Method for facilitating performance calibration of range extender system
By introducing an energy feedback power cabinet and a high-precision combustion analyzer, combined with the joint control of the GCU and the electronic fuel injection controller, the problem of low calibration efficiency of the range extender was solved, achieving efficient conversion of fuel and electricity and stable system operation, thereby improving the overall vehicle energy consumption and user experience.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- CHONGQING ZONGSHEN ENGINE MFG
- Filing Date
- 2026-02-28
- Publication Date
- 2026-05-12
AI Technical Summary
In existing technologies, the calibration efficiency of range extenders is low, resulting in insufficient fuel and electricity conversion efficiency, incomplete coverage of operating conditions, and impact on vehicle energy consumption and user experience.
By introducing an energy feedback power cabinet and a high-precision combustion analyzer, combined with the joint control of the GCU and the electronic fuel injection controller, full-condition data acquisition and optimization are achieved, a performance MAP is plotted, the optimal operating curve is selected and closed-loop verification is performed, ensuring that the range extender system operates in the best condition.
It improves the efficiency of fuel and electricity conversion, reduces fuel consumption, ensures the accuracy and efficiency of the calibration process, and optimizes the operational stability and fuel economy of the range extender system.
Smart Images
Figure CN122016341A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of vehicle range extender technology, and more specifically to a method for calibrating the performance of a range extender system. Background Technology
[0002] As the core energy supply unit of range-extended electric vehicles (REEVs), the range extender's core working mechanism involves an engine driving a generator to produce electricity, which directly supplies the drive motor or charges the battery. The engine does not directly participate in vehicle propulsion. This effectively alleviates industry pain points faced by pure electric vehicles, such as range anxiety, charging difficulties for long-distance travel, and battery capacity degradation in low-temperature environments, while maintaining the smoothness of pure electric driving. This significantly expands the vehicle's applicable scenarios and driving range. In the context of the rapid expansion of the new energy vehicle market and the not yet fully widespread availability of charging infrastructure, the performance of the range extender directly determines the vehicle's energy consumption, power response, and user experience. Therefore, the calibration of the range extender system, as a key step in optimizing its performance, has a decisive impact on the range extender's energy conversion efficiency, fuel economy, and operational stability. Chinese patent literature discloses a method for optimizing the power generation efficiency of a range-extended electric vehicle range-extending system, relating to the field of range extender calibration technology. This method includes the following steps: S1. Completing individual calibration of the engine and generator; S2. Testing the economic efficiency of the range-extending system on a range extender bench or in a complete vehicle; S3. Installing and adjusting calibration control parameters using a combustion analyzer to improve combustion stability in the engine's operating range; S4. Repeating steps S2 and S3, recording and comparing various engine technical indicators until the range extender's design and development goals are met or the optimization effect reaches its limit; S5. Organizing the test results before and after the optimization calibration data and generating a corresponding report, outputting the optimized calibration data.
[0003] The existing technology has the following shortcomings: When the range extender is running, the range extender generates electricity according to the calibrated operating point and operates at the optimal operating point. However, the current existing technology has low calibration efficiency and incomplete operating condition coverage, which indirectly leads to insufficient fuel and electricity conversion efficiency. Summary of the Invention
[0004] To address the technical problem of improving the conversion efficiency between fuel and electrical energy in range extenders, this invention provides a method for calibrating the performance of a range extender system, characterized by the following steps: S1. Electrically connect the high-voltage circuit of the range extender system to the high-voltage circuit of the power supply cabinet, so that the electrical energy generated during the calibration of the overall performance and economy of the range extender is directly fed back to the power supply cabinet; at the same time, with the help of the monitoring function of the power supply cabinet, real-time data on power generation and power conversion efficiency can be obtained. S2. Integrate the combustion analyzer into the engine detection circuit, and adjust the calibration quantity of the range extender system according to the monitoring parameters of the combustion analyzer until the performance, fuel consumption and engine stability of the engine at each operating point are adjusted to the optimal state. S3 and GCU control the operation status of the range extender system through the host computer, while the electronic fuel injection controller is responsible for controlling the electronic fuel injection system. At the same time, the entire range of the range extender system speed from zero to maximum speed and the engine throttle opening from zero to maximum opening are divided into several continuous data sampling points. S4 and GCU adjust the operating speed of the range extender system through the host computer, and the electronic fuel injection controller adjusts the throttle opening synchronously through the host computer, thereby calibrating and optimizing each operating point; at the same time, core data such as fuel consumption and power generation after calibration at each operating point are recorded, and a performance MAP of the range extender system is drawn based on the above data. S5. By analyzing the performance MAP of the range extender system, the optimal operating curve of the range extender system is selected and the selected operating curve is adapted into the GCU. The range extender system can be operated in the operating curve through joint control between the GCU and the electronic fuel injection controller, thereby optimizing the working efficiency of the range extender system. S6. Verify the selected working curve using the CAN tool to check if the data meets the design requirements.
