A welding power station, a power supply method, an electronic device, and a storage medium

Abstract

This application discloses a welding power station, power supply method, electronic equipment, and storage medium, relating to the field of welding power station technology. The system includes: an engine, a generator, a power battery, and a welding machine. The engine and generator are mechanically connected, and the generator, power battery, and welding machine are sequentially connected via wires. The power battery supplies power to the welding machine under the following conditions: the actual discharge power of the power battery is greater than the welding power requirement; the state of charge (SOC) of the power battery is greater than a preset SOC threshold; and there is no thermal management start-up requirement. The engine operates at a target operating point to drive the generator to generate electricity under any of the following conditions: the actual discharge power of the power battery is less than the welding power requirement; the SOC of the power battery is less than the SOC threshold; and there is a thermal management start-up requirement. The generator generates electricity driven by the engine and supplies power to the welding machine, enhancing load adaptability and stability while reducing fuel consumption.

Description

Technical Field

[0001] This application relates to the field of welding power plant technology, and in particular to a welding power plant, power supply method, electronic equipment, and storage medium. Background Technology

[0002] In recent years, mobile welding vehicles have been widely used in outdoor oil and gas pipeline construction, providing mechanical assistance and power supply for pipeline hoisting, welding, grinding, and other processes on construction sites. Existing mobile welding vehicles typically use an engine to drive a generator for power, which in turn provides a stable power supply to equipment such as welding machines, angle grinders, and windproof canopies via an inverter. In stationary welding conditions, the engine drives the generator to produce electricity, which is then used to power the welding equipment via an inverter. Its operating characteristic is that the load changes abruptly with the welding stage.

[0003] However, existing mobile welding vehicles still have certain limitations under welding conditions. Due to sudden load changes, it is difficult to maintain stable engine speed control, which in turn leads to fluctuations in the inverter primary voltage, affecting the stability of the welding machine's output current and ultimately reducing welding quality. Decreased welding quality not only increases weld defects but may also cause rework and repairs, reducing construction efficiency and increasing project costs. Furthermore, in complex outdoor environments, welding equipment requires high power supply stability, and the response capability of existing systems under sudden load changes still needs improvement.

[0004] Therefore, in response to the problem of power supply stability of existing mobile welding vehicles under welding conditions, this application proposes a new welding machine power station. Summary of the Invention

[0005] In view of the above problems, embodiments of this application provide a welding power station, a power supply method, an electronic device, and a storage medium to overcome or at least partially solve the above problems.

[0006] In a first aspect, this application provides a welding power station, which includes at least: an engine, a generator, a power battery, and a welding machine, wherein the engine is mechanically connected to the generator, and the generator is sequentially connected to the power battery and the welding machine via wires; The power battery is used to supply power to the welding machine under the following conditions: the actual discharge power of the power battery is greater than the welding power requirement, the state of charge (SOC) of the power battery is greater than the preset SOC threshold, and there is no thermal management start-up requirement. The engine is used to operate at a target operating point to drive the generator to generate electricity under any of the following conditions: the actual discharge power of the power battery is less than the welding power requirement, the state of charge (SOC) of the power battery is less than the SOC threshold, and there is a thermal management start-up requirement. The generator is used to generate electricity driven by the engine and to supply power to the welding machine.

[0007] Optionally, it may also include: a vehicle controller; The vehicle controller is used to acquire the welding power requirement, the SOC state of the power battery, and the actual discharge power of the power battery, respectively. The vehicle controller is also used to determine the target operating point of the engine based on the welding power requirement and the SOC state of the power battery.

[0008] Optionally, it further includes: a single planetary gear set, the single planetary gear set being disposed between the engine and the generator, the single planetary gear set including at least a first gear set and a second gear set; The first gear set is used to transmit the torque of the engine to the generator so that the engine drives the generator to generate electricity; The second gear set is used to transmit the first negative torque of the generator to the engine so that the generator regulates the speed of the engine.

