Integrated temperature control method for a hybrid power plant

Abstract

This invention discloses an integrated temperature control method for a hybrid power unit, relating to the field of thermal management technology. The method includes: a water channel temperature control step: a serpentine hollow, zigzag water channel is configured circumferentially within the housings of the generator and drive motor of the hybrid power unit, corresponding to the stator region. The cooling medium flows through the hollow, zigzag water channel in a continuous, zigzag flow path. A power margin temperature control step: based on the rated power of the generator of the hybrid power unit, the rated power of the drive motor is configured to be greater than the rated power of the generator, while ensuring that the actual output power of the drive motor during normal operation is lower than its rated power, thereby reducing the load rate and current intensity of the drive motor under the same operating load. The water channel temperature control step and the power margin temperature control step work synergistically to reduce the operating temperature rise of the drive motor and decrease heat accumulation. This reduces the operating temperature rise of the drive motor, decreases heat accumulation, and improves reliability and safety.

Description

Technical Field

[0001] This invention relates to the field of thermal management technology, and in particular to an integrated temperature control method for a hybrid power device. Background Technology

[0002] When hybrid tractors perform operations such as traction, rotary tillage, deep loosening, seeding, and long-distance transportation, the electric drive system needs to operate under high load for a long time. The drive motor is the core heat-generating component, and its temperature rise control directly determines the stability and service life of the entire machine.

[0003] In existing technologies, the cooling structure of the drive motor in hybrid power systems typically employs a conventional water channel design. This traditional water channel structure is relatively simple, and the flow path of the cooling medium through the motor housing is often short and singular, resulting in a limited contact area between the cooling medium and the motor housing and stator region. This makes it difficult to further improve heat exchange efficiency, failing to remove the large amount of heat accumulated inside the motor in a short time. Consequently, the heat dissipation capacity of the drive motor housing and stator region is insufficient, easily leading to excessively high localized temperatures.

[0004] Furthermore, in existing hybrid power system matching designs, the rated power of the drive motor is usually set to be equivalent to the rated power of the generator, or with only a small margin. This configuration results in the drive motor frequently operating at near or even full load under actual working conditions. According to the motor's operating characteristics, a high load rate means a high current intensity, and the thermal effect of the current significantly increases the intensity of heat generation.

[0005] Therefore, existing technologies lack a comprehensive temperature control solution that can both reduce heat generation at the source and significantly improve internal heat dissipation capacity. Summary of the Invention

[0006] The purpose of this invention is to provide an integrated temperature control method for a hybrid power system, in order to solve the problems existing in the prior art, reduce the operating temperature rise of the drive motor, reduce heat accumulation, and improve reliability and safety.

[0007] To achieve the above objectives, the present invention provides the following solution: This invention provides an integrated temperature control method for a hybrid power system, comprising: a water channel setting temperature control step: a serpentine hollow zigzag water channel is set in the circumferential position corresponding to the stator region within the housing of the drive motor of the hybrid power system; the inlet and outlet ends of the hollow zigzag water channel are connected to a cooling circulation system; and the cooling medium passes through the hollow zigzag water channel in a continuous zigzag flow path. A power margin temperature control step: the rated power of the drive motor is configured according to the rated power of the generator of the hybrid power system, such that the rated power of the drive motor is greater than the rated power of the generator, and the actual output power of the drive motor under normal operating conditions is lower than its rated power, thereby reducing the load rate and current intensity of the drive motor under the same operating load. The water channel setting temperature control step and the power margin temperature control step work synergistically to reduce the operating temperature rise of the drive motor and reduce heat accumulation.

[0008] Preferably, the method further includes an end winding potting and temperature control step: thermally conductive potting material is injected into the end winding areas of the generator and drive motor of the hybrid power unit. The injected thermally conductive potting material cures and makes the end winding area thermally contacted with the housing of the drive motor or the generator, thereby reducing the operating temperature rise of the end winding.

[0009] Preferably, the method further includes a step of cooling medium carrying heat and air dissipation for temperature control: the cooling medium absorbs heat from the drive motor, the generator, and the electronic control system of the hybrid power unit, and the heat carried by the cooling medium is dissipated to the outside air through heat exchange via the radiator assembly.

