An active cooling circulation system for a hydraulic system of a mining vehicle

Abstract

This invention belongs to the technical field of hydraulic control and thermal management, and relates to an active cooling circulation system for the hydraulic system of mining vehicles. The system includes: a hydraulic parameter acquisition module, generating hydraulic mechanical work parameter flow; a heat flux prediction module, generating heat source signals reflecting instantaneous thermal shock; an engine heat capacity assessment module, generating engine dynamic heat capacity reference signals; a cross-system interlock control module, outputting cross-system interlock authorization commands; a heat exchange actuation module, establishing a heat exchange circulation path between the hydraulic main circuit and the engine cooling circulation circuit; a cooling mode switching module to provide compensatory cooling; and an oil quality management module, performing oil flow limiting and filtration operations. This invention solves the problem of difficulty in rationally utilizing the vehicle-level heat dissipation potential when facing instantaneous high heat loads, which limits the timeliness of predictive cooling intervention and the efficiency of heat load distribution.

Description

Technical Field

[0001] This invention belongs to the technical field of hydraulic control and thermal management, and relates to an active cooling circulation system for hydraulic systems of mining vehicles. Background Technology

[0002] Hydraulic systems in heavy construction machinery such as mining vehicles operate under harsh conditions, often requiring high-load and high-frequency reciprocating motions. This results in energy loss of the hydraulic oil as it flows through various valves and throttle orifices, causing the oil temperature to rise. Particularly during rapid switching of operating conditions or the execution of impact loads, instantaneous localized heat accumulation and thermal shock can easily occur within the system. This transient overheating phenomenon poses a potential threat to the physicochemical properties of the hydraulic oil and the precision of hydraulic component fittings, and is a technical factor affecting the long-term stable operation of the hydraulic system.

[0003] To address the aforementioned impacts, the industry typically employs a solution of configuring an independent cooling circuit for the hydraulic system. Chinese Invention Patent Application No. 202210679932.8 discloses a composite heat dissipation hydraulic oil temperature control system. This system uses a temperature sensor to detect the overall oil temperature within the hydraulic oil tank. When the detected hydraulic oil temperature exceeds a preset temperature, the controller activates the return oil switching valve assembly, causing the high-temperature hydraulic return oil to flow into the hydraulic oil cooler for cooling before returning to the tank. This control strategy primarily relies on macroscopic oil temperature threshold feedback to passively adjust the operating state of the heat dissipation components, thereby dissipating accumulated heat to maintain the system's basic temperature balance.

[0004] The aforementioned independent control scheme based on macroscopic temperature feedback suffers from a technical problem of untimely response to transient thermal shock suppression when dealing with dynamic and complex operating conditions. Since the rise in oil temperature is the ultimate manifestation of prolonged and continuous heat accumulation, relying on temperature sensors not only makes it difficult for the cooling mechanism to detect the surge in localized heat power caused by fluid throttling in the early stages of a thermal shock, but also fails to consider the vehicle engine's current real-time heat absorption limits in a coordinated manner. This makes it difficult for the system to effectively utilize the vehicle-wide heat dissipation potential when facing instantaneous high heat loads, limiting the timeliness of predictive cooling intervention and the efficiency of heat load distribution.

[0005] Therefore, how to provide an active cooling cycle scheme that can proactively predict transient heating trends and coordinate with the engine's dynamic heat capacity is a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0006] To address the aforementioned problems, this invention provides an active cooling circulation system for the hydraulic system of mining vehicles.

[0007] An active cooling circulation system for a hydraulic system of a mining vehicle, comprising: The hydraulic parameter acquisition module acquires the high-frequency differential pressure waveform characteristics and the original transient flow data stream of the hydraulic main circuit. It performs common-mode noise reduction and absolute timestamp alignment on the high-frequency differential pressure waveform characteristics and the original transient flow data stream to generate the hydraulic mechanical work parameter stream. The heat flux prediction module calculates the pressure change gradient based on the hydraulic mechanical work parameter flow and solves the transient heat generation power mapping basis. It then performs pulse width modulation conversion on the transient heat generation power mapping basis to generate a heat source signal that reflects the instantaneous thermal shock. The engine heat capacity assessment module acquires the water pump back pressure data and real-time coolant temperature of the engine cooling circulation loop, and inputs the two into the preloaded thermal balance physical model to solve for the current heat absorption safety margin, generating the engine dynamic heat capacity reference signal. The cross-system interlock control module performs a logical comparison and judgment between the heat source signal and the engine dynamic heat capacity reference signal. When it is determined that the engine dynamic heat capacity reference signal is greater than the preset safe thermal shock resistance threshold, it outputs a cross-system interlock authorization command. The heat exchange actuation module responds to the cross-system interlock authorization command and opens the plate heat exchanger located at the intersection of the hydraulic unloading bypass branch and the engine coolant drain branch, thus establishing a heat exchange circulation path between the hydraulic main circuit and the engine cooling circulation circuit. The cooling mode switching module continuously tracks the engine's dynamic heat capacity reference signal. When it detects that the reference signal has fallen below the safe thermal shock resistance threshold, it mechanically locks the plate heat exchanger and redirects the heat source signal to the independent air-cooled heat dissipation terminal, driving the fan to perform forced air-cooling heat dissipation to provide compensatory cooling. The oil quality management module intercepts the return hydraulic fluid after heat exchange or air cooling to perform online contamination identification. When it is confirmed that the concentration of solid particulate matter exceeds the preset fluid quality inspection allowable baseline, it triggers the flow restriction action and starts the deep micro-nano filtration program to perform oil flow restriction and filtration operations.

[0008] In a further embodiment of the present invention, the hydraulic parameter acquisition module is specifically configured to perform the following operations: Wideband dynamic differential pressure sensors arranged at both ends of the inlet and outlet of the main valve group in the hydraulic main circuit are used to synchronously extract the pressure drop waveform and generate high-frequency differential pressure waveform characteristics. Using a non-intrusive transient flow monitor, capture the raw transient flow data stream corresponding to the overlapping coverage area of ​​the absolute time axis; The solid-state coprocessing unit is invoked to filter the common-mode background noise of the high-frequency differential pressure waveform using a hardware differential network. Based on a high-precision time synchronization protocol, the original transient flow data stream is interpolated into the same microsecond-level time reference coordinate system for resampling, generating a time-aligned hydraulic mechanical work parameter stream.

[0009] In a further embodiment of the present invention, the heat flux prediction module is specifically configured to perform the following operations: The differential control unit uses the backward difference method to analyze the change in absolute pressure difference before and after the hydraulic mechanical work parameter flow, and generates a pressure change gradient. By performing a logical dot product operation between the pressure change gradient and the instantaneous flow characteristics at that moment, the transient heating power mapping cardinality reflecting the conversion of mechanical kinetic energy into thermal energy is solved. The transient heating power mapping base is converted into a high-frequency pulse width modulation duty cycle sequence by a normalized ratio through a hardware frequency conversion module, thereby generating a heating source signal.

[0010] In a further embodiment of the present invention, the engine thermal capacity assessment module is specifically configured to perform the following operations: The back pressure data of the water pump connected to the engine water pump drive end is obtained through the communication bus, and the coolant temperature is captured synchronously using the physical path. The driving thermal balance modeling algorithm converts the water pump back pressure data into circulation flow rate, and calculates the current heat absorption safety margin by combining the coolant temperature and the coolant's predetermined boiling point limit. By using a digital-to-analog decoding chip in conjunction with a calibration spectrum, the current heat absorption safety margin is converted into a direct-read voltage proportionally, generating a dynamic heat capacity reference signal for the engine.

[0011] In a further embodiment of the present invention, the cross-system interlock control module is specifically configured to perform the following operations: The heat source signal is guided to the trigger pin of the external electro-hydraulic valve island, and the engine dynamic heat capacity reference signal is acquired in parallel. The engine dynamic thermal capacity reference signal is input into a multi-channel physical comparator component and compared with the preset safe thermal shock resistance threshold voltage in differential mode amplitude. When the comparator determines that the positive overshoot is true, it releases the latching pulse, which activates the electromagnetic contacts of the main control relay to close, opens the hardware information transfer path, and outputs a cross-system interlocking authorization command.

[0012] In a further embodiment of the present invention, the heat exchange actuation module is specifically configured to perform the following operations: The intelligent switching valve coil responds to the cross-system interlock authorization command, analyzes the PWM duty cycle value in the heat source signal, and converts it into the corresponding electromagnetic driving force through the drive circuit. The electromagnetic driving force overcomes the preload of the mechanical spring, pushing the main flow-blocking proportional valve core to undergo axial displacement, thereby connecting the oil guide path of the plate heat exchanger; The displacement stroke of the main flow-blocking proportional valve core is detected, and a speed control command is generated proportionally and sent to the external variable frequency hydraulic circulation pump to accelerate the flow of hydraulic fluid through the plate heat exchanger to perform heat exchange and establish a heat exchange circulation path.

