conveyor 1-15 drives the tested range extender hot test pallet to transfer the tested range extender to the discharge conveyor 1-13. The discharge conveyor 1-13 then drives the tested range extender hot test pallet to transfer the tested range extender to the loading conveyor 1-4. Afterward, the conveyor conversion slide 1-12 slides, causing the storage conveyor 1-3 to align with the inner conveyor 1-15 inside the hot test container 1-1. The storage conveyor 1-3 drives the range extender to be tested hot test pallet 6-1 to transport the range extender to be tested 100 to the inner conveyor 1-15 inside the hot test container 1-1.

[0043] The underside of the hot test tray 6-1 adopts a flat plate structure. The conveyor lines on the feeding conveyor line 1-4 and the storage conveyor line 1-3 use a roller structure to transport the hot test tray 6-1. The hot test tray 6-1 is transported by friction rollers on the feeding conveyor line 1-4 and the storage conveyor line 1-3. The feeding conveyor line 1-4 transports the range extender to be hot tested to the inlet side conveyor line on the storage conveyor line 1-3, and the storage conveyor line 1-3 transports the range extender that has completed hot testing to the feeding conveyor line 1-4. The hot test tray 6-1 can be continuously transported on the feeding conveyor line 1-4 and the storage conveyor line 1-3 respectively, which improves capacity and shortens the production cycle.

[0044] The roller structure consists of a motor driving a metal roller 200 to rotate, which in turn moves the hot test tray 6-1 along the conveyor line. As the roller 200 rotates, friction is generated between the hot test tray 6-1 and the roller 200, propelling the hot test tray 6-1 forward. The roller 200 also supports the hot test tray 6-1 on the conveyor line, typically ensuring that the hot test tray 6-1 is in contact with at least three rollers simultaneously.

[0045] The power transmission between the roller 200 and the motor can take many forms, mainly chain drive and bevel gear drive.

[0046] The slide base 10-1 is equipped with a drive cylinder 10-6 for driving the conveyor line conversion slide 1-12 to slide.

[0047] A cantilever crane 1-2 is installed beside the conveyor line conversion slide 1-12, and an electric hoist 1-7 is installed on the cantilever crane 1-2. The equipment of this invention can be used in two forms: a production line and a stand-alone production line. In production line mode, the hot test tray 6-1 is directly conveyed to the storage conveyor line 1-3 via the system conveyor line. In stand-alone production, there is no system conveyor line, only the loading conveyor line 1-4 and the storage conveyor line. The hot test tray 6-1 is conveyed back and forth, and the range extender 100 needs to be manually hoisted onto the hot test tray 6-1 using the cantilever crane 1-2 and the electric hoist 1-7 for pre-installation.

[0048] The cooling section 1-6 includes a profile frame 2-1, within which a range extender engine cooling section 2-3 and a range extender motor cooling section 2-2 are disposed.

[0049] The range extender engine cooling section 2-3 includes a second liquid reservoir 2-11, a first circulating pump 2-12, a first tubular heat exchanger 2-13, a first high-level water tank 2-14, a first replenishment pump 2-15, and a first three-way temperature regulating valve 2-21. The replenishment port of the second liquid reservoir 2-11 is connected to the water inlet of the range extender through the first replenishment pump 2-15. The first port of the first three-way temperature regulating valve 2-21 is connected to the water inlet of the range extender, and the second port of the first three-way temperature regulating valve 2-21 is connected to the water outlet of the heating tank. The third port of 21 is connected to one end of the first channel of the first tubular heat exchanger 2-13; the other end of the first channel of the first tubular heat exchanger 2-13 is connected to the return water port of the range extender and the water supply port of the first high-level water tank 2-14 respectively through the first circulating pump 2-12; the cooling water inlet of the first tubular heat exchanger 2-13 is connected to the outlet of the air-cooled unit 1-10, the cooling water outlet of the first tubular heat exchanger 2-13 is connected to the inlet of the air-cooled unit 1-10, and the water supply port and drain port of the second liquid storage tank 2-11 are connected to the coolant centralized supply and recovery section 1-11.

[0050] like Figure 12 As shown, the working process of the range extender engine cooling section 2-3 is as follows: (1) Water replenishment stage: The coolant in the second reservoir 2-11, driven by the first replenishment pump 2-15, enters the engine coolant inlet of the range extender through valve LQ-CC. After the engine coolant is filled, it enters the first high-level water tank 2-14 through the return port and valve LQ-FF. When the water level in the first high-level water tank 2-14 reaches the upper level, replenishment is stopped. Valves LQ-CC and LQ-FF are closed.