[0010] Preferably, the system further includes an electronic control system monitoring and protection step: the electronic control system monitors one or more parameters in real time, including the load rate of the drive motor, the temperature of the drive motor, the temperature of the cooling medium, and the temperature of the electronic control system. When the load rate of the drive motor exceeds the set allowable range corresponding to the rated power, the electronic control system automatically cuts off the power or controls the hybrid power unit to enter a shutdown protection state.

[0011] Preferably, in the waterway temperature control step, the hollow return waterway includes waterways along the axial and circumferential directions of the housing of the generator or the drive motor.

[0012] Preferably, in the power margin temperature control step, the rated power of the drive motor is configured to be 20% greater than the rated power of the generator; and the actual output power of the drive motor is operated at 80% of its rated power.

[0013] Preferably, the thermally conductive potting material is thermally conductive epoxy resin, which fills the gap in the end winding region of the generator or the drive motor.

[0014] Preferably, the load rate of the drive motor exceeding the rated power is defined as the actual output power of the drive motor exceeding the rated power of the drive motor, or the load rate of the drive motor exceeding 100%.

[0015] Preferably, the heat sink assembly includes a fan, and the fan speed is adjustable.

[0016] The present invention achieves the following technical effects compared to the prior art: The integrated temperature control method for a hybrid power device provided by this invention utilizes a water channel temperature control step. A serpentine hollow, zigzag water channel is arranged circumferentially around the stator of the drive motor housing and connected to the cooling circulation system. The cooling medium forms a continuous zigzag flow path, extending the heat exchange stroke and increasing the heat exchange contact area, effectively improving the heat dissipation capacity of the drive motor housing and stator area, and solving the problems of low heat exchange efficiency and heat accumulation in traditional water channels. Simultaneously, a power margin temperature control step ensures that the rated power of the drive motor is greater than the rated power of the generator. During normal operation, the actual output power of the motor is lower than its own rated power, reducing the load rate and current intensity under the same load, thus reducing heat generation at the source. These two steps work together to simultaneously reduce heat generation and enhance heat dissipation, forming a comprehensive temperature control solution that overcomes the shortcomings of existing technologies that only optimize a single aspect and cannot simultaneously solve the problems of insufficient heat dissipation and excessive heat generation. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A logic diagram of the integrated temperature control method for a hybrid power device provided by the present invention; Figure 2 A schematic diagram of the hollow folding water channel in the integrated temperature control method for the hybrid power device provided by the present invention; Figure 3 This is a schematic diagram of the power transmission route of the hybrid power device corresponding to the present invention. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] The purpose of this invention is to provide an integrated temperature control method for a hybrid power system, in order to solve the problems existing in the prior art, reduce the operating temperature rise of the drive motor, reduce heat accumulation, and improve reliability and safety.

[0021] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0022] Example 1 This embodiment provides an integrated temperature control method for a hybrid power device, such as... Figures 1-3 As shown, the integrated temperature control method includes hollow foldback water channel temperature control, power margin temperature control, end winding potting temperature control, cooling medium heat transfer and air heat dissipation temperature control, and electronic control system monitoring and protection. These steps are not isolated from each other, but rather work together in the thermal management process of the hybrid power unit.

[0023] In the hollow folding water channel temperature control step, hollow folding water channels are installed inside the generator and drive motor housings. After entering the hollow folding water channels, the cooling medium flows in a folding pattern inside the generator and drive motor housings, absorbing heat transferred from the drive motor housing, stator region, and adjacent heat-generating components during the flow. Through the high-flow-rate folding water channel structure, the cooling medium can form a longer heat exchange path within the drive motor housing (increasing the heat exchange path and heat exchange area between the cooling medium and the drive motor housing to remove the heat generated during drive motor operation), thereby improving the liquid cooling capacity of the drive motor.