[0013] In a further embodiment of the present invention, the cooling mode switching module is specifically configured to perform the following operations: Activate the detection program and compare the rate of decrease of the engine dynamic thermal capacity reference signal in adjacent sampling periods; When continuous verification confirms that the rate of decline is irreversible and the reference signal falls below the safe thermal shock threshold, the power supply line of the main control relay is disconnected to cancel the electromagnetic driving force, so that the main flow isolation proportional valve core is silently reset by spring force, and the hydraulic pipeline to the plate heat exchanger is physically cut off. The intercepted heat source signal is redirected to an independent air-cooled heat dissipation terminal, which controls and increases the operating voltage or frequency of the cooling fan to accelerate the dissipation of heat inside the system and perform independent cooling.

[0014] In a further embodiment of the present invention, the oil quality management module is specifically configured to perform the following operations: The traction return hydraulic fluid slows down the flow rate, penetrates the window of the photoelectric vision particle spectral analysis probe, and calculates the concentration of micro-nano solid particles in the fluid through spectral image processing algorithms; When the concentration exceeds the preset fluid quality inspection allowable baseline, the control hydraulic scheduling unit forcibly reduces the displacement of the external variable frequency hydraulic circulation pump according to the preset ratio to prioritize the pressure requirements of the main working oil circuit. The hydraulic fluid, after being restricted in flow, is guided to the deep precision fiber bundle filter element base to perform sedimentation and separation, thus completing the deep purification of the oil.

[0015] A further aspect of the present invention involves guiding the limited-flow hydraulic fluid into a deep precision fiber bundle filter cartridge base for sedimentation and separation, and further includes the following steps: By reducing the pump displacement, the flow rate of the returning hydraulic fluid is forced to decrease to a state of weak permeation and pressure maintenance. The fluid under weak permeation and pressure maintenance conditions is allowed to enter the deep precision fiber bundle filter cartridge base equipped with multi-gradient filter screens and hydrophobic chassis; By utilizing low flow rate to increase the probability of collision and adhesion between tiny suspended particles and fiber bundle micropores, the retention time is extended, and sedimentation, stripping, and descaling operations are performed to recover the purified oil to the main oil tank.

[0016] A further embodiment of the present invention performs sedimentation, stripping, and descaling operations, including the following steps: Within the area affected by weak permeation and pressure maintenance, the fluid velocity is reduced to the critical range for the settling of suspended particles, so that the suspended particles are removed from the fluid. By using a maze-like, tortuous channel arranged within the micro-nano separation space, the residence time of free-state hard particles and the entanglement points of the filter mesh skeleton is increased; By extending the residence time, free hard particles are encouraged to adhere to the filter screen frame, and water and impurities with different densities are allowed to settle and separate, thus completing the oil purification.

[0017] In summary, the present invention has the following beneficial technical effects: 1. By synchronously acquiring high-frequency differential pressure and instantaneous flow data of the main valve group of the hydraulic system, a power parameter flow reflecting the energy dissipation within the system is constructed. By extracting the hydrodynamic pressure change gradient and multiplying it with the instantaneous flow rate, the rate of transient heat power generation caused by fluid throttling and shearing is monitored. Compared to the traditional passive feedback method that relies on heat accumulation to cause macroscopic temperature changes, this method can predict the trend of local thermal shock before the hydraulic oil temperature rises significantly, providing time margin for subsequent cooling intervention and thus achieving predictive suppression of local thermal shock.

[0018] 2. By acquiring the physical parameters of the engine cooling circuit and calculating its heat absorption tolerance, a dynamic heat capacity reference signal is generated. The system logically compares this signal with the instantaneous heat flux prediction signal of the hydraulic system. Only when it is determined that the engine cooling system has sufficient heat dissipation margin will the heat exchange tubes between the high-temperature hydraulic oil and the engine coolant be authorized to be connected. This mechanism treats the engine cooling system, the main heat sink of the vehicle, as a dynamic auxiliary heat dissipation unit of the hydraulic system, making reasonable use of the heat dissipation potential at the vehicle level; at the same time, it avoids placing additional burden on the engine when it is under high heat load, which is conducive to maintaining the overall thermal balance of the vehicle.

[0019] 3. Control strategy for dynamically switching cooling modes based on the overall thermal state of the engine. During cross-system heat exchange, the system continuously tracks the dynamic heat capacity of the engine. When the system detects a decrease in the heat absorption capacity of the engine side and reaches the set safety threshold, it actively triggers a hard isolation mechanism to disconnect the heat exchange channel between the two systems to ensure the engine's own operational safety. At the same time, the system switches the cooling task of the hydraulic system to an independent compensated forced air cooling terminal and adjusts the fan speed according to the heat flux intensity to provide heat dissipation compensation.

[0020] 4. Optical particle monitoring of the return hydraulic fluid is introduced into the cooling circuit to identify the degree of oil contamination in real time. When the concentration of wear particles exceeds the set allowable threshold, the system actively reduces the discharge rate of the external variable frequency circulating pump to prioritize ensuring the high-pressure power requirements of the main working circuit under load; simultaneously, the low-flow-rate hydraulic oil subject to flow restriction is guided to a deep ultrafiltration nano-micro separation device for fine purification. This design expands the hydraulic thermal management system from simple temperature control to a comprehensive platform encompassing system health monitoring and fluid purification, achieving dual system-level protection against instantaneous thermal shock and potential mechanical wear. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. The drawings are used to provide a further understanding of the present invention.

[0022] Figure 1 This discloses a schematic diagram of the framework in the embodiments of this application.

[0023] Figure 2 This discloses a flowchart of an embodiment of this application.

[0024] Figure 3 This application discloses a schematic diagram of the pressure difference and flow data stream after noise reduction and alignment in an embodiment of the present application; Figure 4 This application discloses a schematic diagram of transient heating power assessment and prediction in its embodiments; Figure 5 This application discloses a schematic diagram of the instantaneous heat flux generation source signal generation in an embodiment of the present application. Detailed Implementation

[0025] The following is in conjunction with the appendix Figure 1 - Figure 5 A preferred description of the present invention is provided below.

[0026] See attached document Figure 1 - Figure 2 This invention proposes an active cooling circulation system for the hydraulic system of mining vehicles, comprising the following modules: The hydraulic parameter acquisition module acquires the high-frequency differential pressure waveform characteristics and the original transient flow data stream of the hydraulic main circuit. It performs common-mode noise reduction and absolute timestamp alignment on the high-frequency differential pressure waveform characteristics and the original transient flow data stream to generate the hydraulic mechanical work parameter stream. The heat flux prediction module calculates the pressure change gradient based on the hydraulic mechanical work parameter flow and solves the transient heat generation power mapping basis. It then performs pulse width modulation conversion on the transient heat generation power mapping basis to generate a heat source signal that reflects the instantaneous thermal shock. The engine heat capacity assessment module acquires the water pump back pressure data and real-time coolant temperature of the engine cooling circulation loop, and inputs the two into the preloaded thermal balance physical model to solve for the current heat absorption safety margin, generating the engine dynamic heat capacity reference signal. The cross-system interlock control module performs a logical comparison and judgment between the heat source signal and the engine dynamic heat capacity reference signal. When it is determined that the engine dynamic heat capacity reference signal is greater than the preset safe thermal shock resistance threshold, it outputs a cross-system interlock authorization command. The heat exchange actuation module responds to the cross-system interlock authorization command and opens the plate heat exchanger located at the intersection of the hydraulic unloading bypass branch and the engine coolant drain branch, thus establishing a heat exchange circulation path between the hydraulic main circuit and the engine cooling circulation circuit. The cooling mode switching module continuously tracks the engine's dynamic heat capacity reference signal. When it detects that the reference signal has fallen below the safe thermal shock resistance threshold, it mechanically locks the plate heat exchanger and redirects the heat source signal to the independent air-cooled heat dissipation terminal, driving the fan to perform forced air-cooling heat dissipation to provide compensatory cooling. The oil quality management module intercepts the return hydraulic fluid after heat exchange or air cooling to perform online contamination identification. When it is confirmed that the concentration of solid particulate matter exceeds the preset fluid quality inspection allowable baseline, it triggers the flow restriction action and starts the deep micro-nano filtration program to perform oil flow restriction and filtration operations.

[0027] In one embodiment of the present invention, the hydraulic parameter acquisition module is used to perform the following operations: Wideband dynamic differential pressure sensors arranged at both ends of the inlet and outlet of the main valve group in the hydraulic main circuit are used to synchronously extract the pressure drop waveform and generate high-frequency differential pressure waveform characteristics. Using a non-intrusive transient flow monitor, capture the raw transient flow data stream corresponding to the overlapping coverage area of ​​the absolute time axis; The solid-state coprocessing unit is invoked to filter the common-mode background noise of the high-frequency differential pressure waveform using a hardware differential network. Based on a high-precision time synchronization protocol, the original transient flow data stream is interpolated into the same microsecond-level time reference coordinate system for resampling, generating a time-aligned hydraulic mechanical work parameter stream.