[0005] Furthermore, in step S1, the range extender system adopts a bench-integrated installation and overall calibration strategy. The system introduces an energy feedback power cabinet, which not only achieves efficient energy recovery and zero waste during the calibration process, but also monitors power generation efficiency, power generation and fuel consumption in real time and accurately, providing full-dimensional data support for system energy efficiency optimization. Furthermore, in step S2, the range extender system introduces a high-precision combustion analyzer to monitor and diagnose the combustion process in the engine cylinder in real time. Based on this, the range extender system achieves precise matching of the optimal ignition advance angle under different power generation, thereby reducing fuel consumption, effectively increasing output torque, and significantly optimizing combustion stability. Furthermore, in step S3, the range extender system calibration data adopts a two-dimensional gridded (MAP) management strategy based on throttle opening and engine speed. Through full coverage testing and in-depth mining of data points under all operating conditions, the system can accurately fit the optimal power generation curve.
[0006] Furthermore, in step S4, the range extender system performs full-condition calibration and iterative optimization of the system economy based on the multi-dimensional mapping relationship between throttle opening and engine speed. By screening and recording the operating point with the best fuel economy, an efficient operating database is constructed and solidified into the GCU (generator controller), thereby achieving the global optimization of the range extender system's fuel efficiency. Furthermore, in step S4, the recorded key data, such as the temperature, fuel consumption, and power generation of the range extender system, are analyzed to determine if there are any abnormal phenomena or data, so as to facilitate optimization and rectification.
[0007] Furthermore, in step S5, after the range extender system is calibrated, the selection of the optimal operating curve should be strictly limited to the system's most efficient operating range. At the same time, the boundary of the selected curve needs to be precisely defined and verified to ensure that the system's operating trajectory is strictly constrained on the optimal curve, thereby balancing the working efficiency and operational reliability of the range extender system. To effectively ensure the robustness and accuracy of the point selection strategy, S6 uses the CAN tool to simulate the command interaction between the GCU and the electronic fuel injection controller, which can perform closed-loop verification of the optimal operating point of the range extender system. By quantitatively evaluating fuel consumption and power generation performance, it verifies whether the operating point selected by the GCU meets the calibration and design requirements. If it does not meet the calibration and design requirements, S3-S6 are repeated above; thus effectively ensuring the robustness and accuracy of the point selection strategy.
[0008] Furthermore, in step S6, the CAN tool is used to simulate vehicle operation commands, constructing a joint control closed loop between the GCU and the electronic fuel injection controller. By reproducing the vehicle's operating conditions, the power performance and fuel economy of the range extender system are comprehensively tested to verify whether the selected operating curve meets the calibration design specifications and functional requirements. This invention has the following beneficial effects: 1. This invention introduces an energy feedback power cabinet, achieving efficient recovery and zero waste of electrical energy during calibration. Simultaneously, leveraging the power cabinet's precise monitoring capabilities, combined with a high-precision combustion analyzer for real-time diagnosis of the engine's in-cylinder combustion process, it enables precise matching of the ignition advance angle under different power outputs. This ensures the range extender system achieves optimal performance and stability at various operating speeds, effectively reducing combustion losses and improving the fuel-electric energy conversion efficiency of the range extender, thereby increasing fuel utilization and reducing fuel consumption.
