Surplus energy utilization device, electric drive system, control method, and vehicle

Abstract

This application discloses a surplus energy utilization device, an electric drive system, a control method, and a vehicle. The surplus energy utilization device includes a bearing and a surplus energy utilization unit mounted on the bearing. The bearing includes an outer ring, rolling elements, and an inner ring arranged sequentially from the outside to the inside. The surplus energy utilization unit includes a conductive element, an energy storage device, and a voltage modulation module. One end of the conductive element is in conductive contact with the inner ring, and the conductive element can extract the surplus energy induced in the bearing by the motor shaft voltage. The other end of the conductive element is electrically connected to the charging terminal of the energy storage device, which is used to collect and store the surplus energy extracted by the conductive element. The discharging terminal of the energy storage device is electrically connected to the voltage modulation module, and the electrical energy stored inside the energy storage device can be discharged stably after being modulated by the voltage modulation module. This surplus energy utilization device recovers the energy of the shaft voltage and also solves the problem of bearing electro-corrosion caused by excessive shaft voltage breaking down the oil film.

Description

Technical Field

[0001] This application belongs to the field of intelligent bearing technology, and particularly relates to an energy utilization device, an electric drive system, a control method, and a vehicle. Background Technology

[0002] In high-voltage electric drive platforms employing pulse width modulation (PWM) technology (such as electric vehicle drive motors), common-mode voltage is generated at the motor winding terminals due to high-frequency switching and parasitic parameters. This voltage is coupled to the shaft through internal parasitic capacitance, inducing a shaft voltage. When the shaft voltage exceeds the breakdown threshold of the bearing oil film, it breaks down the oil film insulation, forming a bearing current (shaft current). This leads to electro-corrosion of the bearing, reducing its service life and reliability. This is one of the key technical challenges faced by electric drive systems.

[0003] Currently, common solutions include installing grounding devices at the non-drive ends of the motor or using insulated bearings to block or reduce shaft current. However, these methods are all passive protection methods, resulting in energy waste. Summary of the Invention

[0004] This application aims to address at least one of the technical problems existing in the prior art. To this end, this application proposes a surplus energy utilization device, an electric drive system, a control method, and a vehicle capable of recovering and utilizing the potential "surplus energy" (idle / recoverable energy) of axle voltage.

[0005] In a first aspect of this application, a surplus energy utilization device is provided, comprising a bearing and a surplus energy utilization unit mounted on the bearing; the bearing comprises an outer ring, rolling elements, and an inner ring arranged sequentially from the outside to the inside; the surplus energy utilization unit comprises a conductive element, an energy storage device, and a voltage modulation module, one end of the conductive element being in conductive contact with the inner ring, the other end of the conductive element being electrically connected to the charging terminal of the energy storage device, and the discharging terminal of the energy storage device being electrically connected to the voltage modulation module.

[0006] In some embodiments, the energy utilization unit further includes a temperature sensor electrically connected to the voltage modulation module; the temperature sensor is mounted on the outer ring.

[0007] In some embodiments, the energy utilization unit further includes a first wireless communication module, which is electrically connected to the voltage modulation module and the temperature sensor, respectively.

[0008] In some embodiments, the energy utilization device further includes a mounting plate connected to the outer ring; the energy utilization unit is mounted on the mounting plate.

[0009] In some embodiments, the energy utilization unit is encapsulated in an insulating resin, which forms the mounting plate.

[0010] In some embodiments, the energy storage device includes two or more capacitors connected in parallel, the capacitors being ceramic capacitors or film capacitors; and / or, the conductive element is a brush.

[0011] In some embodiments, the voltage modulation module includes a hysteresis comparator, and the discharge terminal of the energy storage device is electrically connected to the voltage input terminal of the hysteresis comparator; or, the voltage modulation module further includes a modulation circuit electrically connected to the hysteresis comparator, and the output terminal of the modulation circuit is used to connect to an electrical load.

[0012] In a second aspect of this application, an electric drive system is provided, including a housing, a motor, and at least one energy utilization device as described in the first aspect above; the output shaft of the motor is rotatably connected to the housing via the energy utilization device.