[0028] Specifically, this step begins with the control system activating a pair of wideband dynamic differential pressure sensing nodes located on both sides of the inlet and outlet of the main valve assembly in the hydraulic system. These sensing nodes physically consist of two synchronously acquiring piezoelectric pressure sensors: one installed at the high-pressure inlet of the main valve assembly, and the other at the corresponding low-pressure return port. The sensor response frequency range is set from 0.5 Hz to 20 kHz, covering a range from 0 MPa to 40 MPa. The 0 MPa to 40 MPa range is chosen because the peak operating pressure of the main oil circuit in the hydraulic system of heavy-duty mining vehicles is typically between 25 MPa and 35 MPa, and the upper limit of 40 MPa safely covers the peak water hammer impact under extreme loads. The upper limit of the response frequency is set to 20kHz because the high-frequency shearing generated by the fluid flowing through the throttling valve orifice and the transient pressure pulsation caused by the collapse of cavitation bubbles have physical characteristic frequencies mostly concentrated in the 1 kHz to 10 kHz frequency band. The 20kHz response frequency can ensure that the microsecond-level high-frequency differential pressure distortion caused by the initial thermal shock is captured without distortion, thereby completely capturing the pressure transient response caused by the opening or closing of the valve orifice.

[0029] The control system uses a preset sampling frequency. Synchronous data acquisition is performed from two pressure sensors, wherein the sampling frequency is... The sampling frequency is set based on the Nyquist sampling theorem, and its value is typically set to more than twice the upper limit of the sensor's response frequency, for example, 50 kHz. This frequency setting aims to capture the microsecond-level pressure fluctuations derived from high-pressure shearing and turbulence effects when hydraulic oil flows through damping structures such as throttling orifices and spool valve edges within the valve assembly, ensuring distortion-free reconstruction of the high-frequency pressure waveform. This sampling frequency setting follows the Nyquist-Shannon sampling theorem. To prevent high-frequency noise aliasing and to reconstruct the pressure waveform with a maximum frequency of 20 kHz with high fidelity, the sampling frequency must be greater than 40 kHz. Setting it to 50 kHz provides a 2.5-fold oversampling margin, effectively filtering out parasitic electromagnetic interference and providing a solid data foundation for subsequent microsecond-level differential pressure gradient calculations.

[0030] The acquisition process generates two discrete pressure signal sequences. By calculating the difference in readings from the two sensors at the same moment, the original high-frequency differential pressure waveform characteristics, including high-frequency noise and common-mode interference, are generated in real time. Simultaneously, the control system activates a wide-range transient flow monitor embedded in the downstream or upstream main pipeline of the hydraulic main circuit. This monitor can be a non-invasive clamp-on ultrasonic flow meter, with its range set according to the displacement of the main pump in the mining vehicle's hydraulic system, typically from 50 L / min to 600 L / min. The upper limit of the 600 L / min range is suitable for the typical maximum displacement operating conditions of the main hydraulic pump in large mining excavators or articulated trucks, such as the flow rate when the main pump is running at full speed. The monitor uses a sampling frequency... Capture the original transient flow data stream where the characteristics of the original high-frequency differential pressure waveform overlap with those of the original high-frequency differential pressure waveform on the time axis; this sampling frequency... To ensure the timing alignment accuracy with the pressure signal, it is usually set to no less than 1 kHz. Due to the macroscopic inertia of fluid mass, the physical rate of change of global flow is much slower than the propagation rate of pressure wave. Therefore, a sampling frequency of 1 kHz, i.e. a sampling period of 1 ms, is sufficient to cover the transient flow step caused by the mechanical switching action of the main control slide valve.

[0031] The acquired raw high-frequency differential pressure waveform characteristics and raw transient flow data stream are fed into a coprocessing unit, which can be a field-programmable gate array (FPGA) or a digital signal processor (DSP). Inside this coprocessing unit, hardware-level differential amplification is applied to the raw high-frequency differential pressure waveform characteristics to suppress common-mode voltage noise. Specifically, a differential amplifier is used to subtract the signals from the two pressure sensors, amplifying the differential signal (the true pressure difference) while suppressing common-mode interference signals of the same amplitude and phase generated on the two signal lines due to electromagnetic interference. Furthermore, a sliding window-based FIR low-pass filter is independently applied to each of the two data streams to filter out white noise exceeding the system's physical response bandwidth.

[0032] The coprocessor unit performs absolute timestamp stitching alignment. Specifically, this process uses linear interpolation for resampling, assuming two consecutive original flow sampling points. and Between these points, there exists a pressure differential sampling point that needs to be aligned. The interpolated result is Flow value at any time The calculation formula is: This processing aims to eliminate minor time asynchrony caused by factors such as hardware delays from different sensors, differences in data transmission paths, and operating system task scheduling jitter. It assumes an application scenario of heavy-duty excavation operations with extremely high requirements for thermal shock prediction, where alignment accuracy better than 100 μs is needed. In this process, the coprocessor reads high-precision timestamps injected by global clock synchronization protocols such as NTP or PTP from each sensor data frame, using a unified interpolation time base. Resample both data streams to ensure that at each output time point Above, differential pressure value With flow value This establishes a correspondence. The final product of this alignment and noise reduction process is a two-dimensional data sequence that encapsulates pressure drop gradient timing information and flow timing information. This sequence is defined as a hydraulic mechanical work parameter stream that combines pressure drop gradient and flow timing characteristics, and is transmitted to the subsequent processing module.

[0033] It should be noted that the hydraulic machinery work parameter stream is a data structure, and its format can be as follows: ,in This represents the total number of data points contained in the data sequence. For timestamps, That is, the text This is expressed as the net differential pressure value after alignment at that moment. That is, the text This represents the instantaneous flow rate value after alignment at that moment.

[0034] For example, suppose that within a very small time interval, the control system activates the associated node. A pressure sensor deployed at the inlet of the main valve assembly... The pressure value collected at any given time was 25.1 MPa. The pressure was consistently measured at 25.3 MPa. The pressure sensor deployed at the outlet... The pressure value collected at any given time was 1.5 MPa. The pressure was 1.6 MPa at all times.

[0035] Simultaneously, the transient flow monitor... The flow rate was consistently recorded as 200 L / min. The flow rate was captured at 205 L / min. This raw data was then fed into the coprocessing unit. The coprocessing unit first performed noise reduction, a process omitted here for simplicity. Next, timestamp alignment was performed, selecting... As an alignment point. For differential pressure, it needs to be determined according to the imported sensor. and The readings and the outlet sensor at and The readings were calculated using linear interpolation. The import and export pressures at any given moment. Import pressure is approximately... Export pressure is approximately .

[0036] Therefore, in The differential pressure value after time alignment is And traffic is At this point, a sampled value of 205 L / min has been obtained. At the output of the coprocessor unit, a data point in the hydraulic machinery work parameter stream is generated, namely (1.010 ms, 23.655 MPa, 205 L / min). This data point integrates pressure drop and flow characteristics and is passed to the next calculation step.

[0037] See Figure 3 This demonstrates the hydraulic mechanical work parameter flow output by the hydraulic parameter acquisition module. The solid line represents the high-frequency differential pressure change waveform ΔP after common-mode noise reduction. It can be seen that it undergoes a non-linear and drastic fluctuation from high to low within a very short time, such as 1.0050 ms to 1.0150 ms, reflecting the transient throttling pressure drop at the hydraulic valve port. The dashed line represents the instantaneous flow rate data Q at the corresponding moment. The strict alignment of the two curves on the absolute timestamp removes the timing error obstacle for subsequent calculation of the instantaneous heat power generated by throttling in the system.

[0038] In one embodiment of the present invention, the heat flux prediction module is configured to perform the following steps: The differential control unit uses the backward difference method to analyze the change in absolute pressure difference before and after the hydraulic mechanical work parameter flow, and generates a pressure change gradient. By performing a logical dot product operation between the pressure change gradient and the instantaneous flow characteristics at that moment, the transient heating power mapping cardinality reflecting the conversion of mechanical kinetic energy into thermal energy is solved. The transient heating power mapping base is converted into a high-frequency pulse width modulation duty cycle sequence by a normalized ratio through a hardware frequency conversion module, thereby generating a heating source signal.