[0051] (2) Circulation stage: Open valves LQ-DD and LQ-EE, start the first circulation pump 2-12, and the coolant enters the heating tank and the first tubular heat exchanger 2-13 through the first circulation pump 2-12. The hot coolant and the low temperature coolant are mixed in different proportions through the first three-way temperature regulating valve 2-21. After the mixed coolant reaches the set temperature, it enters the engine coolant inlet through valve LQ-EE, and then returns to the first circulation pump 2-12 through the engine coolant return port and valve LQ-DD to realize the coolant circulation. If the coolant is insufficient during the circulation process, gravity water is added through the first high-level water tank 2-14.

[0052] (3) Flushing stage: After the test, close valves LQ-DD and LQE-E, open valve LQ-BB, and the compressed air in air source Q31 enters the circulation system. After passing through the engine coolant return port and engine coolant inlet port, it passes through valve LQ-BB and blows the coolant back to the second reservoir 2-11.

[0053] The range extender motor cooling section 2-2 includes a first liquid storage tank 2-10, a second circulating pump 2-17, a second high-level water tank 2-18, a second tubular heat exchanger 2-19, a second replenishment pump 2-16, and a second three-way temperature regulating valve 2-22. The outlet of the first liquid storage tank 2-10 is connected sequentially to the cooling water inlet of the range extender motor, one end of a DJ-BB solenoid valve, and one end of a DJ-EE solenoid valve via the second replenishment pump 2-16 and a DJ-CC solenoid valve, respectively. The other end of the DJ-BB solenoid valve is connected to the return port of the first liquid storage tank 2-10. The other end of the DJ-EE solenoid valve is connected to the first port of the second three-way temperature regulating valve 2-22. The second port of the second three-way temperature regulating valve 2-22 is connected to one end of the first channel of the second tubular heat exchanger 2-19. The other end of the first channel of the tubular heat exchanger 2-19 is connected to the third port of the second three-way temperature regulating valve 2-22 and the outlet of the second circulating pump 2-17. The inlet of the second circulating pump 2-17 is connected to the medium inlet of the intercooler and the water inlet of the second high-level water tank 2-18. The exhaust port of the second high-level water tank 2-18 is connected to the medium outlet of the intercooler through the DJ-FF solenoid valve. The water inlet of the intercooler is connected to the cooling water inlet of the range extender motor. The cooling water inlet of the second tubular heat exchanger 2-19 is connected to the outlet of the air-cooled unit 1-10. The cooling water outlet of the second tubular heat exchanger 2-19 is connected to the inlet of the air-cooled unit 1-10. The water inlet and outlet of the first liquid storage tank 2-10 are connected to the coolant centralized supply and recovery section 1-11.

[0054] like Figure 13 As shown, the working process of the range extender motor cooling section 2-2 is as follows: (1) Water replenishment stage: The coolant in the first storage tank 2-10, driven by the second replenishment pump 2-16, enters the motor's cooling water inlet through DJ-CC, then passes through the intercooler, and finally enters the second high-level water tank 2-18 through DJ-FF. When the water level in the second high-level water tank 2-18 reaches the upper level, replenishment is stopped. Close valves DJ-CC and DJ-FF.

[0055] (2) Circulation stage: Open valves DJ-DD and DJ-EE, start the second circulation pump 2-17, and the coolant enters the second tubular heat exchanger 2-19 through the second circulation pump 2-17. The hot coolant and the low temperature coolant are mixed in different proportions through the second three-way temperature regulating valve 2-22. After the mixed coolant reaches the set temperature, it enters the motor cooling water inlet through DJ-EE, and then returns to the second circulation pump 2-17 through the intercooler and DJ-DD to realize the coolant circulation. If the coolant is insufficient during the circulation process, it is replenished by gravity through the second high-level water tank 2-18.

[0056] (3) Flushing stage: After the test, close valves DJ-DD and DJ-EE, turn on DJ-BB, and the compressed air in air source Q41 enters the circulation system. After passing through the intercooler return port, intercooler inlet port, motor return port, and motor inlet port, the coolant is blown back to the first liquid storage tank 2-10 via DJ-BB.

[0057] The engine cooling section 2-3 and the motor cooling section 2-2 are two independent systems, except that the coolant and chilled water are supplied through the same pipeline.