[0013] In some embodiments, the electric drive system further includes: a cooling and lubrication system, comprising an oil pump, a cooling and lubrication channel, and at least one electrically controlled valve, wherein the outlet of at least one cooling and lubrication branch of the cooling and lubrication channel is opposite to the location of the energy utilization device, and the electrically controlled valve is located on the cooling and lubrication branch; a controller, electrically connected to the electrically controlled valve and the oil pump respectively; and the controller is provided with a second wireless communication module.

[0014] In a third aspect of this application, a control method for an electric drive system described in the second aspect is provided, comprising the following steps: obtaining the temperature of the bearing of the energy utilization device; and, if the temperature of the bearing exceeds a set threshold, adjusting the operating state of the electronically controlled valve and / or the oil pump to increase the amount of oil flowing to the bearing.

[0015] In a fourth aspect of this application, a vehicle is provided, including at least one of the energy utilization devices of the first aspect described above; and / or, including at least one of the electric drive systems of the second aspect described above.

[0016] An energy recovery device according to one or more embodiments of this application includes a bearing and an energy recovery unit mounted on the bearing. The bearing includes an outer ring, rolling elements, and an inner ring arranged sequentially from the outside to the inside. The energy recovery unit includes a conductive element, an energy storage device, and a voltage modulation module. One end of the conductive element is in conductive contact with the inner ring, and the conductive element can discharge the energy induced in the bearing by the motor shaft voltage. The other end of the conductive element is electrically connected to the charging end of the energy storage device, which is used to collect and store the energy discharged by the conductive element. The discharging end of the energy storage device is electrically connected to the voltage modulation module, and the electrical energy stored inside the energy storage device can be discharged stably after being modulated by the voltage modulation module. By installing the energy recovery unit on the bearing, the energy induced in the bearing by the motor shaft voltage can be collected and stored, and this part of the energy can be supplied to the outside, thus recovering the energy of the shaft voltage and solving the problem of bearing electro-corrosion caused by excessive shaft voltage breaking down the oil film. Attached Figure Description

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

[0018] Figure 1 A full cross-sectional view of the energy utilization device in one or more embodiments of this application is shown.

[0019] Figure 2 It shows Figure 1 The structural block diagram of the surplus energy utilization unit of the surplus energy utilization device.

[0020] Figure 3 The shaft voltage detection curve of the bearing in the electric drive system of the related art is shown.

[0021] Figure 4 A circuit diagram of a hysteresis comparator of a power utilization device in one or more embodiments of this application is shown.

[0022] Figure 5 A structural block diagram of the energy utilization unit of the energy utilization device in some other embodiments of this application is shown.

[0023] Figure 6 It shows Figure 5 The circuit block diagram of the modulation circuit of the power utilization unit.

[0024] Figure 7 The diagram shows a structural block diagram of the energy utilization unit of the energy utilization device in some further embodiments of this application.

[0025] Figure 8A structural block diagram of the energy utilization unit of the energy utilization device in some further embodiments of this application is shown.

[0026] Figure 9 A structural block diagram of an electric drive system according to one or more embodiments of this application is shown.

[0027] Figure 10 A block diagram of the cooling and lubrication structure of an electric drive system in one or more embodiments of this application is shown.

[0028] Explanation of reference numerals in the attached drawings: 1000-Electric drive system; 100-Energy utilization device; 10-Bearing; 11-Outer ring; 12-Rolling element; 13-Inner ring; 1-Raceway; 20-Energy utilization unit; 21-Conductive component; 22-Energy storage device; 23-Voltage modulation module; 231-Hysteresis comparator; 232-Modulation circuit; 24-Temperature sensor; 25-First wireless communication module; 30-Mounting plate; 200-Motor; 210-Output shaft; 300-Housing; 400-Transmission mechanism; 410-Transmission shaft; 420-Gear; 500-Cooling and lubrication system; 510-Oil pump; 520-Cooling and lubrication channel; 521-Cooling and lubrication branch; 530-Electrically controlled valve; 600-Controller; 610-Second wireless communication module. Detailed Implementation

[0029] To enable those skilled in the art to more clearly understand this application, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0030] Furthermore, reference numerals and / or reference letters may be repeated in different examples in this application. Such repetition is for simplification and clarity purposes and does not in itself indicate a relationship between the various embodiments and / or settings discussed. In addition, this application provides examples of various specific processes and materials; however, those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0031] The specific technical solutions of this application will be described in detail below with reference to the accompanying drawings, which are not necessarily drawn to scale. Similar or identical reference numerals may be used to designate the same or similar parts in different drawings. The use of similar or identical reference numerals in different drawings does not mean that all drawings including similar or identical reference numerals constitute a single or the same embodiment. The accompanying drawings illustrate the various embodiments discussed in this application in a generalized manner, by way of example and not limitation.