[0039] Specifically, based on the aforementioned steps, the control system calculates the instantaneous heat accumulation rate within the system using the extracted hydraulic mechanical work parameter flow, which combines pressure drop gradient and flow time-series characteristics. First, the system analyzes each data point of the hydraulic mechanical work parameter flow... The differential pressure component, i.e., the original high-frequency differential pressure waveform characteristics, is extracted from the data. This sequence of differential pressure data points is fed into a differential control unit, which is implemented in engineering as a numerical differentiation algorithm running on a coprocessor unit. The differential control unit uses the backward difference method to ensure real-time computation, relying only on current and historical data. The algorithm uses the backward difference method to calculate the hydrodynamic pressure change gradient. The calculation formula is: In the above formula, Indicates at time The hydrodynamic pressure change gradient, with units of Pa / s; and They represent the current time. and the previous sampling time The differential pressure value obtained by the hydraulic parameter acquisition module, in Pa; The sampling time interval is expressed in seconds. The calculated gradient represents the rate of pressure drop change within the hydraulic system per unit time due to throttling or shearing. It is not a direct temperature measurement, but rather a proactive prediction of the heat source using mechanical parameters, enabling it to detect the initial signs of thermal shock tens to hundreds of milliseconds earlier than traditional temperature sensors.

[0040] Subsequently, a multiplication module is invoked, which receives the hydrodynamic pressure change gradient output from the differential control unit. Simultaneously acquire the hydraulic machinery work parameters stored in the stream at the same timestamp. Aligned raw transient flow data stream The multiplication module performs a logical dot product on these two values, as shown in the following equation: In the formula, For a moment The instantaneous flow rate, in m³ / s. 3 / s. The result of this dot product operation is defined as the cardinality of the transient heating power mapping for the rapid conversion of mechanical energy into thermal energy. Its unit is J / s 2 This reflects the rate of change in power. As a metric, this baseline combines the severity of pressure changes with the current energy transport capacity of the system, i.e., the flow rate, and can assess the potential risk level of thermal shock. Physically, this baseline is proportional to the rate of increase in the system's thermal power; a dramatic increase in its value indicates the occurrence of a thermal shock event.

[0041] The system operates a hardware frequency converter, which in practical applications is a pulse width modulation signal generator. Based on a preset frequency control rule, it maps the calculated transient heating power to a base value. Convert the modulation to the corresponding square wave duty cycle. The high-frequency pulse width modulation message. Its conversion relationship is as follows: ,in The value is limited to between 0 and 1; This is a preset linear scaling factor, with units of s. 2 / J, used to... The value is normalized to the effective range of the duty cycle. The frequency control law is essentially a calibration process, performed on a specific hydraulic system under typical heavy-load conditions. Perform statistical analysis on the numerical range and set the maximum expected value. Thus, the proportionality coefficient is determined. The value is .

[0042] The carrier frequency of the final generated high-frequency pulse-width modulation message is set at a fixed high-frequency value, such as 20 kHz. This setting is based on two principles: firstly, it exceeds the human hearing sensitivity range of 20 Hz to 20 kHz, eliminating the high-frequency howling noise generated by the solenoid valve coil during frequent adjustments; secondly, this frequency is much higher than the mechanical self-oscillation response frequency of the hydraulic proportional valve core, typically below 100 Hz, ensuring that the valve core can only sense a smooth and continuous average DC thrust under the integral effect of electromagnetic induction. This avoids high-frequency mechanical oscillation of the valve core, extends the lifespan of the actuator, ensures smooth control of downstream actuators, and avoids the resonant frequency of the mechanical system. At the output layer, this message is ultimately defined as an instantaneous heat flux source signal indicating the risk of instantaneous local thermal shock. As a standardized digital signal, it encapsulates all dynamic information about the thermal shock risk, facilitating subsequent control logic calls and judgments, and is ready to be delivered to the downstream early warning control module.

[0043] For example, following the output of the previous step, assume that the hydraulic machinery work parameter flow is at the current moment... The data points are (1.010 ms, 23.655 MPa, 205 L / min), and the previous time step is obtained from the data stream. The data points are (1.000 ms, 23.600 MPa, 200 L / min). The differential control unit calculates the hydrodynamic pressure gradient. After unifying the data units to the International System of Units (SI), , The time interval is Pressure change gradient .

[0044] The multiplication module reads the current flow rate. Calculate the mapping cardinality for transient heating power. The hardware frequency converter modulates according to frequency control laws. Assuming that, based on equipment calibration, the system's maximum transient heat generation power mapping base is set to... Then the proportionality coefficient Therefore, the output duty cycle The system generates and sends a high-frequency pulse width modulation message with a carrier frequency of 20 kHz and a duty cycle of 37.58% to the early warning control module, which is the instantaneous heat flux generation source signal.

[0045] See Figure 4 The figure shows the core intermediate calculation results of the heat flux prediction module. The solid line in the figure represents the transient heating power mapping base. This base figure is obtained by performing a backward differential solution to calculate the pressure change gradient from the top pressure difference, and then performing a logical dot product with the instantaneous flow rate. As can be seen, The waveform exhibits multiple steep peaks and troughs, and these fluctuations map the transient extreme points of the rapid conversion of mechanical kinetic energy into thermal energy. This proves that the system no longer relies on the slow rise of macroscopic oil temperature, but can predict the explosive trend of local thermal shock from fluid dynamic parameters.

[0046] See Figure 5 The figure displays the core intermediate calculation results of the heat flux prediction module. The solid lines in the figure represent transient heating power, and the figure shows the high-frequency pulse width modulation message finally output by the hardware frequency conversion module. The stepped solid lines in the figure represent the modulation duty cycle. It can be seen that this duty cycle signal is a discrete digital sequence, and the overall envelope trend of its waveform is similar to... Figure 4 of Maintaining a high degree of positive correlation, the system maps continuous transient heat generation power to a duty cycle ratio between 0.0 and 1.0 through this normalized proportional conversion. This stepped heat source signal is ultimately delivered to the downstream electro-hydraulic proportional bridge valve drive circuit, enabling the interlocked heat exchange actuation action across the system to adaptively adjust to the burst intensity of instantaneous heat flux.

[0047] In one embodiment of the present invention, the engine thermal capacity assessment module is configured to perform the following steps: The back pressure data of the water pump connected to the engine water pump drive end is obtained through the communication bus, and the coolant temperature is captured synchronously using the physical path. The driving thermal balance modeling algorithm converts the water pump back pressure data into circulation flow rate, and calculates the current heat absorption safety margin by combining the coolant temperature and the coolant's predetermined boiling point limit. By using a digital-to-analog decoding chip in conjunction with a calibration spectrum, the current heat absorption safety margin is converted into a direct-read voltage proportionally, generating a dynamic heat capacity reference signal for the engine.

[0048] Specifically, this module operates in parallel with the aforementioned modules, performing operations to acquire physical parameters of the engine cooling cycle loop across the control domain to establish a dynamic heat capacity reference signal for the engine that reflects the environmental heat capacity reception limit. This process actively sends periodic request messages to the pressure sensor mounted on the engine coolant pump drive end via a bus controller integrated in the vehicle's main controller, such as a CAN bus controller conforming to the SAE J1939 protocol, to read real water pump back pressure pulse data. This data is represented as a series of discrete pressure values ​​reflecting the water pump impeller speed and the load on the circulation system. The actual water pump back pressure pulse data is not a constant value, but contains dynamic information related to engine speed. At the same time as acquiring each pressure data point, the control system uses a multi-channel synchronous analog-to-digital converter (ADC) to acquire the real-time dynamic temperature characteristics of the coolant fed back by a thermocouple probe inserted at the outlet of the engine's main radiator circuit. This ensures that pressure and temperature data are aligned in timestamps.

[0049] Subsequently, these two time-aligned data streams—the actual water pump back pressure pulse data and the real-time coolant dynamic temperature characteristics—are jointly input into a physical state thermal balance model pre-loaded in the controller's memory. This thermal balance model is a white-box model based on the law of conservation of energy, and its parameters, such as coolant volume and radiator efficiency, are calibrated at the factory, ensuring the physical interpretability of the calculation results. Based on the first law of fluid thermodynamics, the thermal balance model estimates the steady-state flow rate by filtering and averaging the discrete pressure value sequence, and incorporates the actual water pump back pressure pulse data... Converted to real-time mass flow rate of coolant Among them, mass flow rate For a moment The value, in units of kg / s, is derived from an empirical formula based on the fluid resistance characteristics of pipe networks. The calculation shows that, among which This is the equivalent flow resistance coefficient calibrated at the system's factory settings. This formula reflects the positive correlation between flow rate and the square root of the system back pressure in a closed-loop cooling system. The model is then combined with real-time dynamic temperature characteristics of the coolant. and the preset maximum safe temperature of the engine coolant. Perform heat balance calculations to determine the system heat absorption margin that the engine cooling system can continuously inject heat under the current operating conditions. The calculation formula is as follows: In the above formula, Representative moment The system's heat absorption tolerance safety margin, in W, is essentially an assessment of how much heat the engine cooling circuit, like a thermal sponge, can still absorb at the current moment without exceeding the safety limit. In other words, its physical meaning is the additional heat power that the engine cooling system can absorb under the current conditions. is the specific heat capacity of the coolant, a preset constant, with units of J / (kg·K); This is the maximum permissible operating temperature of the engine cooling system, expressed in K or °C, as set according to the engine manufacturer's safety specifications. For a moment Coolant outlet temperature measured by thermocouple probe, in units of... .