[0058] Air-cooled units 1-10 cool the water (i.e., the heat exchange medium in the cooling circulation system) of the tubular heat exchanger. Air-cooled units 1-10 can use variable frequency fans to dynamically adjust the cooling intensity according to the load.

[0059] The coolant centralized replenishment and recovery section 1-11 replenishes the coolant tank and recovers any coolant that overflows from the tank.

[0060] Water temperature is detected by water supply temperature sensors 2-24 and 2-27, and the three-way temperature regulating valves 2-22 and 2-21 are controlled accordingly.

[0061] The fuel control unit 1-5 includes a frame 3-2, on which a fuel consumption meter 3-1 is mounted. Inside the frame 3-2 are a dual-fuel fuel tank 3-3, a dual-fuel fuel supply pump 3-4, a dual-fuel fuel recovery pump 3-5, and a fuel overflow valve 3-6. One end of the fuel consumption meter 3-1 is connected to the fuel inlet of the engine and the inlet of the dual-fuel fuel recovery pump 3-5, respectively. The other end of the fuel consumption meter 3-1 is connected to the outlet of the dual-fuel fuel supply pump 3-4 and one end of the fuel overflow valve 3-6 through a fuel switching valve 3-13. The inlet of the dual-fuel fuel supply pump 3-4 is connected to the outlet of the dual-fuel fuel tank 3-3, and the other end of the fuel overflow valve 3-6 is connected to the inlet of the dual-fuel fuel tank 3-3 and the outlet of the dual-fuel fuel recovery pump 3-5, respectively.

[0062] The components within frame 3-2 supply fuel to the fuel consumption meter 3-1. The fuel is supplied to the meter via one of the dual-fuel supply pumps 3-4. A fuel overflow valve 3-6 ensures stable fuel pressure. After hot-testing, a dual-fuel fuel recovery pump 3-5 draws fuel from the supply line back to the dual-fuel fuel tank 3-3. Fuel type switching is performed via a fuel type switching valve 3-13.

[0063] The main control computer connects to the CAN card via USB. The DB9 interface of the CAN card is connected to the ECU and GCU of the range extender engine via a cable. The main control computer first sends a command to the GCU to control the speed, and at the same time triggers the fuel cut-off command of the ECU. The range extender motor rises to 1500 rpm, the engine is driven and the ignition conditions are met. The fuel cut-off command is canceled, the engine starts, torque control is performed, and the test conditions are entered to test the performance of the range extender engine at different speeds and torques.

[0064] The main control computer is connected to the DC power supply via a USB to 232 cable. The main control computer controls the voltage and current settings of the linear DC power supply to meet the testing requirements of the range extender. The power output port of the linear DC power supply is connected to the GCU and ECU of the range extender, and is responsible for supplying low-voltage DC power.

[0065] The power output port of the dual-phase DC power supply is connected to the high-voltage DC power supply port of the range extender motor, which is responsible for the high-voltage DC supply during the start-up phase and the reverse power feedback during power generation.

[0066] A dual-phase DC power supply is used as a power battery simulation device. The dual-phase DC power supply can not only simulate the battery pack supplying power to the electric drive system, but also absorb the electrical energy generated by the electric drive system.

[0067] The power analyzer measures the power generation of the range extender engine. The PLC sets the engine inlet water temperature, generator inlet water temperature, and water blowing time of the range extender engine according to the formula issued by the main control computer. At the same time, it specifies the voltage, current, and power settings of the dual-phase DC power supply to the range extender engine.

[0068] The fuel output port of the fuel consumption meter 3-1 can be connected to the engine's fuel inlet via a quick-connect fitting. The fuel consumption meter measures the engine's fuel consumption and operating time in real time, feeds the data back to the upper-level controller, and performs data analysis and aggregation after collection.

[0069] The system can be controlled via PLC (e.g., controlling valve opening size, pump operation, etc.). The main control computer can interact with the PLC to test limits. These limits typically include: engine coolant supply temperature sensor 2-24, return temperature 2-26, inlet pressure 2-23, return pressure 2-25; supply temperature sensor 2-27, return temperature 2-30, coolant inlet pressure 2-27, return pressure 2-29; fuel pressure 3-14. Starting conditions can be determined based on the data detected by the sensors. Specific determinations need to be confirmed according to the user's testing specifications. Generally, the required coolant temperature is 70-80℃, coolant pressure is 0.1-0.12 MPa, and fuel pressure is 0.4-0.55 MPa.