[0032] Please see Figure 1 According to a first aspect of this application, a surplus energy utilization device 100 is provided, which includes a bearing 10 and a surplus energy utilization unit 20 mounted on the bearing 10. The bearing 10 includes an outer ring 11, rolling elements 12, and an inner ring 13 arranged sequentially from the outside to the inside. The inner ring 13 is usually interference-fitted or keyed to a rotating shaft, so that it rotates together with the rotating shaft. To ensure load-bearing capacity, both the inner ring 13 and the rotating shaft are metal. Therefore, the inner ring 13 is mechanically connected to the rotating shaft and also electrically connected, so the shaft voltage on the rotating shaft can be directly transmitted to the inner ring 13 of the bearing 10.

[0033] Please see Figure 1 The bearing 10 has raceways 1 on its outer ring 11 and / or inner ring 13, or a cage between the outer ring 11 and inner ring 13. The rolling element 12 rotates in the raceway 1 or the cage. The lubricating oil of the bearing 10 is mainly concentrated at the location of the rolling element 12, reducing the friction when the rolling element 12 rotates. Therefore, the bearing 10 can be divided into a load-bearing area and a non-load-bearing area according to the location of the rolling element 12. The area in the outer ring 11 and inner ring 13 corresponding to the rolling element 12 is the load-bearing area, and the remaining areas are the non-load-bearing areas. The inner surface of the outer ring 11 located in the load-bearing area and the outer surface of the inner ring 13 located in the load-bearing area are the working surfaces of the bearing 10. Taking a bearing 10 in which both the outer ring 11 and inner ring 13 have raceways 1 as an example, the raceway 1 is the working surface.

[0034] Figure 2 A structural block diagram of the surplus energy utilization unit 20 in some embodiments is shown. Please refer to [link / reference]. Figure 2 The energy utilization unit 20 includes a conductive element 21, an energy storage device 22, and a voltage modulation module 23. One end of the conductive element 21 is in conductive contact with the inner ring 13 of the bearing 10, and the conductive element 21 can conduct the shaft voltage transmitted from the motor 200 shaft to the inner ring 13 of the bearing 10. The other end of the conductive element 21 is electrically connected to the charging end of the energy storage device 22, which is used to collect and store the shaft voltage conducted by the conductive element 21. The discharging end of the energy storage device 22 is electrically connected to the voltage modulation module 23, and the electrical energy stored inside the energy storage device 22 can be discharged stably after being modulated by the voltage modulation module 23. By installing the energy utilization unit 20 on the bearing 10, the shaft voltage of the inner ring 13 of the bearing 10 can be collected and stored, and this part of the energy can be supplied to the outside, thus recovering the energy of the shaft voltage and solving the problem of electrical corrosion of the bearing 10 caused by excessive shaft voltage breaking down the oil film.

[0035] Figure 3 The measured data of the shaft voltage in a certain electric drive system 1000 are shown. Under stable operating conditions, the measured peak-to-peak value of the shaft voltage (peak value minus trough value) is close to 50V. Figure 3The maximum value of the shaft voltage is 49.6V. Even with the oil film of bearing 10 breaking down, the circuit resistance is very small (less than 10 ohms). Calculating the instantaneous power using the formula P=U² / R, where U is the shaft voltage / 2, the instantaneous power of the shaft voltage can reach 60 watts. This means the energy storage device 22 stores approximately 60 watts of energy. Some common sensing elements (such as temperature sensors, flow sensors, current sensors, and voltage sensors) have low power consumption, typically ranging from a few microwatts to several hundred milliwatts. Therefore, the electrical energy stored in the energy storage device 22 can ensure a sufficient energy supply.

[0036] The energy storage device 22 can be a battery or a capacitor, and the specific structure is not limited in this application. In some embodiments, the energy storage device 22 includes two or more capacitors connected in parallel. The capacitors can be high-voltage resistant, small-volume ceramic capacitors or film capacitors, and their specific size allows them to be mounted on the bearing 10.