[0009] 2. Improve calibration efficiency and accuracy: By dividing continuous data sampling points, drawing performance MAP diagrams, and jointly controlling the GCU and electronic fuel injection controller, accurate matching and iterative optimization of calibration parameters are achieved, avoiding the problems of incomplete operating condition coverage and rough parameter matching in traditional calibration methods; in the closed-loop verification process, the vehicle's operating conditions are reproduced using CAN tools, and fuel consumption and power generation performance are quantitatively evaluated, ensuring the reliability and adaptability of the optimal working curve, significantly shortening the calibration cycle and reducing calibration costs. Attached Figure Description
[0010] Figure 1 A flowchart of the range extender system performance calibration method; Figure 2For the test bench calibration structure of the range extender system; Figure 3 A flowchart illustrating the performance calibration method for range extender systems. Detailed Implementation
[0011] The following detailed description illustrates the specific implementation method: The reference numerals in the accompanying drawings include: ISG motor 1, engine 2, generator controller 3, electronic fuel injection system 4, and controller host computer 5.
[0012] Example 1 like Figure 1-3 As shown, this invention is applicable to range-extended hybrid systems, which consist of an ISG motor 1, an engine 2, a generator controller 3 (GCU), an electronic fuel injection system 4, a high-voltage power supply cabinet, a combustion analyzer, a controller host computer 5, and power acquisition equipment. During calibration, key parameters such as DC generator current, motor phase current, engine fuel consumption, output power, and temperature are collected and recorded in real time, enabling accurate calibration of the overall performance and power generation performance of the range-extended hybrid system, thus ensuring that the range-extended system always operates within its most efficient range. When connecting the system, the ISG motor 1 and engine 2 are mechanically coupled; the positive and negative terminals of the power supply and the three-phase lines of the ISG motor 1 are all connected to the corresponding terminals of the GCU; the electronic fuel injection system 4 is adapted to connect to the engine 2, and the combustion analyzer is integrated into the engine 2's detection circuit.
[0013] The ISG motor 1 is a bidirectional motor that can be used as a starter motor to start the engine 2, or it can act as a generator to generate electricity when the engine 2 is running. The GCU is responsible for controlling the driving operation of the ISG motor 1. The electronic fuel injection system 4 is used to start the engine 2. The power cabinet has energy storage and energy supply functions. The combustion analyzer can monitor the combustion status of the engine 2 in real time and calibrate the performance and stability of the engine 2 accordingly. The host computer sends real-time status information to associated devices through a communication link. The power acquisition device is used to visually display the motor phase current and the generator current under the operating conditions of the engine 2.