[0009] Optionally, it may also include: a motor controller and a drive motor; The motor controller is electrically connected to the drive motor and the generator respectively, and the drive motor is mechanically connected to the wheel end output shaft of the welding power station; The motor controller is used to acquire the target operating point of the engine and determine the adjustment operating point of the generator based on the target operating point of the engine, so as to control the generator to operate based on the adjustment operating point; The motor controller is further configured to acquire the wheel end required torque of the wheel end output shaft, and determine the suppression operating point of the drive motor based on the wheel end required torque of the wheel end output shaft, so as to control the drive motor to operate based on the suppression operating point; The generator is configured to operate based on the adjusted operating point to generate the first negative torque; The drive motor is configured to operate based on the suppression operating point to generate a second negative torque, which is used to suppress the rotation of the wheel-end output shaft.

[0010] A second aspect of this application provides a power supply method for a welding power station as described in the first aspect of this application, the method comprising: After the welding station enters the welding state, the vehicle controller obtains the welding power required under the current welding conditions, the SOC state of the power battery, and the actual discharge power of the power battery. Under the conditions that the actual discharge power of the power battery is greater than the welding power requirement, the SOC state of the power battery is greater than the preset SOC state threshold, and there is no thermal management start-up requirement, the power battery supplies power to the welding machine of the welding power station. Under any of the following conditions: the actual discharge power of the power battery is less than the welding demand power, the state of charge (SOC) of the power battery is less than the SOC threshold, and there is a thermal management start-up requirement, the target operating point of the engine is determined based on the welding demand power and the SOC of the power battery. The target operating point includes the first torque and the first speed of the engine. The engine is controlled to operate based on the target operating point so that the engine drives the generator to generate electricity to power the welding machine of the welding power station.

[0011] Optionally, determining the target operating point of the engine based on the welding power requirement and the state of charge (SOC) of the power battery includes: Based on the welding power requirement, the theoretical power requirement of the engine is determined; The actual power demand of the engine is determined based on the SOC state of the power battery and the theoretical power demand of the engine. Based on the actual power demand of the engine, the target operating point of the engine is determined by querying the pre-established engine universal characteristic diagram and the pre-established motor efficiency MAP diagram.

[0012] Optionally, after the engine operates based on the target operating point, the method further includes: The target operating point is obtained through the motor controller; Based on the target operating point, the adjustment operating point of the generator is determined, and the adjustment operating point includes the second torque and the second speed of the generator; Based on the adjusted operating point, the generator is controlled to operate so that the generator limits the speed of the engine.

[0013] Optionally, after the engine operates based on the target operating point, the method further includes: The required torque at the wheel end of the output shaft of the welding power station is obtained through the motor controller. Based on the required torque at the wheel end, the suppression operating point of the drive motor of the welding power station is determined, and the suppression operating point includes the third torque and the third speed of the drive motor; Based on the suppression operating point, the drive motor is controlled to suppress the rotation of the wheel-end output shaft.

[0014] In a third aspect, this application provides an electronic device including a memory, a processor, and a program or instructions stored in the memory and executable on the processor, wherein the program or instructions, when executed by the processor, implement the steps of the power supply method as described in the second aspect of this application.

[0015] In a fourth aspect, this application provides a readable storage medium on which a program or instructions are stored, which, when executed by a processor, implement the steps of the power supply method as described in the second aspect of this application.

[0016] The beneficial effects of this application are: This application proposes a welding power station, which includes at least: an engine, a generator, a power battery, and a welding machine. The engine is mechanically connected to the generator, and the generator, power battery, and welding machine are sequentially connected via wires. The power battery supplies power to the welding machine under the following conditions: the actual discharge power of the power battery is greater than the welding power requirement; the state of charge (SOC) of the power battery is greater than a preset SOC threshold; and there is no thermal management start-up requirement. The engine operates at a target operating point to drive the generator to generate electricity under the following conditions: the actual discharge power of the power battery is less than the welding power requirement; the SOC of the power battery is less than the SOC threshold; and there is a thermal management start-up requirement. The generator generates electricity driven by the engine and supplies power to the welding machine. This application achieves enhanced load adaptability and stability, ensures welding continuity, and reduces fuel consumption through the coordinated control of the engine, generator, and power battery. It directly supplies power at low power levels, reducing voltage fluctuations and improving welding quality. At high power levels, intelligent control of the engine's start-stop ensures efficient operation. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments of this application will be briefly introduced below. Obviously, the drawings described below are only 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 This is a schematic diagram of the connection structure of a welding power station provided in an embodiment of this application; Figure 2 This is a schematic flowchart illustrating the steps of a power supply method for a welding power station provided in an embodiment of this application; Figure 3 This is a schematic diagram of the working principle of pure electric welding provided in an embodiment of this application; Figure 4This is a schematic diagram of the working principle of hybrid welding provided in an embodiment of this application; Figure 5 This is a universal characteristic curve of an engine provided in an embodiment of this application; Figure 6 This is a motor efficiency MAP provided in an embodiment of this application; Figure 7 This is a schematic diagram of a welding lever provided in an embodiment of this application; Figure 8 This is a flowchart illustrating a power supply method for a welding power station provided in an embodiment of this application. Figure 9 This is a schematic diagram of an electronic device provided in an embodiment of this application. Detailed Implementation