[0037] In some embodiments, the conductive element 21 is a brush, and the output end of the brush is electrically connected to the charging end of the energy storage device 22. The brush portion of the brush contacts the inner ring 13 of the bearing 10, thereby forming an electrical path. As the inner ring 13 rotates with the shaft, the brush remains in contact with the inner ring 13, thus enabling the conduction and transmission of the shaft voltage of the inner ring 13. The brush can be arc-shaped or ring-shaped; the specific structure is not limited in this application.

[0038] Due to the start-stop control of motor 200 and the changes in its drive voltage, the shaft voltage of bearing 10 is unstable. Voltage modulation module 23 can monitor the voltage of energy storage device 22 and control its charging and discharging process, ultimately outputting a stable voltage usable by the electrical load, such as 5V or 12V. As one implementation, voltage modulation module 23 may include an electrically connected voltage comparison circuit and a switching circuit. When the discharge voltage of energy storage device 22 reaches a preset discharge threshold of the voltage comparison circuit, the switching circuit controls the external power supply circuit to conduct and supply power to the electrical load.

[0039] In some embodiments, the voltage modulation module 23 includes at least a hysteresis comparator 231. The discharge terminal of the energy storage device 22 is electrically connected to the voltage input terminal of the hysteresis comparator 231, and the voltage output terminal of the hysteresis comparator 231 is used to connect to the electrical load. The hysteresis comparator 231, also known as a Schmitt trigger, works by introducing a positive feedback mechanism to give the circuit two different threshold voltages, thereby creating hysteresis characteristics.

[0040] Figure 4 The circuit diagram of the hysteresis comparator 231 in some embodiments is shown below, in conjunction with... Figure 4 The charging and discharging processes of the energy storage device 22 are described.

[0041] The voltage accumulation process of energy storage device 22: When the input voltage ui (i.e., the discharge voltage of energy storage device 22) is less than the lower threshold voltage of hysteresis comparator 231, the output voltage uo of hysteresis comparator 231 is a low voltage close to 0V. As the voltage of energy storage device 22 accumulates, the discharge voltage continues to increase. When the input voltage ui does not exceed the upper threshold voltage of hysteresis comparator 231, due to the hysteresis characteristic of hysteresis comparator 231, the output voltage uo of hysteresis comparator 231 remains unchanged, continuously outputting a low voltage.

[0042] The voltage release process of energy storage device 22: When the input voltage ui is greater than the upper threshold voltage, the output state of hysteresis comparator 231 flips, and at this time, hysteresis comparator 231 outputs a high voltage. As the voltage of energy storage device 22 releases, the discharge voltage continues to decrease. If the input voltage ui still exceeds the lower threshold voltage of hysteresis comparator 231, due to the hysteresis characteristic of hysteresis comparator 231, the output voltage uo of hysteresis comparator 231 remains unchanged, and it continues to output a high voltage.

[0043] As the input voltage ui decreases further, when the input voltage ui is less than the lower threshold voltage of the hysteresis comparator 231, the output state of the hysteresis comparator 231 flips again. At this time, the hysteresis comparator 231 outputs a low voltage and enters the voltage accumulation process of the energy storage device 22 again.

[0044] Figure 5 A structural block diagram of the surplus energy utilization unit 20 in other embodiments is shown; please refer to [link / reference]. Figure 5 The voltage modulation module 23 also includes a modulation circuit 232 electrically connected to the hysteresis comparator 231. The discharge terminal of the energy storage device 22 is electrically connected to the voltage input terminal of the hysteresis comparator 231, and the voltage output terminal of the hysteresis comparator 231 is connected to the input terminal of the modulation circuit 232. The output terminal of the modulation circuit 232 is used to connect to the electrical load and output a stable voltage.

[0045] Figure 6 A circuit block diagram of the modulation circuit 232 in some embodiments is shown; please refer to [link / reference]. Figure 6 The modulation circuit 232 uses a three-terminal Zener diode electronic component. Its main function is to convert an unstable higher voltage into a stable lower voltage, such as 3.3V, 5V, 12V, or 24V, so as to provide stable power to the subsequent electrical load.