[0050] Finally, the system's thermal absorption tolerance safety margin. The signal is sent to a signal generator circuit, which is essentially a digital-to-analog converter (DAC). The DAC, based on a fixed digital-to-analog calibration profile, converts the digital signal to a signal with a system thermal tolerance safety margin. The linear fit is converted into an analog voltage signal, namely the reference amplitude analog voltage. The generation process of this voltage follows the formula below: In the formula, The output is the reference reduced analog voltage, in V; This is the upper limit of the reference voltage output of the digital-to-analog converter, measured in volts (V), for example, 5V. 5V is chosen as the upper limit because it is the standard TTL / CMOS operating level commonly used in industrial-grade automotive electronic control units and microcontrollers' underlying logic gates and analog-to-digital / digital-to-analog converter chips. This setting avoids introducing additional level conversion circuitry into the logic control center, reducing hardware design complexity and improving the anti-interference stability of signal transmission. The maximum heat absorption tolerance of the system design is used as a normalization coefficient, with units of W. The analog-to-digital calibration spectrum defines a linear mapping relationship to ensure that the reference reduction analog voltage reflects changes in the system's heat absorption tolerance safety margin. This analog voltage signal is defined as an engine dynamic heat capacity reference signal containing physical heat dissipation reference information. As an analog voltage, it can be used for high-speed hardware-level comparison with other analog signals or threshold voltages, providing a basis for subsequent offset determination. It is continuously output as a reference input for downstream determination modules.

[0051] For example, suppose that at a certain moment, the bus controller reads the average value of the processed real water pump back pressure pulse data as 310 kPa. The synchronously acquired real-time coolant dynamic temperature characteristic is 88 °C. These data are input into the physical state thermal equilibrium model. The thermal equilibrium model first calls the calibration function. To calculate mass flow rate, where The equivalent flow resistance coefficient of the pipeline network is calibrated in kPa. Approximately ,get The solidification parameter in the model is the specific heat capacity of the coolant. Maximum safe temperature The model calculates the system's heat absorption tolerance safety margin based on this. That is, approximately 260.3 kW.

[0052] This value is then fed into the signal generator circuit, whose parameters are set to: upper limit of reference voltage. Maximum heat absorption tolerance The circuit is calibrated to 500 kW. The circuit performs conversion calculations. Finally, the system generates and outputs a 2.60V DC analog voltage signal, which is the engine dynamic thermal capacity reference signal. This signal is taken out by the physical circuitry and used for hardware comparison in the next stage.

[0053] In one embodiment of the present invention, the cross-system interlock control module is configured to perform the following steps: The heat source signal is guided to the trigger pin of the external electro-hydraulic valve island, and the engine dynamic heat capacity reference signal is acquired in parallel. The engine dynamic thermal capacity reference signal is input into a multi-channel physical comparator component and compared with the preset safe thermal shock resistance threshold voltage in differential mode amplitude. When the comparator determines that the positive overshoot is true, it releases the latching pulse, which activates the electromagnetic contacts of the main control relay to close, opens the hardware information transfer path, and outputs a cross-system interlocking authorization command.

[0054] Specifically, the method of the present invention synchronously imports the instantaneous heat flux generation source signal captured in step S2 and the engine dynamic heat capacity reference signal established in step S3 into the logic control center of the electro-hydraulic proportional bridge valve to perform offset determination. This logic control center is physically a dedicated controller integrating digital and analog input interfaces; specifically, it can be an embedded microcontroller (MCU) that integrates a PWM capture unit, ADC, and digital I / O functions.

[0055] The instantaneous heat flux generation signal, i.e., the high-frequency pulse-width modulation message carrying thermal shock distortion information, is guided to the first hardware trigger terminal of the electro-hydraulic proportional bridge valve control electrode. This trigger terminal is a high-speed digital input pin capable of resolving the duty cycle of the PWM signal. In parallel, the issued engine dynamic thermal capacity reference signal, i.e., the reference amplitude analog voltage, is connected to the second analog monitoring port of this logic control center through an independent physical circuit. This port continuously reads the input analog voltage value to achieve real-time monitoring of the engine's heat dissipation potential.

[0056] The processing unit inside the logic control center extracts the reference amplitude analog voltage from the second analog monitoring port. The voltage value is then fed into an array-level physical comparator component in real time. This component consists of a set of hardware comparators and a precision resistor network, with one input connected to a reference amplitude-dropped analog voltage. The other input is connected to the safety thermal shock threshold voltage that is programmed into the underlying register. The unit is V. This threshold voltage is a calibrated key parameter, and its value corresponds to the minimum heat absorption margin required for the engine cooling system to maintain stable operation. Assuming this value is set to 1.0 V, the basis for this setting is to reserve a physical buffer against sudden changes in thermal load for the engine. In complex mining road conditions, vehicles may face sudden uphill climbs or heavy-load traction demands, causing the engine's heat generation to surge within seconds. Setting a safety threshold equivalent to 20% of the maximum heat absorption tolerance, i.e., 1.0 V / 5.0 V, forcibly cuts off heat exchange, ensuring that the engine cooling system always retains at least one-fifth of its redundant heat dissipation potential to cope with its own extreme operating conditions. This achieves an engineering balance between hydraulic system-assisted cooling and the absolute safety of the vehicle's engine operation. This means that when the engine's heat dissipation potential is less than 20% of its maximum value, referring to the aforementioned example of 5 V at full scale, the system will determine that it is no longer suitable to receive additional heat from the hydraulic system. The function of this component is to trigger its internal high-speed operational amplifier to continuously perform amplitude comparison calculations of the two voltages.

[0057] If and only if the array-level physical comparator component detects the reference amplitude-drop analog voltage through a comparison operation. The amplitude is higher than the safe thermal shock threshold voltage. Above, that is When the relationship is true, the comparator outputs a high-level signal. The judgment logic of the positive difference being greater than is implemented by the comparator's inherent high-gain open-loop characteristic. Even if the voltage difference is only a few millivolts, the output will instantly flip to a high or low level, thus achieving fast and unambiguous judgment.

[0058] This high-level signal acts as an enable signal, activating the coil of the underlying master control relay. The relay engages, its hard contacts close, thus establishing a physical control bus connection. This connection can physically be an internal logic gate circuit within the MCU, or an external physical connection switched by a relay or solid-state switch. This ensures that, in the absence of authorization, the instantaneous heat flux source signal is physically isolated and cannot affect the bridge valve actuator. This bus connection routes the instantaneous heat flux source signal received by the first hardware trigger to the underlying bridge valve actuator. The completion of this action signifies that the system has issued a cross-system interlock authorization command to the underlying bridge valve actuator to release the single-loop natural thermal isolation. This command is not a software-level logic flag, but rather a physical signal path status indicator, possessing high reliability and extremely low latency, used to authorize subsequent modules to perform physical heat exchange operations.

[0059] For example, following the preceding module, the instantaneous heat flux generation source signal is a PWM signal with a duty cycle of 37.58%, which is sent to the first hardware trigger terminal of the logic control center. Simultaneously, the engine dynamic thermal capacity reference signal is a 2.60 V DC voltage, which is input to the second analog monitoring port. The internal processing unit of the logic control center sends the 2.60 V reference amplitude-reduced analog voltage to the array-level physical comparator assembly.

[0060] Assuming a pre-programmed safe thermal shock threshold voltage within the register The value is 1.0 V. The physical comparator component performs an amplitude comparison operation to determine... Since this condition is met, the comparator outputs a high-level signal, such as +5V. This high-level signal drives the coil of the underlying master relay, causing its mechanical contacts to close. The closure of the relay creates a physical path from the first hardware trigger terminal to the bridge valve actuation unit.

[0061] At this point, the instantaneous heat flux source signal with a duty cycle of 37.58% is able to pass through this constructed physical control bus through-channel. This complete physical process is equivalent to the system releasing a cross-system interlock authorization command, allowing the instantaneous thermal shock of the hydraulic system to be transferred to the engine cooling system. If the engine coolant temperature rises, causing the reference descent analog voltage to drop to 0.9 V, then the comparator will determine... When the output is low, the relay will disconnect, and the authorization instruction will be revoked.