[0014] like Figure 1 As shown, a method for calibrating the performance of a range extender system is characterized by the following steps: S1. Electrically connect the high-voltage circuit of the range extender system to the high-voltage circuit of the power supply cabinet. The electrical energy generated during the calibration of the range extender's overall performance and economy is directly fed back to the power supply cabinet. At the same time, the power supply cabinet's monitoring function is used to acquire real-time data on power generation and power conversion efficiency. The GCU controls the ISG motor 1 to drive the engine 2 to the target ignition speed, and then works in coordination with the electronic fuel injection system 4 to ignite and start the engine 2. The electronic fuel injection system 4 adjusts the throttle opening through the host computer software to change the load on the engine 2, and at the same time sends the target speed command to the GCU through the host computer software to control the operating speed of the range extender system, thereby carrying out performance calibration. Finally, the power acquisition device reads the current power generation current, and calculates the power generation and motor torque based on the current parameter. S2. Integrate the combustion analyzer into the engine 2 detection circuit, and adjust the range extender system calibration quantity according to the combustion analyzer monitoring parameters until the performance, fuel consumption and stability of engine 2 at each operating point are adjusted to the optimal state. During the calibration process, S3, GCU, and the electronic fuel injection controller control the operating status of the range extender system through the host computer. The electronic fuel injection controller is responsible for controlling the electronic fuel injection system 4. At the same time, the entire range of the range extender system speed from zero to maximum speed and the engine throttle opening from zero to maximum opening are divided into several continuous data sampling points. The electronic fuel injection controller synchronously calibrates the actual measured and calculated torque value into its built-in torque model. When it receives the target torque command issued by the GCU, the electronic fuel injection controller can query the calibrated torque value in the torque model to make the range extender system operate stably according to the calibrated working curve. S4 and GCU adjust the operating speed of the range extender system through the host computer, and the electronic fuel injection controller adjusts the throttle opening synchronously through the host computer, thereby calibrating and optimizing each operating point; at the same time, core data such as fuel consumption and power generation after calibration at each operating point are recorded, and a performance MAP of the range extender system is drawn based on the above data. During the calibration of the range-extended hybrid system, under the premise of adjusting the throttle opening through the electronic fuel injection controller and controlling the engine 2 through the GCU to achieve the calibrated target speed, it is necessary to calibrate the air-fuel ratio, fuel injection quantity, ignition angle, fuel consumption, etc., to ensure the overall power generation performance and fuel economy of the range-extended system. During the calibration process, key parameters at each operating point (including range extender system temperature, fuel consumption, power generation, measured output torque, engine stability, etc.) are monitored and recorded in real time. The output torque is calculated from the power generation (P) and the real-time speed (N) using the formula: T=9550×P / N, to ensure the accuracy and consistency of the data. S5. By analyzing the performance MAP of the range extender system, the optimal operating curve of the range extender system is selected, and the selected operating curve is adapted to the GCU. The range extender system can be operated in the operating curve through joint control of the GCU and the electronic fuel injection controller, thereby optimizing the working efficiency of the range extender system. During the overall performance calibration of the range-extended hybrid system, the ignition advance angle of the electronic fuel injection system (FFI) needs to be matched and calibrated for different operating conditions of the range-extended system under different speeds and loads. This establishes a one-to-one correspondence between the operating conditions of the range-extended system and the ignition advance angle of the FFI, ensuring that the range-extended system always operates at the optimal operating point and guarantees efficient and stable power output. During the calibration, the combustion analyzer needs to be integrated into the engine 2 detection circuit to ensure that the range-extended system can match the optimal ignition advance angle under all power output conditions, avoiding combustion knocking in engine 2 due to excessive ignition advance angle. S6. By using the CAN tool to simulate the command interaction between the GCU and the electronic fuel injection controller, the optimal operating point of the range extender system can be verified in a closed loop. By quantitatively evaluating fuel consumption and power generation performance, the robustness and accuracy of the point selection strategy can be effectively ensured.
[0015] After the overall performance calibration of the range-extended hybrid system is completed, core performance parameters such as output power, fuel consumption rate, and output torque need to be calculated based on the data such as generator current, fuel consumption, and operating speed recorded during the calibration process. Based on the calculation results of output torque, range-extended system operating speed, generator power, and fuel consumption rate, a range-extended system performance MAP is generated. The GCU selects the optimal operating point according to this performance MAP and then performs joint control with the electronic fuel injection system 4 to ensure efficient and stable operation of the range-extended system. After the optimal operating point is selected, the range-extended system operating commands can be simulated and controlled using the CAN tool to test and verify whether the operating point selected by the GCU meets the calibration and design requirements. If it does not meet the calibration and design requirements, the above steps S3-S6 are repeated.
[0016] The above descriptions are merely embodiments of the present invention. Commonly known structures and characteristics are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are aware of all existing technologies in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can, under the guidance of this application, improve and implement this solution in combination with their own capabilities. Some typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention. These should also be considered within the scope of protection of the present invention, and will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.