[0046] Insufficient lubrication or overload can both cause the temperature of bearing 10 to rise. To address the temperature rise issue of bearing 10, relevant technologies typically rely on post-event diagnosis using indicators such as the oil temperature sensor in the cooling and lubrication system 500 or the output torque and noise of the electric drive system 1000, thereby increasing the supply of lubricating oil to bearing 10. This approach results in a delayed response to the temperature rise problem of bearing 10 and lacks precise and proactive thermal management capabilities for the bearing 10.

[0047] For this purpose, please refer to Figure 7 In some embodiments, the energy utilization unit 20 further includes a temperature sensor 24, which is electrically connected to the voltage modulation module 23. The temperature sensor 24 acts as an electrical load; the electrical energy stored in the energy storage device 22 can be modulated by the voltage modulation module 23 and directly supplied to the temperature sensor 24. The temperature sensor 24 is used to detect the temperature of the bearing 10. In some embodiments, the temperature sensor 24 is installed in the non-load-bearing area of ​​the outer ring 11. The temperature sensor 24 (such as a thermocouple) can be embedded inside the outer ring 11 of the bearing 10 or attached to the surface of the outer ring 11 to detect the temperature of the non-load-bearing area of ​​the bearing 10 in real time. The probe of the temperature sensor 24 can be brought close to the rolling element 12 to ensure that the temperature sensor 24 can measure the temperature near the working surface of the bearing 10. Insulation treatment is required between the temperature sensor 24 and the outer ring 11, for example, by adding an insulating wrap to the probe surface.

[0048] In some embodiments, the temperature data detected by the temperature sensor 24 can be electrically connected to an external controller 600 via a wire to transmit signals. In other embodiments, the temperature data detected by the temperature sensor 24 can also be transmitted wirelessly. Figure 8 A structural block diagram of the energy utilization unit 20 in some other embodiments is shown; please refer to [link / reference]. Figure 8 The energy utilization unit 20 also includes a first wireless communication module 25, which is electrically connected to the voltage modulation module 23 and the temperature sensor 24, respectively. The first wireless communication module 25 also serves as an electrical load; the electrical energy stored in the energy storage device 22 is modulated by the voltage modulation module 23 and directly supplied to the first wireless communication module 25. Temperature data detected by the temperature sensor 24 is transmitted wirelessly (e.g., via Zigbee or Bluetooth BLE) through the first wireless communication module 25. The first wireless communication module 25 can be simply a wireless transmitter or a wireless communication device with both transmitting and receiving functions; this application does not impose any limitations.

[0049] Therefore, the entire energy utilization device 100 does not require external wiring, can achieve self-powered operation, and has temperature monitoring capabilities. The installation and use of this energy utilization device 100 are no different from ordinary bearings, making it suitable for various scenarios.

[0050] Please see Figure 1In some embodiments, the energy-saving device 100 further includes a mounting plate 30, which is connected to the outer ring 11. The connection method can be bonding, interference fit, or fastener connection. The energy-saving unit 20 is mounted on the mounting plate 30, and the energy-saving unit 20 can be installed in the annular space formed by the mounting plate 30 and the outer ring 11. In some embodiments, the bearing 10 is mounted on the end of the shaft. If the shaft does not pass through the bearing 10, the mounting plate 30 can be annular or circular.

[0051] In some embodiments, the energy storage device 22, the voltage modulation module 23, and the first wireless communication module 25 can be integrated on a single circuit board, for example, by using a printed circuit board to arrange the energy storage device 22, the voltage modulation module 23, and the first wireless communication module 25 on the same PCB substrate. The conductive component 21 and the temperature sensor 24 are electrically connected to the pins of the circuit board, thereby enabling the energy utilization unit 20 to form an independent integrated module.

[0052] As a further implementation, the energy utilization unit 20 is encapsulated in insulating resin, which forms the mounting plate 30. The insulating resin can be epoxy resin, silicone resin, polyurethane resin, polyimide resin, etc., and the specific material is not limited in this application. The insulating resin has insulating properties and a certain hardness after curing. After curing, the insulating resin can be fixedly connected to the outer ring 11 by screws; or the outer ring 11 can be provided with a sleeve structure, and the cured insulating resin can be interference-fitted with this sleeve structure. It is understood that since the conductive element 21 needs to make conductive contact with the inner ring 13, the conductive element 21 needs to extend at least partially beyond the insulating resin. To ensure that the probe of the temperature sensor 24 can directly contact the bearing 10, the probe of the temperature sensor 24 can also extend beyond the insulating resin.