[0070] The hot test tray 6-1 includes a base plate 11-1, which is connected to an upper tray support plate 11-3 via a shock-absorbing block 11-2. The hot test tray 6-1 is equipped with a tray cooling pipe docking component 6-3 and a tray exhaust docking component 6-2. The upper tray support plate 11-3 is equipped with an engine positioning post 6-9 and a motor support structure 6-10. The underside of the base plate 11-1 rests on the conveyor friction rollers to support the entire tray. The shock-absorbing block 11-2 is fixed to the base plate 11-1 to support the upper tray 11-3. During testing, this effectively reduces the transmission of range extender vibration to the equipment, preventing resonance. The tray cooling pipe docking component 6-3 connects the range extender cooling pipes to the test bench cooling pipes. The tray exhaust docking component 6-2 connects the range extender exhaust pipes to the test bench exhaust pipes. The engine positioning post 6-9 typically positions the positioning process hole and support block under the cylinder block of the range extender engine and requires specific design based on the engine's specific process.

[0071] Tray cooling pipe connection component 6-3 and tray exhaust connection component 6-2 can be made of Staubli. https: / / www.staubli.com / cn-zh / Or Japan http: / / www.nitto-kohki.cn / product.

[0072] The motor support structure 6-10 is made of polyoxymethylene (POM). POM is a non-metallic material with high hardness, good machinability, and good wear resistance, which can reduce weight and avoid wear and scratches on the workpiece. The motor support structure 6-10 supports the positioning surface on the lower side of the range extender motor, preventing the range extender from tipping over due to a shift in the center of gravity.

[0073] The hot test container 1-1 is equipped with a hot test stand 1-8. The hot test stand 1-8 includes a stand base 6-8, a docking slide 6-6 and a docking cylinder 6-7 on the stand base 6-8, the docking cylinder 6-7 drives the docking slide 6-6, and the docking slide 6-6 is equipped with a stand exhaust docking component 6-4 and a stand cooling pipe docking component 6-5.

[0074] The bench exhaust connection component 6-4 and the bench cooling pipe connection component 6-5 can be made of Staubli. https: / / www.staubli.com / cn-zh / Or Japan http: / / www.nitto-kohki.cn / product.

[0075] The docking process is as follows: the docking cylinder 6-7 drives the docking slide 6-6 to move, so that the platform exhaust docking component 6-4 and the platform cooling pipe docking component 6-5 are pressed together with the tray exhaust docking component 6-2 and the tray cooling pipe docking component 6-3 to complete the docking.

[0076] It is understood that the above specific description of the present invention is only for illustrating the present invention and is not limited to the technical solutions described in the embodiments of the present invention. Those skilled in the art should understand that modifications or equivalent substitutions can still be made to the present invention to achieve the same technical effect; as long as the use needs are met, they are all within the protection scope of the present invention.

Claims

1. A production range extender test bench, including a hot-test container (1-1), characterized in that... A feed conveyor conversion slide (1-12) is provided at the inlet of the hot test container (1-1). A storage conveyor line (1-3) and a discharge conveyor line (1-13) are provided on the feed conveyor conversion slide (1-12) along the direction of movement of the feed conveyor conversion slide (1-12); the feed conveyor conversion slide (1-12) is provided on the slide base (10-1); A feeding conveyor line (1-4) is provided in front of the conveyor line conversion slide (1-12). The conveying direction of the feeding conveyor line (1-4) is perpendicular to the moving direction of the conveyor line conversion slide (1-12). The range extender to be tested (100) is placed on the hot test tray (6-1) of the range extender to be tested on the feeding conveyor line (1-4). The feeding conveyor line (1-4) is aligned with the storage conveyor line (1-3). The storage conveyor line (1-3) is aligned with the inner conveyor line (1-15) inside the hot test container (1-1). The feeding conveyor line (1-4) transports the hot test tray (6-1) of the range extender to be tested to the storage conveyor line (1-3). The hot test container (1-1) is equipped with an experimental fuel control unit (1-5) and an experimental cooling unit (1-6). The hot test container (1-1) is equipped with an air-cooled unit (1-10) for cooling the heat exchange medium of the cooling section (1-6) and a coolant centralized replenishment and recovery section (1-11) for replenishing and recovering the coolant of the cooling section (1-6).