[0019] Exemplary embodiments of this application will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of this application are shown in the drawings, it should be understood that this application may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of this application and to fully convey the scope of this application to those skilled in the art.

[0020] In a first aspect, this application provides a welding power station, such as... Figure 1 As shown, the welding power station includes at least: an engine, a generator, a power battery, and a welding machine, wherein the engine is mechanically connected to the generator, and the generator is sequentially connected to the power battery and the welding machine via wires; The power battery is used to supply power to the welding machine under the following conditions: the actual discharge power of the power battery is greater than the welding power requirement, the state of charge (SOC) of the power battery is greater than the preset SOC threshold, and there is no thermal management start-up requirement. The engine is used to operate at a target operating point to drive the generator to generate electricity under any of the following conditions: the actual discharge power of the power battery is less than the welding power requirement, the state of charge (SOC) of the power battery is less than the SOC threshold, and there is a thermal management start-up requirement. The generator is used to generate electricity driven by the engine and to supply power to the welding machine.

[0021] Specifically, this application provides a welding power station that achieves intelligent power supply management through the coordinated operation of an engine, generator, power battery, and welding machine, thereby improving the stability of the welding process and energy utilization efficiency.

[0022] like Figure 1As shown, the welding power station includes at least the following core components: an engine, a generator, a power battery, and a welding machine. The engine provides mechanical power and drives the generator via a mechanical connection. The generator, driven by the engine, generates electricity and is connected to the power battery and welding machine sequentially via wires. The power battery directly supplies power to the welding machine under specific conditions to reduce engine operating time and improve energy efficiency. The welding machine, which ultimately performs the welding task, is provided with stable electrical power by the power battery or the generator.

[0023] In this application, the welding power station achieves power supply optimization through intelligent coordination of the power battery and the engine to adapt to load changes during the welding process.

[0024] Specifically, when the actual discharge power of the power battery is greater than the welding power requirement, the state of charge (SOC) of the power battery is higher than the preset SOC threshold, and there is no need for thermal management start-up (i.e., no need to start the engine for temperature management), the system enters the main power supply mode of the power battery, i.e., the pure electric welding mode, where the power battery directly supplies power to ensure the stable operation of the welding machine, while reducing the engine start frequency and improving fuel economy. When the actual discharge power of the power battery is less than the welding power requirement, the SOC of the power battery is lower than the preset SOC threshold, and there is a need for thermal management start-up (i.e., the engine needs to be started to maintain the system temperature or meet other operating requirements), the engine starts, entering the engine power generation mode, i.e., the hybrid welding mode. The engine operates at the target operating point, driving the generator to generate electricity, ensuring a stable power supply to the welding machine, and in some cases, it can also charge the power battery.

[0025] This application achieves efficient and stable welding power supply through the intelligent coordination of the engine, generator, and power battery. The power battery prioritizes power supply under low power demand conditions, reducing engine running time and improving energy efficiency; the engine only starts during high power demand periods and operates at its most efficient target operating point to ensure a continuous and stable supply of welding power. This application effectively overcomes the problems of unstable power supply, high fuel consumption, and poor load adaptability of traditional mobile welding vehicles, significantly improving welding quality and construction efficiency, and is suitable for complex construction environments.