[0053] Please see Figure 9 According to a second aspect of this application, an electric drive system 1000 is provided, which includes a housing 300, a motor 200, and at least one energy utilization device 100 as described in the first aspect. The output shaft 210 of the motor 200 is rotatably connected to the housing 300 via the energy utilization device 100. Since the shaft voltage is generated by the common-mode voltage of the motor 200 windings, the closer the bearing 10 is to the motor 200, the greater the shaft voltage it bears. Therefore, the energy utilization device 100 is at least mounted on the output shaft 210 of the motor 200.

[0054] Please continue reading. Figure 9In some embodiments, the electric drive system 1000 typically also includes a transmission mechanism comprising several drive shafts 410 and gears 420. Each drive shaft 410 is also mounted on the housing 300 via bearings 10. The drive shafts 410 and gears 420 are typically made of metal, and the mechanical transmission connection also forms an electrical connection, allowing the shaft voltage to be transmitted step-by-step to each bearing 10. Current electric drive systems 1000 are gradually increasing from a 400V voltage platform to 800V and even 1000V voltage platforms. As the drive voltage of the motor 200 continues to increase, the problem of electro-corrosion of the bearings 10 is becoming increasingly prominent. Therefore, the shaft voltage of each bearing 10 in the electric drive system 1000 can be tested in advance, and the bearing 10 with the higher shaft voltage can be replaced with the energy utilization device 100 described in the first aspect.

[0055] Please see Figure 9 and Figure 10 In some embodiments, the electric drive system 1000 further includes a cooling and lubrication system 500 and a controller 600. The cooling and lubrication system 500 includes an oil pump 510, a cooling and lubrication passage 520, and at least one electrically controlled valve 530. The outlet of at least one cooling and lubrication branch 521 of the cooling and lubrication passage 520 is positioned opposite the energy utilization device 100, and the oil output from this cooling and lubrication branch 521 can flow directly to the bearing 10 of the energy utilization device 100. The electrically controlled valve 530 is disposed on the cooling and lubrication branch 521 and can adjust the oil flow rate of the cooling and lubrication branch 521. The electrically controlled valve 530 can be a solenoid valve, such as a solenoid proportional valve. The controller 600 is electrically connected to at least the electrically controlled valve 530 and the oil pump 510, respectively. The controller 600 can control the operating state of the electrically controlled valve 530 and / or the oil pump 510, thereby adjusting the amount of oil flowing to the energy utilization device 100. As a further implementation, the controller 600 can also be electrically connected to the motor 200 to control the operating status of the motor 200.

[0056] Please see Figure 9In an embodiment where the energy utilization unit 20 also includes a temperature sensor 24 and a first wireless communication module 25, the controller 600 further includes a second wireless communication module 610, which can communicate wirelessly with the first wireless communication module 25. The first wireless communication module 25 can be a wireless transmitter, and the second wireless communication module 610 corresponds to a wireless receiver. The energy utilization unit 20 collects and stores the shaft voltage surplus energy of the bearing 10, and uses this energy to intermittently power the temperature sensor 24 and the first wireless communication module 25 integrated on the bearing 10. The first wireless communication module 25 transmits the temperature data collected inside the bearing 10 to the outside, and the second wireless communication module 610 receives the temperature data transmitted by the first wireless communication module 25 and transmits it to the controller 600. After receiving the temperature data, the controller 600 determines how to adjust the speed of the oil pump 510 and the opening of the electronic control valve 530 according to the built-in control logic, increasing or decreasing the oil supply of a specific cooling and lubrication branch 521. The controller 600 continuously receives temperature data and realizes closed-loop temperature control of the bearing 10 of the energy utilization device 100 based on the temperature data.

[0057] The operating temperature of bearing 10 is a signal collected by temperature sensor 24. The temperature of bearing 10 originates from heat generated by mechanical friction and heat generated by oil film discharge due to shaft voltage breakdown. Therefore, the temperature of bearing 10 can indirectly reflect the lubrication status of bearing 10. Heat generated by mechanical friction is affected by the friction state between the mechanical parts of bearing 10. When the amount of lubricating oil increases, the oil film thickness between the mechanical parts increases, mechanical friction decreases, and frictional heat generation decreases. Heat generated by oil film discharge due to shaft voltage breakdown is one of the main phenomena of electro-corrosion of bearing 10. Increasing the amount of lubricating oil increases the oil film thickness of bearing 10, making shaft voltage breakdown more difficult and reducing discharge heat generation.