[0024] In the power margin temperature control step, the rated power of the drive motor is determined based on the rated power of the generator in the hybrid power unit, and the rated power of the drive motor is made greater than the rated power of the generator. Through this power matching method, the actual output power of the drive motor under normal operating conditions is lower than its rated power, giving the drive motor a certain power margin, reducing the load rate and current intensity of the drive motor, and reducing the heat generated during the operation of the drive motor from the source. The rated power of the drive motor is greater than the rated power of the generator, giving the drive motor a power margin greater than the normal operating power requirement, thus allowing the drive motor to operate at a lower power than its rated power under normal operating conditions. Taking 260 hp and 300 hp hybrid tractors as examples, the engine transmits power to the power supply device, which is a generator; for the 260 hp hybrid tractor, the rated power of the generator is 191 kW, and the corresponding rated power of the matched drive motor is 220 kW; for the 300 hp hybrid tractor, the rated power of the generator is 220 kW, and the corresponding rated power of the matched drive motor is 260 kW. By increasing the rated power of the drive motor, the actual load rate of the drive motor under the same traction load conditions is reduced, and the drive motor is kept in a load state below full load during normal operation. Preferably, the actual power is reduced to about 80% of the rated power, thereby reducing the heat accumulation generated by the drive motor when it is running close to full load for a long time.

[0025] In the end-winding potting and temperature control step, thermally conductive epoxy resin is injected into the end-winding region of the generator and drive motor. The thermally conductive epoxy resin fills the gaps in the end-winding region (to improve the thermal conductivity between the end winding and the motor housing, cooling channels, or other heat-conducting components), creating a thermally conductive channel between the end winding and the motor (generator and drive motor) housing. The heat generated by the end winding is transferred to the motor housing through the thermally conductive epoxy resin and further carried away by the cooling medium, thereby reducing the local temperature rise of the end winding.

[0026] In the cooling medium heat transfer and air heat dissipation temperature control step, the cooling medium absorbs heat generated by the heat-generating components in the generator, drive motor, and electronic control system (the electronic control system of the hybrid power unit is existing technology and equipment, and will not be elaborated further; similarly, for the generator and drive motor, except for the modifications mentioned in this text, the other settings are existing technology, and will not be elaborated further here), and enters the radiator. The radiator exchanges heat with the outside air, the fan promotes airflow through the radiator, and the air guide structure (an existing component, i.e., the structure used to introduce air into the radiator, i.e., the fan) guides the flow of outside air, thereby dissipating the heat carried by the cooling medium into the outside air. In the cooling medium heat transfer and air heat dissipation temperature control step, the cooling medium, after absorbing heat, enters the radiator, and the fan adjusts its speed according to one or more parameters of the cooling medium temperature, generator and drive motor temperature, and electronic control system temperature to improve the efficiency of the cooling medium in dissipating heat to the outside air.

[0027] In the monitoring and protection steps of the electronic control system, the system monitors one or more parameters in real time, including the drive motor load rate, generator and drive motor temperatures, cooling medium temperature, and electronic control system temperature. This ensures that the monitored components operate within set thresholds, maintaining normal operating temperatures. Furthermore, the system controls the drive motor load rate to not exceed the allowable range corresponding to the rated power, or to not exceed 100%; otherwise, it enters a power-off shutdown protection state. When the drive motor load rate exceeds the allowable range corresponding to the rated power, or exceeds 100%, the electronic control system automatically cuts off the drive motor's external power supply circuit, thereby preventing the drive motor from continuously operating under overload conditions.

[0028] The temperature control steps of the hollow return water channel, the power margin temperature control step, the end winding potting temperature control step, the cooling medium heat carrying and air heat dissipation temperature control step, and the electrical control system monitoring and protection step work together to reduce the heat generation of the generator and drive motor, improve the internal heat conduction capacity of the generator and drive motor, enhance the heat carrying capacity of the cooling medium and the external air heat dissipation capacity, and automatically perform power-off protection when the drive motor is overloaded.

[0029] In practical applications, the hollow folding water channel temperature control step is used to improve the liquid cooling capacity of the generator and drive motor; the power margin temperature control step is used to reduce the intensity of heat generation from the drive motor; the end winding potting temperature control step is used to improve local heat dissipation of the end winding; the cooling medium heating and air cooling temperature control step is used to transfer heat from the heat-generating components to the external air; and the electronic control system monitoring and protection step is used to provide protection under overload or abnormal temperature rise conditions. Through the synergistic effect of the above steps, this embodiment can reduce the operating temperature rise of the hybrid power unit and improve the reliability and safety of the generator, drive motor, and electric drive system.

[0030] First, this embodiment provides hollow folding water channels within the generator and drive motor housings, enabling the cooling medium to form a continuous folding flow path within the generator and drive motor housings. This increases the heat exchange area and heat exchange path, thereby improving the heat dissipation capacity of the drive motor housing and stator region.