[0026] In one embodiment, the welding power station further includes: a vehicle controller; the vehicle controller is used to acquire the welding power requirement, the SOC state of the power battery, and the actual discharge power of the power battery, respectively. The vehicle controller is also used to determine the target operating point of the engine based on the welding power requirement and the SOC state of the power battery.

[0027] Continue to refer to Figure 1The welding power station shown in this embodiment includes a vehicle controller in addition to the original engine, generator, power battery and welding machine.

[0028] The vehicle controller is used to acquire the welding power requirement, the SOC state of the power battery, and the actual discharge power of the power battery. Based on the acquired welding power requirement, the SOC state of the power battery, and the actual discharge power of the power battery, the vehicle controller determines the target operating point of the engine and controls the engine to operate at the determined target operating point.

[0029] In this embodiment, the vehicle controller enables the welding power station to have intelligent energy management capabilities, which can monitor welding needs and battery status in real time, thereby determining the engine's target operating point, ensuring the stability of welding power supply, reducing fuel consumption, and improving overall construction efficiency.

[0030] In one embodiment, the welding power station further includes: a single planetary gear set, the single planetary gear set being disposed between the engine and the generator, the single planetary gear set including at least a first gear set and a second gear set; The first gear set is used to transmit the torque of the engine to the generator so that the engine drives the generator to generate electricity; The second gear set is used to transmit the first negative torque of the generator to the engine so that the generator regulates the speed of the engine.

[0031] Continue to refer to Figure 1 The welding power station shown also includes a single planetary gear set disposed between the engine and the generator. The single planetary gear set includes a first gear set and a second gear set, which are respectively responsible for the power transmission from the engine to the generator and the feedback regulation of the generator speed on the engine.

[0032] Specifically, the first gear set transmits the engine's torque to the generator, enabling the engine to drive the generator to produce electricity to meet the welding machine's power requirements. This first gear set optimizes engine speed through a set first gear ratio, ensuring it operates within its optimal fuel economy range. Compared to traditional direct drive systems, the introduction of planetary gears provides more flexible power distribution and improves power transmission efficiency during engine operation. The second gear set transmits the first negative torque back to the engine when the generator generates it, enabling fine-tuning of engine speed. Sudden changes in generator load can cause engine speed fluctuations, affecting the stability of the welding current. Through the feedback effect of the second gear set, the generator can apply appropriate torque adjustment to the engine, keeping it within a stable speed range and improving system stability.

[0033] In one embodiment, the welding power station further includes: a motor controller and a drive motor; The motor controller is electrically connected to the drive motor and the generator respectively, and the drive motor is mechanically connected to the wheel end output shaft of the welding power station; The motor controller is used to acquire the target operating point of the engine and determine the adjustment operating point of the generator based on the target operating point of the engine, so as to control the generator to operate based on the adjustment operating point; The motor controller is further configured to acquire the wheel end required torque of the wheel end output shaft, and determine the suppression operating point of the drive motor based on the wheel end required torque of the wheel end output shaft, so as to control the drive motor to operate based on the suppression operating point; The generator is configured to operate based on the adjusted operating point to generate the first negative torque; The drive motor is configured to operate based on the suppression operating point to generate a second negative torque, which is used to suppress the rotation of the wheel-end output shaft.

[0034] Continue to refer to Figure 1 The welding power station shown also includes a motor controller and a drive motor. The motor controller is electrically connected to both the drive motor and the generator, and the drive motor is mechanically connected to the wheel end output shaft of the welding power station.

[0035] Specifically, the motor controller is responsible for coordinating the control of the generator and the drive motor, mainly including the following two aspects: The motor controller obtains the engine's target operating point, which is the engine's optimal operating state under the current welding requirements and power battery status. Based on the target operating point, it determines the generator's adjustment operating point and controls the generator to operate according to this adjustment operating point to generate a first negative torque. This first negative torque provides an appropriate amount of negative torque to the generator when the welding load changes abruptly, thus buffering engine speed fluctuations and ensuring the stability of welding current and voltage.