[0058] The control objective of the controller 600 is to enhance the lubrication effect by increasing the oil supply to the working area of ​​the bearing 10 when it is detected that the operating temperature of a specific bearing 10 is too high (requiring enhanced lubrication). This is achieved by increasing the amount of oil supplied to the working area of ​​the bearing 10, thereby improving the lubrication state of the working area of ​​the bearing 10 and reducing the temperature of the working area of ​​the bearing 10.

[0059] Understandably, the energy storage unit 20 utilizes the shaft voltage reserve of the inner ring 13 to intermittently supply power to the temperature sensor 24 and the first wireless communication module 25. When the shaft voltage of the inner ring 13 increases or the energy storage device 22 stores a large amount of electrical energy (indicating a longer operating time of the motor 200), the energy storage device 22 can supply power to the temperature sensor 24 and the first wireless communication module 25. This situation also presents a higher risk of electro-corrosion of the bearing 10. When the temperature sensor 24 and the first wireless communication module 25 are powered, the controller 600 of the electric drive system 1000 can obtain the temperature of the bearing 10's operating area and perform closed-loop temperature control of the bearing 10. In this way, by storing and utilizing the shaft voltage, on the one hand, the degree of electro-corrosion damage is reduced by decreasing discharge energy; on the other hand, the lubrication status of the bearing 10 is intermittently monitored, allowing for timely increases in the amount of lubricating oil in the bearing 10, thus reducing the risk of the bearing 10's oil film being broken down. The electric drive system 1000 actively recovers and utilizes the shaft voltage surplus energy to power the bearing 10 temperature detection device, and realizes closed-loop control of the bearing 10 oil supply based on the detection results, thereby improving the reliability and intelligence level of the electric drive system 1000 and reducing energy consumption to a certain extent.

[0060] A third aspect of this application provides a control method applied to an electric drive system 1000 according to any of the second aspects described above. This control method can be executed by the controller 600 of the electric drive system 1000 in the above embodiments of this application, or by the vehicle controller 600 of the vehicle on which the electric drive system 1000 is mounted. In other embodiments, the control method can also be executed by other devices that communicate data with the vehicle controller 600 or the controller 600 of the electric drive system 1000, such as remote control via a mobile phone, computer, tablet computer, cloud platform, etc. This application does not limit the implementation methods of other devices or the execution entities of each embodiment.

[0061] The control method includes the following steps: obtaining the temperature of the bearing 10 of the energy utilization device 100; and adjusting the working state of the electronic control valve 530 and / or the oil pump 510 when the temperature of the bearing 10 exceeds a set threshold, so as to increase the amount of oil flowing to the bearing 10.

[0062] The temperature of bearing 10 can be detected by the temperature sensor 24 integrated into the energy utilization device 100, or by additionally installing a temperature detection element on bearing 10 in the energy utilization device 100. The execution unit of this control method determines whether the received real-time temperature of bearing 10 exceeds the limit. When it is determined that the temperature of bearing 10 exceeds the set threshold, a control command is generated to drive the oil pump 510 or the solenoid valve 530 on the cooling and lubrication branch 521 corresponding to the bearing 10 to increase the supply of lubricating oil to the specific bearing 10, thereby achieving forced cooling.

[0063] When the drive oil pump 510 increases its speed, the amount of oil in the entire cooling and lubrication channel 520 increases, and correspondingly, the amount of oil in the cooling and lubrication branch 521 corresponding to the bearing 10 of the energy utilization device 100 also increases. This adjustment method is suitable for situations where the motor 200 also has a relatively large load. If the motor 200 has a small load and there is no need to increase the amount of oil in the cooling and lubrication channel 520, then only the solenoid valve 530 corresponding to the cooling and lubrication branch 521 of the bearing 100 of the energy utilization device 100 needs to be controlled to increase its opening, thereby increasing the amount of oil in the energy utilization device 100. Of course, in some emergency situations, such as when the bearing 10 is too hot and there is a risk of burning, the oil pump 510 can be controlled to increase its speed and the solenoid valve 530 can be controlled to increase its opening simultaneously.