[0062] In one embodiment of the present invention, the heat exchange actuation module is configured to perform the following steps: The intelligent switching valve coil responds to the cross-system interlock authorization command, analyzes the PWM duty cycle value in the heat source signal, and converts it into the corresponding electromagnetic driving force through the drive circuit. The electromagnetic driving force overcomes the preload of the mechanical spring, pushing the main flow-blocking proportional valve core to undergo axial displacement, thereby connecting the oil guide path of the plate heat exchanger; The displacement stroke of the main flow-blocking proportional valve core is detected, and a speed control command is generated proportionally and sent to the external variable frequency hydraulic circulation pump to accelerate the flow of hydraulic fluid through the plate heat exchanger to perform heat exchange and establish a heat exchange circulation path.

[0063] Specifically, upon receiving the cross-system interlock authorization command generated by the previous module, the system begins to execute the pipeline drainage unblocking action. The bus actuator installed on the electro-hydraulic proportional bridge valve, such as an intelligent execution unit integrating a CAN transceiver, verifies the validity of the cross-system interlock authorization command through bus communication, that is, confirms that the physical control bus connection channel is indeed in a physically connected state.

[0064] Once verification is successful, the bus actuator immediately activates the electromagnetic proportional conversion coil external to the electro-hydraulic proportional bridge valve. This coil receives and analyzes the instantaneous heat flux generation source signal, i.e., the high-frequency pulse-width modulation (PWM) message, transmitted through the physical control bus's through-channel. The drive circuit inside the electromagnetic proportional conversion coil integrates or low-pass filters the duty cycle of the PWM message, converting it into a proportional DC drive current. This DC current flows through the coil windings, generating a precisely controllable electromagnetic push-pull direct drive force according to the law of electromagnetic induction. The electromagnetic proportional converter coil simplifies this relationship to the following formula: In the formula, The duty cycle of the aforementioned instantaneous heat flux generation source signal. The electromechanical conversion factor is expressed in nanometers (N). This continuously generated electromagnetic push-pull direct drive force overcomes the initial spring preload provided by the spring embedded in the valve body for reset. Its unit is N. When At this time, the valve core begins to move, pushing the main flow-blocking proportional valve core, which is mechanically connected to the coil armature, to produce a continuous linear axial feed mechanical stroke. The unit is mm. The displacement of this valve core linearly opens and bridges the junction of the originally isolated hydraulic unloading return bypass branch fluid and the engine coolant drain branch, which is physically a compact plate heat exchange tube bundle.

[0065] Valve core stroke The larger the diameter, the larger the cross-sectional area of ​​the connected flow channel, allowing more high-temperature hydraulic oil to flow into the plate heat exchanger tube bundle. The mechanical stroke of the main flow-blocking proportional valve core. Hydraulic oil flow rate through the heat exchanger There exists a non-linear functional relationship between them. This relationship is determined by the geometry of the valve port.

[0066] Meanwhile, a displacement sensor, such as a linear variable differential transformer (LVDT), is used to calculate and obtain the current linear axial feed mechanical stroke parameter of the main flow-blocking proportional valve core. This parameter is used by the system to generate a speed-following pulse width control reference flow in real time. This reference flow is related to the valve spool opening. A PWM signal proportional to the signal strength is sent to the inverter of an external variable frequency hydraulic suction / discharge pump, which is located within a separate bypass assembly.

[0067] The logic for generating the reference flow based on the speed-following pulse width control ensures that the displacement of the external variable frequency hydraulic suction / discharge pump matches the flow capacity of the main flow-blocking proportional valve, resolving system pressure fluctuations or cavitation caused by flow mismatch. The external variable frequency hydraulic suction / discharge pump is an independent power source; its operation and speed are entirely determined by heat exchange requirements, decoupled from the vehicle's main hydraulic pump or engine speed. The frequency converter adjusts its output frequency accordingly, thereby controlling the pump's actual drive speed. The unit is r / min.

[0068] The increase in engine speed forces the high-temperature hydraulic oil, which has absorbed excessive heat load, to be drawn from the main return line and flow into the plate heat exchange tube bundle at a larger displacement matching the intensity of the thermal shock. Within this bundle, the high-temperature hydraulic oil undergoes efficient temperature difference heat exchange with the low-temperature coolant from the engine cooling system, thereby rapidly mitigating localized heat load peaks in the hydraulic system and ultimately establishing a positive heat exchange circulation path. This positive heat exchange circulation path means that the heat generated by the hydraulic system is continuously and stably transferred to the engine cooling system, and then uniformly dissipated into the environment, maintaining the hydraulic oil temperature at an ideally low level.

[0069] For example, following the previous step, the cross-system interlock authorization command has taken effect, and a transient heat flux generation source signal with a duty cycle of 37.58% is applied to the electromagnetic proportional conversion coil. Assume the electromechanical conversion coefficient... If the value is 200 N, then the generated electromagnetic push-pull direct drive force will be... Let the initial spring preload of the return spring inside the valve be... It is 20 N, because The valve core is pushed.

[0070] Assume the relationship between valve core stroke and driving force is as follows: Then the valve core will generate a linear axial feed mechanical stroke. The displacement sensor measured this stroke to be 5.516 mm. Based on this stroke, the system generates a speed-following pulse width control reference flow, assuming the mapping relationship is the actual drive speed of the suction / discharge pump. Then the driving speed of the command pump is r / min. An external variable frequency hydraulic suction and discharge pump operates at this speed, forcibly pumping high-temperature hydraulic oil into the plate heat exchange tube bundle.

[0071] Assuming the hydraulic oil is at 110°C and the coolant from the engine cooling system is at 88°C, heat exchange occurs inside the heat exchanger. This process continues until the pressure fluctuations in the hydraulic system weaken, causing the duty cycle of the instantaneous heat flux generation signal output in step S2 to decrease, the driving force to decrease, the valve core stroke to retract, and the suction and discharge pumps to slow down. This dynamically adjusts the heat exchange intensity, establishing a steady state of heat exchange that stabilizes the hydraulic oil temperature at, for example, around 95°C.

[0072] In one embodiment of the present invention, the cooling mode switching module is used to perform the following steps: Activate the detection program and compare the rate of decrease of the engine dynamic thermal capacity reference signal in adjacent sampling periods; When continuous verification confirms that the rate of decline is irreversible and the reference signal falls below the safe thermal shock threshold, the power supply line of the main control relay is disconnected to cancel the electromagnetic driving force, so that the main flow isolation proportional valve core is silently reset by spring force, and the hydraulic pipeline to the plate heat exchanger is physically cut off. The intercepted heat source signal is redirected to an independent air-cooled heat dissipation terminal, which controls and increases the operating voltage or frequency of the cooling fan to accelerate the dissipation of heat inside the system and perform independent cooling.

[0073] Specifically, throughout the entire physical lifecycle of the heat exchange cycle established by the aforementioned modules for closed-loop cooling and work, this invention simultaneously initiates a resident guardian program. The function of this program is to collect and track the engine's dynamic heat capacity reference signal in parallel, i.e., the real-time amplitude evolution trend of the reference voltage drop analog voltage, aiming to detect the boundary conditions of physical thermal saturation on the receiver side. This guardian program continuously records the instantaneous decay value of the reference voltage drop analog voltage at a fixed sampling frequency. This instantaneous decay value refers to the rate at which the voltage value decreases over time. The guardian program determines the decreasing trend by comparing the voltage values ​​of consecutive sampling points; for example, when five consecutive sampling points are all lower than the previous point, it is determined to be an irreversible decrease.

[0074] When the program detects, through continuous sampling and iterative updates, that the value of the reference amplitude analog voltage shows an irreversible downward trend and approaches and falls below the safety thermal shock threshold voltage protection line previously solidified and recorded in the underlying register in step S4, the system triggers a hard isolation fuse protection action. This hard isolation action is a hardware-level protection measure that transcends software logic, ensuring isolation can be performed in the event of any software failure or delay. This action disconnects the power supply to the coil of the underlying master control relay via an independent control signal. After the power supply is cut off, the relay coil loses its magnetism, and its hard contacts instantly open under the action of an internal spring, resulting in a physical disintegration of the physical control bus communication channel.

[0075] As the channel is disconnected, the signal from the instantaneous heat flux source that was previously able to pass through is immediately blocked. Relying on the elastic potential energy released by the embedded reset spring pre-stored in the valve body, the kinetic energy drives the main flow-blocking proportional valve core to be quickly pushed back to its silent zero point, i.e., the fully closed position. This action physically locks the valve core in the closed position, meaning that the valve core is mechanically locked in the closed position and cannot be reopened unless specific unlocking conditions are met, thereby shutting off the heat flux exchange network segment leading to the plate heat exchange tube bundle.