Claims
1. A method for calibrating the performance of a range extender system, comprising the following steps: S1. Electrically connect the high-voltage circuit of the range extender system to the high-voltage circuit of the power supply cabinet, so that the electrical energy generated during the calibration of the overall performance and economy of the range extender is directly fed back to the power supply cabinet; at the same time, with the help of the monitoring function of the power supply cabinet, real-time data on power generation and power conversion efficiency can be obtained. S2. Integrate the combustion analyzer into the engine detection circuit, and adjust the calibration quantity of the range extender system according to the monitoring parameters of the combustion analyzer until the performance, fuel consumption and engine stability of the engine at each operating point are adjusted to the optimal state. S3 and GCU control the operation status of the range extender system through the host computer, while the electronic fuel injection controller is responsible for controlling the electronic fuel injection system. At the same time, the entire range of the range extender system speed from zero to maximum speed and the engine throttle opening from zero to maximum opening are divided into several continuous data sampling points. S4 and GCU adjust the operating speed of the range extender system through the host computer, and the electronic fuel injection controller adjusts the throttle opening synchronously through the host computer, thereby calibrating and optimizing each operating point; at the same time, core data such as fuel consumption and power generation after calibration at each operating point are recorded, and a performance MAP of the range extender system is drawn based on the above data. S5. By analyzing the performance MAP of the range extender system, the optimal operating curve of the range extender system is selected and the selected operating curve is adapted into the GCU. The range extender system can be operated in the operating curve through joint control between the GCU and the electronic fuel injection controller, thereby optimizing the working efficiency of the range extender system. S6. Verify the selected working curve using the CAN tool to check if the data meets the design requirements.
2. The method for calibrating the performance of a range extender system according to claim 1, characterized in that: In step S1, the range extender system adopts a benchtop integrated installation and overall calibration strategy, and the system introduces an energy feedback power cabinet.
3. The method for calibrating the performance of a range extender system according to claim 2, characterized in that: In step S2, the range extender system introduces a high-precision combustion analyzer to monitor and diagnose the in-cylinder combustion process of the engine in real time.
4. The method for calibrating the performance of a range extender system according to claim 3, characterized in that: In step S3, the range extender system calibration data adopts a two-dimensional grid management strategy based on throttle opening and engine speed.
5. The method for calibrating the performance of a range extender system according to claim 4, characterized in that: In step S4, the range extender system performs full-condition calibration and iterative optimization of the system economy based on the multi-dimensional mapping relationship between throttle opening and engine speed. By screening and recording the operating point with the best fuel economy, an efficient operating database is constructed and solidified into the generator controller.
6. The method for calibrating the performance of a range extender system according to claim 5, characterized in that: In step S4, the recorded key data, such as the temperature, fuel consumption, and power generation of the range extender system, are analyzed to determine if there are any abnormal phenomena or data.
7. The method for calibrating the performance of a range extender system according to claim 6, characterized in that: In step S5, after the range extender system is calibrated, the selection of the optimal operating curve should be strictly limited to the system's most efficient operating range. At the same time, the boundaries of the selected curve need to be precisely defined and verified.
8. The method for calibrating the performance of a range extender system according to claim 7, characterized in that: S6. Using the CAN tool to simulate the command interaction between the GCU and the electronic fuel injection controller, the optimal operating point of the range extender system can be verified in a closed loop. By quantitatively evaluating fuel consumption and power generation performance, it can be verified whether the operating point selected by the GCU meets the calibration and design requirements. If it does not meet the calibration and design requirements, repeat the above steps S3-S6.
9. The method for calibrating the performance of a range extender system according to claim 8, characterized in that: In step S6, the CAN tool is used to simulate the vehicle's operating commands, and a joint control closed loop of the GCU and the electronic fuel injection controller is constructed. By reproducing the vehicle's operating conditions, the power performance and fuel economy of the range extender system are tested in all aspects.