[0064] A fourth aspect of this application provides a vehicle that includes at least one of the aforementioned energy utilization devices 100 of the first aspect; and / or, the vehicle includes at least one of the aforementioned electric drive systems 1000 of the second aspect. The vehicle is generally equipped with multiple motors 200, such as drive motors 200, steering motors 200, generators 200, electric fan motors 200, window lift motors, seat adjustment motors, sunroof motors, door lock motors, electric tailgate motors, wiper motors, turbocharger motors, etc. The bearings 10 of the shafts of these motors can all utilize the aforementioned energy utilization device 100 of the first aspect.

[0065] When the vehicle includes at least one electric drive system 1000, the vehicle is a new energy vehicle, specifically a pure electric vehicle, a range-extended electric vehicle, a plug-in hybrid electric vehicle, or a hybrid vehicle (not capable of external charging), etc. Other details not described herein can be found in relevant prior art disclosures and will not be elaborated upon here.

[0066] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0067] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", and "counterclockwise" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0068] It should be noted that all directional indications in the embodiments of this application are only used to explain the relative positional relationship and movement of each component in a specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0069] In this application, unless otherwise expressly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0070] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0071] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0072] Furthermore, the technical solutions of the various embodiments can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0073] Although embodiments of this application have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the claims and their equivalents.

Claims

1. A device for utilizing surplus energy, characterized in that, The device includes a bearing and an energy utilization unit mounted on the bearing. The bearing includes an outer ring, rolling elements, and an inner ring arranged sequentially from the outside to the inside. The energy utilization unit includes a conductive element, an energy storage device, and a voltage modulation module. One end of the conductive element is in conductive contact with the inner ring, and the other end of the conductive element is electrically connected to the charging terminal of the energy storage device. The discharging terminal of the energy storage device is electrically connected to the voltage modulation module.

2. The energy utilization device according to claim 1, characterized in that, The energy utilization unit also includes a temperature sensor, which is electrically connected to the voltage modulation module; the temperature sensor is mounted on the outer ring.

3. The energy utilization device according to claim 2, characterized in that, The energy utilization unit further includes a first wireless communication module, which is electrically connected to the voltage modulation module and the temperature sensor, respectively.

4. The energy utilization device according to any one of claims 1-3, characterized in that, The energy utilization device further includes a mounting plate, which is connected to the outer ring; the energy utilization unit is mounted on the mounting plate.

5. The energy utilization device according to claim 4, characterized in that, The energy utilization unit is encapsulated in insulating resin, which constitutes the mounting plate.

6. The energy utilization device according to any one of claims 1-3, characterized in that, The energy storage device includes two or more capacitors connected in parallel, wherein the capacitors are ceramic capacitors or film capacitors; and / or, the conductive element is a brush.

7. The energy utilization device according to any one of claims 1-3, characterized in that, The voltage modulation module includes a hysteresis comparator, and the discharge terminal of the energy storage device is electrically connected to the voltage input terminal of the hysteresis comparator. Alternatively, the voltage modulation module may further include a modulation circuit electrically connected to the hysteresis comparator, the output of which is used to connect to an electrical load.

8. An electric drive system, characterized in that, It includes a housing, a motor, and at least one energy utilization device according to any one of claims 1-7; the output shaft of the motor is rotatably connected to the housing via the energy utilization device.

9. The electric drive system according to claim 8, characterized in that, The electric drive system also includes: A cooling and lubrication system includes an oil pump, a cooling and lubrication channel, and at least one electrically controlled valve. The outlet of at least one cooling and lubrication branch of the cooling and lubrication channel is opposite to the location of the energy utilization device, and the electrically controlled valve is located on the cooling and lubrication branch. The controller is electrically connected to the electronically controlled valve and the oil pump respectively; the controller is equipped with a second wireless communication module.

10. A control method applied to the electric drive system of claim 9, characterized in that, Includes the following steps: The temperature of the bearing in the energy utilization device is obtained; If the temperature of the bearing exceeds a set threshold, adjust the operating state of the electronic control valve and / or the oil pump to increase the amount of oil flowing to the bearing.

11. A vehicle, characterized in that, It includes at least one energy utilization device according to any one of claims 1-7; and / or includes at least one electric drive system according to claim 8 or 9.

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