[0076] While implementing hard isolation, the instantaneous heat flux source signals that were previously blocked and bounced back are collected and redirected by the system's routing logic to the independent variable-speed air-cooled cooling terminal control board at the end of the hydraulic return loop. This independent variable-speed air-cooled cooling terminal is a backup independent cooling system with its own radiator and variable-speed fan, designed to handle all the heat generated by the hydraulic system itself. Based on the duty cycle command of the reconstructed high-frequency pulse-width modulation message, the control board maximizes the drive voltage or frequency of one or more dedicated cooling fans through its drive circuit to maximize their headwind intensity. This increased airflow blows across the radiator fins, accelerating the dissipation of heat energy dead zones accumulated in the hydraulic main circulation link due to interrupted heat exchange, thereby forcibly establishing and maintaining an independent air-cooled cooling mode in an environment disconnected from the engine cooling system. The so-called independent air-cooling mode refers to the system switching to a backup cooling path, such as forced air cooling, after the heat exchange between the main cooling path and the engine is cut off. This is a cooling mode switch in an emergency to compensate for the failure of the main path and ensure that the temperature of the hydraulic system does not get out of control.

[0077] For example, assume the system is in a state where the heat exchange circulation path is open, and the baseline descent analog voltage is stable at 2.60 V. Due to the continuous high-intensity operation of the hydraulic system, heat is constantly injected into the engine cooling system, causing the engine coolant temperature to gradually rise from 88 ℃ to 102 ℃. According to the calculation logic in step S3, the baseline descent analog voltage also decreases accordingly. The daemon continuously samples voltage values ​​of 1.5 V, 1.3 V, 1.1 V, 1.05 V, and 0.98 V.

[0078] When the voltage drops to 0.98 V, this value is below the previously set safe thermal shock threshold voltage of 1.0 V. The protection mechanism is triggered, the underlying main control relay is de-energized, and the physical control bus connection channel collapses. The valve core instantly returns to zero opening under spring force, cutting off the hydraulic oil flow to the plate heat exchange tube bundle. At this time, the hydraulic system is still generating heat, assuming the duty cycle of the instantaneous heat flux generation source signal output in step S2 is still 37.58%. This signal is redirected to the main control board of the independent transmission air-cooled heat dissipation terminal. According to the 37.58% duty cycle command, the main control board increases the drive voltage of the cooling fan from 20% in standby mode to, for example, 85% of maximum power operation. The fan speed increases sharply, generating a strong airflow to forcibly cool the independent radiator of the hydraulic system. The system thus enters the independent air-cooled heat dissipation mode. Although the heat dissipation efficiency may not be as good as cross-system heat exchange, it is sufficient to keep the hydraulic oil temperature within a safe range in an emergency until the engine cooling system restores its heat dissipation capacity.

[0079] In one embodiment of the present invention, the oil quality management module is used to perform the following steps: The traction return hydraulic fluid slows down the flow rate, penetrates the window of the photoelectric vision particle spectral analysis probe, and calculates the concentration of micro-nano solid particles in the fluid through spectral image processing algorithms; When the concentration exceeds the preset fluid quality inspection allowable baseline, the control hydraulic scheduling unit forcibly reduces the displacement of the external variable frequency hydraulic circulation pump according to the preset ratio to prioritize the pressure requirements of the main working oil circuit. The hydraulic fluid, after being restricted in flow, is guided to the deep precision fiber bundle filter element base to perform sedimentation and separation, thus completing the deep purification of the oil.

[0080] Specifically, the low-temperature reflux deheating hydraulic fluid after the aforementioned steps undergoes further contamination stripping identification and screening. This hydraulic fluid may originate from the cooling core detached from the plate heat exchange tube bundle in the heat exchange circulation path, or from the heat exchange attenuation treatment through the independent variable speed air cooling terminal in the independent air cooling mode.

[0081] Within a bypass network connected in parallel to the main return oil line, a portion of the cryogenic reflux deheated hydraulic fluid is drawn out and guided at a controlled low flow rate, for example, 0.5 m / s, through a photoelectric visual particle spectroscopy probe assembled within this bypass network. This photoelectric visual particle spectroscopy probe is an online oil monitoring device that can provide more timely contamination data than traditional sampling analysis. The core of the probe is a monitoring lens with high light transmittance, through which hydraulic oil flows.

[0082] The probe's built-in laser light source illuminates the fluid, and a high-resolution image sensor captures the scattered light or absorption spectrum image within the fluid's tangential plane. The image is transmitted in real-time to an associated processing unit, which executes image processing algorithms to identify and count micro / nano-sized solid particles in the image. Simultaneously, it distinguishes between metallic wear debris and non-metallic impurities based on their spectral characteristics, calculating the absolute concentration of micro / nano-sized solid particles in the fluid at the current moment, expressed as an ISO 4406 cleanliness level or the number of particles larger than a specific size per milliliter of liquid.

[0083] When the computing unit determines and confirms that the increase in the absolute concentration base of micro-nano solid particulate matter pollution—that is, the difference between the current value and the previous period's value—crosses a preset fluid quality inspection tolerance baseline, this baseline is typically set based on the hydraulic component manufacturer's requirements for oil cleanliness. For example, when the number of particles larger than 4 μm(c) surges from 5,000 per milliliter to 10,000 per milliliter, it is considered a breach, triggering a change in the core scheduling system's access control. Specifically, the system's main control assembly forcibly halves the original predetermined flow pulse base of the external variable frequency hydraulic suction and discharge pump, for example, by reducing the duty cycle or frequency of its drive PWM signal by 50%. This forced flow reduction reflects the system's intelligent trade-off between safety and performance; that is, when a potential risk of increased wear is detected, it prioritizes ensuring that the high-pressure system, which bears the terminal mining load, such as the main valve and cylinders, does not experience pressure loss or sluggish operation, even at the expense of some cooling performance.

[0084] At the same time, the portion of the low-temperature reflux deheating hydraulic fluid that was forced to reduce its flow rate by reducing the pump displacement after encountering the flow reduction command, and turned into a weak permeation and pressure-maintaining condition, was guided into the deep precision fiber bundle filter element base equipped with a multi-gradient filter screen and a hydrophobic chassis.

[0085] Within the area affected by this weak permeation and pressure-maintaining condition, the fluid velocity is reduced to the critical range for suspended particle settling, allowing the suspended particles to detach from the fluid. At this point, the low flow rate increases the probability of collision and adhesion between the tiny suspended particles and the micropores of the fiber bundles, extending the retention time and performing settling, stripping, and descaling operations. Specifically, the labyrinthine tortuous channels arranged within the micro-nano separation space increase the residence time of free hard particles at the points of entanglement with the filter mesh skeleton. By extending the residence time, free hard particles adhere to the filter mesh skeleton, and water and impurities with density differences settle and separate, completing oil purification. The clean hydraulic oil, after deep purification and dehydration, is discharged into the main unit's replenishment oil tank circuit and merges with the main unit's oil supply.

[0086] By integrating the above processes, a dual-layer safety configuration mechanism is constructed, which simultaneously suppresses localized overheating at the front end and intercepts system wear and damage at the back end. In other words, this dual-layer safety configuration mechanism ensures system safety through two relatively independent layers. The first layer is a rapid thermal management network implemented through the aforementioned heat conduction logic, which addresses acute thermal shock issues. The second layer is an oil purification and condition monitoring network implemented through this module, which addresses chronic wear and contamination issues. These two networks work together to improve the long-term reliability and service life of the hydraulic system.

[0087] For example, suppose the cryogenic reflux deheating hydraulic fluid flows through a photoelectric vision particle spectroscopy probe. The processing unit reports a current concentration of 12,000 particles larger than 4 μm(c) / mL, while the system recorded a concentration of 4,500 particles / mL the previous minute. The increment is 7,500 particles / mL, exceeding the set alarm threshold of 5,000 particles / mL. The core scheduling system immediately triggers a change in access control. Assuming the duty cycle of the external variable frequency hydraulic suction / discharge pump's drive PWM signal is currently 60%, the main system control assembly forcibly intervenes, reducing it to 30%, resulting in a significant decrease in the flow rate used for cooling circulation.

[0088] The reduced flow rate of the cryogenic recirculated deheated hydraulic fluid enters the deep-layer precision fiber bundle ultrafiltration nano-micro separation substrate at an extremely low velocity. Within the substrate, the flow rate is reduced to a level sufficient to effectively capture abrasive particles smaller than 5 μm. After 30 minutes of slow-speed circulation filtration, the oil outlet of the separation substrate is retested, and the concentration of particles larger than 4 μm(c) has decreased to 3000 particles / mL, indicating the effectiveness of the purification process. The purified clean oil is then transferred to the replenishment oil tank. By sacrificing some cooling circulation flow, the system successfully suppressed the risk of precision valve jamming that could be caused by increased contamination, while simultaneously achieving online oil purification, thus establishing a dual-layer safety configuration mechanism that combines thermal management and contamination control.

[0089] Each of the modules can be implemented in whole or in part through software, hardware, or a combination thereof. It supports hardware embedded in or independent of the processor in the computer device, and also supports software stored in the memory of the computer device, so that the processor can call and execute the operations corresponding to each of the above modules.