2. The production range extender test bench according to claim 1, characterized in that... When there is no tested range extender in the hot test container (1-1), the storage conveyor line (1-3) drives the hot test tray (6-1) of the range extender to be tested to directly transport the range extender (100) to the inner conveyor line (1-15) in the hot test container (1-1); When there is a tested range extender in the hot test container (1-1), the conveyor line switching slide (1-12) slides, so that the discharge conveyor line (1-13) is connected with the inner conveyor line (1-15) and the loading conveyor line (1-4). The inner conveyor line (1-15) drives the hot test tray of the tested range extender to transfer the tested range extender to the discharge conveyor line (1-13). The discharge conveyor line (1-13) then drives the hot test tray of the tested range extender to transfer the tested range extender to the loading conveyor line (1-4). After that, the conveyor line switching slide (1-12) slides, so that the storage conveyor line (1-3) is aligned with the inner conveyor line (1-15) in the hot test container (1-1). The storage conveyor line (1-3) drives the hot test tray (6-1) of the range extender to transfer the range extender (100) to the inner conveyor line (1-15) in the hot test container (1-1).

3. The production range extender test bench according to claim 1, characterized in that... The bottom of the hot test tray (6-1) adopts a flat plate structure. The conveyor lines on the feeding conveyor line (1-4) and the storage conveyor line (1-3) adopt a roller structure to transport the hot test tray (6-1).

4. The production range extender test bench according to claim 1, characterized in that... The slide base (10-1) is provided with a drive cylinder (10-6) for sliding the conveyor line conversion slide (1-12).

5. The production range extender test bench according to claim 1, characterized in that... A cantilever crane (1-2) is installed on the side of the conveyor line conversion slide (1-12), and an electric hoist (1-7) is installed on the cantilever crane (1-2).

6. The production range extender test bench according to claim 1, characterized in that... The cooling section (1-6) includes a profile frame (2-1), and the profile frame (2-1) contains a range extender engine cooling section (2-3) and a range extender motor cooling section (2-2).

7. The production range extender test bench according to claim 1, characterized in that... The fuel control unit (1-5) includes a frame (3-2), on which a fuel consumption meter (3-1) is installed. Inside the frame (3-2) are a dual-fuel fuel tank (3-3), a dual-fuel fuel supply pump (3-4), a dual-fuel fuel recovery pump (3-5), and a fuel overflow valve (3-6). One end of the fuel consumption meter (3-1) is connected to the fuel inlet of the engine and the inlet of the dual-fuel fuel recovery pump (3-5), respectively. The other end of the fuel consumption meter (3-1) is connected to the outlet of the dual-fuel fuel supply pump (3-4) and one end of the fuel overflow valve (3-6) through a fuel switching valve (3-13). The inlet of the dual-fuel fuel supply pump (3-4) is connected to the outlet of the dual-fuel fuel tank (3-3), and the other end of the fuel overflow valve (3-6) is connected to the inlet of the dual-fuel fuel tank (3-3) and the outlet of the dual-fuel fuel recovery pump (3-5), respectively.

8. The production range extender test bench according to claim 1, characterized in that... The main control computer connects to the CAN card via USB. The DB9 interface of the CAN card is connected to the ECU and GCU of the range extender engine via a cable. The main control computer first sends a command to the GCU to control the speed, and at the same time triggers the fuel cut-off command of the ECU. The range extender motor rises to 1500 rpm, the engine is driven and the ignition conditions are met. The fuel cut-off command is canceled, the engine starts, torque control is performed, and the test conditions are entered to test the performance of the range extender engine at different speeds and torques.

9. The production range extender test bench according to claim 1, characterized in that... The hot test tray (6-1) includes a base plate (11-1), which is connected to the upper tray support plate (11-3) via a shock-absorbing block (11-2). The hot test tray (6-1) is provided with a tray cooling pipe docking component (6-3) and a tray exhaust docking component (6-2). The upper tray support plate (11-3) is provided with an engine positioning column (6-9) and a motor support structure (6-10).

10. The production range extender test bench according to claim 1, characterized in that... The hot test container (1-1) is equipped with a hot test stand (1-8). The hot test stand (1-8) includes a stand base (6-8), a docking slide (6-6) and a docking cylinder (6-7) on the stand base (6-8), the docking cylinder (6-7) drives the docking slide (6-6), and the docking slide (6-6) is equipped with a stand exhaust docking component (6-4) and a stand cooling pipe docking component (6-5).

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