[0031] Secondly, by making the rated power of the drive motor greater than that of the generator, this embodiment enables the drive motor to have a power margin under normal operating conditions, which can reduce the load rate and current intensity of the drive motor under the same operating load, thereby reducing the intensity of heat generation from the source.

[0032] Third, by injecting thermally conductive potting material into the end winding area, this embodiment can improve the thermal conductivity between the end winding and the motor housing (generator and drive motor), which is beneficial to reducing the local temperature rise of the end winding.

[0033] Fourth, this embodiment combines the heat-carrying capacity of the cooling medium with the heat dissipation of the air, so that the cooling medium first absorbs the heat generated by the generator, drive motor and electronic control system, and then dissipates the heat to the outside air through the radiator, fan and air guide structure, forming a continuous heat dissipation path.

[0034] Fifth, this embodiment uses an electronic control system for monitoring and protection. When the load rate of the drive motor exceeds the allowable range corresponding to the rated power, it automatically cuts off the power or enters a protection state, which can avoid heat accumulation caused by overload operation of the drive motor and improve the operational safety of the hybrid power device.

[0035] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. An integrated temperature control method for a hybrid power device, characterized in that: include: Water channel temperature control steps: A serpentine hollow zigzag water channel is set in the circumferential position of the stator area in the housing of the generator and drive motor of the hybrid power unit. The inlet and outlet of the hollow zigzag water channel are connected to the cooling circulation system. The cooling medium passes through the hollow zigzag water channel in the form of a continuous zigzag flow path. Power margin temperature control steps: Based on the rated power of the generator of the hybrid power unit, configure the rated power of the drive motor so that the rated power of the drive motor is greater than the rated power of the generator, and make the actual output power of the drive motor under normal operating conditions lower than its rated power, so as to reduce the load rate and current intensity of the drive motor under the same operating load. The waterway temperature control step works in conjunction with the power margin temperature control step to reduce the operating temperature rise of the drive motor and reduce heat accumulation.

2. The integrated temperature control method for a hybrid power device according to claim 1, characterized in that: It also includes an end winding potting temperature control step: thermally conductive potting material is injected into the end winding areas of the generator and drive motor of the hybrid power unit. The injected thermally conductive potting material cures and makes thermally conductive contact between the end winding area and the housing of the drive motor or the generator, so as to reduce the operating temperature rise of the end winding.

3. The integrated temperature control method for a hybrid power device according to claim 1, characterized in that: It also includes a cooling medium heat transfer and air heat dissipation temperature control step: the cooling medium absorbs the heat generated in the electronic control system of the generator, the drive motor and the hybrid power device, and the heat carried by the cooling medium is dissipated to the outside air through heat exchange via the radiator assembly.

4. The integrated temperature control method for a hybrid power device according to claim 1, characterized in that: It also includes an electronic control system monitoring and protection step: the electronic control system monitors one or more parameters in real time, including the load rate of the drive motor, the temperature of the drive motor, the temperature of the cooling medium, and the temperature of the electronic control system. When the load rate of the drive motor exceeds the set allowable range corresponding to the rated power, the electronic control system automatically cuts off the power or controls the hybrid power unit to enter a shutdown protection state.

5. The integrated temperature control method for a hybrid power device according to claim 1, characterized in that: In the waterway temperature control step, the hollow return waterway includes waterways along the axial and circumferential directions of the housing of the generator or the drive motor.

6. The integrated temperature control method for a hybrid power device according to claim 1, characterized in that: In the power margin temperature control step, the rated power of the drive motor is configured to be 20% greater than the rated power of the generator; and the actual output power of the drive motor is operated at 80% of its rated power.

7. The integrated temperature control method for a hybrid power device according to claim 2, characterized in that: The thermally conductive potting material is thermally conductive epoxy resin, which is filled in the gap of the end winding region of the generator or the drive motor.

8. The integrated temperature control method for a hybrid power device according to claim 4, characterized in that: The load rate of the drive motor exceeds the set allowable range corresponding to the rated power, which means that the actual output power of the drive motor exceeds the rated power of the drive motor, or the load rate of the drive motor exceeds 100%.

9. The integrated temperature control method for a hybrid power device according to claim 3, characterized in that: The heat sink assembly includes a fan, and the fan speed is adjustable.

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