[0090] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.

Claims

1. An active cooling circulation system for a hydraulic system of a mining vehicle, characterized in that, include: The hydraulic parameter acquisition module acquires the high-frequency differential pressure waveform characteristics and the original transient flow data stream of the hydraulic main circuit. It performs common-mode noise reduction and absolute timestamp alignment on the high-frequency differential pressure waveform characteristics and the original transient flow data stream to generate the hydraulic mechanical work parameter stream. The heat flux prediction module calculates the pressure change gradient based on the hydraulic mechanical work parameter flow and solves the transient heat generation power mapping basis. It then performs pulse width modulation conversion on the transient heat generation power mapping basis to generate a heat source signal that reflects the instantaneous thermal shock. The engine heat capacity assessment module acquires the water pump back pressure data and real-time coolant temperature of the engine cooling circulation loop, and inputs the two into the preloaded thermal balance physical model to solve for the current heat absorption safety margin, generating the engine dynamic heat capacity reference signal. The cross-system interlock control module performs a logical comparison and judgment between the heat source signal and the engine dynamic heat capacity reference signal. When it is determined that the engine dynamic heat capacity reference signal is greater than the preset safe thermal shock resistance threshold, it outputs a cross-system interlock authorization command. The heat exchange actuation module responds to the cross-system interlock authorization command and opens the plate heat exchanger located at the intersection of the hydraulic unloading bypass branch and the engine coolant drain branch, thus establishing a heat exchange circulation path between the hydraulic main circuit and the engine cooling circulation circuit. The cooling mode switching module continuously tracks the engine's dynamic heat capacity reference signal. When it detects that the reference signal has fallen below the safe thermal shock resistance threshold, it mechanically locks the plate heat exchanger and redirects the heat source signal to the independent air-cooled heat dissipation terminal, driving the fan to perform forced air-cooling heat dissipation to provide compensatory cooling. The oil quality management module intercepts the return hydraulic fluid after heat exchange or air cooling to perform online contamination identification. When it is confirmed that the concentration of solid particulate matter exceeds the preset fluid quality inspection allowable baseline, it triggers the flow restriction action and starts the deep micro-nano filtration program to perform oil flow restriction and filtration operations.

2. The active cooling circulation system for a hydraulic system of a mining vehicle according to claim 1, characterized in that, The hydraulic parameter acquisition module is specifically configured to perform the following operations: Wideband dynamic differential pressure sensors arranged at both ends of the inlet and outlet of the main valve group in the hydraulic main circuit are used to synchronously extract the pressure drop waveform and generate high-frequency differential pressure waveform characteristics. Using a non-intrusive transient flow monitor, capture the raw transient flow data stream corresponding to the overlapping coverage area of ​​the absolute time axis; The solid-state coprocessing unit is invoked to filter the common-mode background noise of the high-frequency differential pressure waveform using a hardware differential network. Based on a high-precision time synchronization protocol, the original transient flow data stream is interpolated into the same microsecond-level time reference coordinate system for resampling, generating a time-aligned hydraulic mechanical work parameter stream.

3. The active cooling circulation system for a hydraulic system of a mining vehicle according to claim 1, characterized in that, The heat flux prediction module is specifically configured to perform the following operations: The differential control unit uses the backward difference method to analyze the change in absolute pressure difference before and after the hydraulic mechanical work parameter flow, and generates a pressure change gradient. By performing a logical dot product operation between the pressure change gradient and the instantaneous flow characteristics at that moment, the transient heating power mapping cardinality reflecting the conversion of mechanical kinetic energy into thermal energy is solved. The transient heating power mapping base is converted into a high-frequency pulse width modulation duty cycle sequence by a normalized ratio through a hardware frequency conversion module, thereby generating a heating source signal.

4. The active cooling circulation system for a hydraulic system of a mining vehicle according to claim 1, characterized in that, The engine thermal capacity assessment module is specifically configured to perform the following operations: The back pressure data of the water pump connected to the engine water pump drive end is obtained through the communication bus, and the coolant temperature is captured synchronously using the physical path. The driving thermal balance modeling algorithm converts the water pump back pressure data into circulation flow rate, and calculates the current heat absorption safety margin by combining the coolant temperature and the coolant's predetermined boiling point limit. By using a digital-to-analog decoding chip in conjunction with a calibration spectrum, the current heat absorption safety margin is converted into a direct-read voltage proportionally, generating a dynamic heat capacity reference signal for the engine.

5. An active cooling circulation system for a hydraulic system of a mining vehicle according to claim 1, characterized in that, The cross-system interlock control module is specifically configured to perform the following operations: The heat source signal is guided to the trigger pin of the external electro-hydraulic valve island, and the engine dynamic heat capacity reference signal is acquired in parallel. The engine dynamic thermal capacity reference signal is input into a multi-channel physical comparator component and compared with the preset safe thermal shock resistance threshold voltage in differential mode amplitude. When the comparator determines that the positive overshoot is true, it releases the latching pulse, which activates the electromagnetic contacts of the main control relay to close, opens the hardware information transfer path, and outputs a cross-system interlocking authorization command.

6. The active cooling circulation system for a hydraulic system of a mining vehicle according to claim 1, characterized in that, The heat exchange actuation module is specifically configured to perform the following operations: The intelligent switching valve coil responds to the cross-system interlock authorization command, analyzes the PWM duty cycle value in the heat source signal, and converts it into the corresponding electromagnetic driving force through the drive circuit. The electromagnetic driving force overcomes the preload of the mechanical spring, pushing the main flow-blocking proportional valve core to undergo axial displacement, thereby connecting the oil guide path of the plate heat exchanger; The displacement stroke of the main flow-blocking proportional valve core is detected, and a speed control command is generated proportionally and sent to the external variable frequency hydraulic circulation pump to accelerate the flow of hydraulic fluid through the plate heat exchanger to perform heat exchange and establish a heat exchange circulation path.

7. An active cooling circulation system for a hydraulic system of a mining vehicle according to claim 1, characterized in that, The cooling mode switching module is specifically configured to perform the following operations: Activate the detection program and compare the rate of decrease of the engine dynamic thermal capacity reference signal in adjacent sampling periods; When continuous verification confirms that the rate of decline is irreversible and the reference signal falls below the safe thermal shock threshold, the power supply line of the main control relay is disconnected to cancel the electromagnetic driving force, so that the main flow isolation proportional valve core is silently reset by spring force, and the hydraulic pipeline to the plate heat exchanger is physically cut off. The intercepted heat source signal is redirected to an independent air-cooled heat dissipation terminal, which controls and increases the operating voltage or frequency of the cooling fan to accelerate the dissipation of heat inside the system and perform independent cooling.

8. An active cooling circulation system for a hydraulic system of a mining vehicle according to claim 1, characterized in that, The oil quality management module is specifically configured to perform the following operations: The traction return hydraulic fluid slows down the flow rate, penetrates the window of the photoelectric vision particle spectral analysis probe, and calculates the concentration of micro-nano solid particles in the fluid through spectral image processing algorithms; When the concentration exceeds the preset fluid quality inspection allowable baseline, the control hydraulic scheduling unit forcibly reduces the displacement of the external variable frequency hydraulic circulation pump according to the preset ratio to prioritize the pressure requirements of the main working oil circuit. The hydraulic fluid, after being restricted in flow, is guided to the deep precision fiber bundle filter element base to perform sedimentation and separation, thus completing the deep purification of the oil.

9. An active cooling circulation system for a hydraulic system of a mining vehicle according to claim 8, characterized in that, When guiding the limited hydraulic fluid into the deep precision fiber bundle filter cartridge base to perform sedimentation and separation, the following steps are also included: By reducing the pump displacement, the flow rate of the returning hydraulic fluid is forced to decrease to a state of weak permeation and pressure maintenance. The fluid under weak permeation and pressure maintenance conditions is allowed to enter the deep precision fiber bundle filter cartridge base equipped with multi-gradient filter screens and hydrophobic chassis; By utilizing low flow rate to increase the probability of collision and adhesion between tiny suspended particles and fiber bundle micropores, the retention time is extended, and sedimentation, stripping, and descaling operations are performed to recover the purified oil to the main oil tank.

10. An active cooling circulation system for a hydraulic system of a mining vehicle according to claim 9, characterized in that, The following steps are included when performing sedimentation, stripping, and descaling operations: Within the area affected by weak permeation and pressure maintenance, the fluid velocity is reduced to the critical range for the settling of suspended particles, so that the suspended particles are removed from the fluid. By using a maze-like, tortuous channel arranged within the micro-nano separation space, the residence time of free-state hard particles and the entanglement points of the filter mesh skeleton is increased; By extending the residence time, free hard particles are encouraged to adhere to the filter screen frame, and water and impurities with different densities are allowed to settle and separate, thus completing the oil purification.

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