[0036] The motor controller obtains the required torque at the wheel end of the output shaft, which is the torque requirement of the welding power station for the wheel under different terrain or movement conditions. Based on the required torque at the wheel end, it determines the suppression operating point of the drive motor and controls the drive motor to operate at the suppression operating point to generate a second negative torque. This second negative torque suppresses the rotation of the output shaft at the wheel end, preventing the vehicle from shifting due to external factors during the welding process and affecting the accuracy of the operation.

[0037] In this embodiment, the generator's first negative torque regulates the engine speed, ensuring a stable power supply to the system when the welding load changes. The drive motor's second negative torque controls the welding station's driving stability, preventing unnecessary wheel-end movement from affecting the welding operation. Through their coordinated operation, the welding station can maintain efficient power supply and stable operation under complex conditions, improving welding quality and increasing construction efficiency.

[0038] This application proposes a welding power station, which includes at least: an engine, a generator, a power battery, and a welding machine. The engine is mechanically connected to the generator, and the generator, power battery, and welding machine are sequentially connected via wires. The power battery supplies power to the welding machine under the following conditions: the actual discharge power of the power battery is greater than the welding power requirement; the state of charge (SOC) of the power battery is greater than a preset SOC threshold; and there is no thermal management start-up requirement. The engine operates at a target operating point to drive the generator to generate electricity under the following conditions: the actual discharge power of the power battery is less than the welding power requirement; the SOC of the power battery is less than the SOC threshold; and there is a thermal management start-up requirement. The generator generates electricity driven by the engine and supplies power to the welding machine. This application achieves enhanced load adaptability and stability, ensures welding continuity, and reduces fuel consumption through the coordinated control of the engine, generator, and power battery. It directly supplies power at low power levels, reducing voltage fluctuations and improving welding quality. At high power levels, intelligent control of the engine's start-stop ensures efficient operation.

[0039] In some embodiments, such as Figure 1 The welding power station shown also includes: a coupling, an axial piston pump, a boom, and tracks. The input end of the coupling is mechanically connected to the drive motor, the generator, and the engine, respectively. The output end of the coupling is mechanically connected to the input end of the axial piston pump. The first output end of the axial piston pump is connected to the boom, and the second output end of the axial piston pump is connected to the tracks.

[0040] Specifically, the walking system of the welding power station adopts a multi-gear control mode. By selecting different gears, the driver determines the target speed of the wheel-end output shaft and adjusts the power output of the engine, generator and drive motor in real time to ensure the accurate maintenance of the target speed. In this embodiment, the wheel-end output shaft is the output end of the walking system as a whole.

[0041] In this embodiment, when the walking system is activated, and the driver presses any of the 1st, 2nd, 3rd, and 4th gear switches, in the pure electric mode powered by the power battery, the electrical power stored in the power battery drives the coupling via the drive motor, which in turn drives the plunger pump. The hydraulic system regulates the pressure (e.g., 4.4 MPa for stationary travel, 8-10 MPa for concrete walking, 22-24 MPa for turning on concrete, and 30-32 MPa for turning on mud), thus driving the tracks and also powering the boom. In the hybrid mode powered by the engine, a portion of the engine power is transmitted sequentially through the single planetary gear set, generator, drive motor, and coupling to actively drive the plunger pump. In some cases, excess power generated by the engine is transferred to the power battery for energy storage, which can drive the tracks, power the boom, and charge the power battery simultaneously. This not only meets the needs of lifting and walking operations but also significantly reduces fuel consumption.

[0042] In one embodiment, such as Figure 1 The welding power station shown also includes a driver's cab and a diesel tank. Inside the driver's cab, the vehicle controller, relay box, battery and wiring harness are integrated in the narrow space under the driver's table and chair. The driver's cab is equipped with 1st, 2nd, 3rd and 4th gear travel switches, welding switch, battery correction switch, key switch, two travel levers and instruments.

[0043] When the key switch is turned on, the welding station enters a low-voltage state. When the key is turned to the Start position, the whole vehicle can enter a high-voltage state normally. In this embodiment, an instrument panel is installed in the cockpit. Under low pressure, the instrument panel can display the temperature of the motor controller, generator and drive motor, battery SOC status, power battery temperature, current and voltage, engine speed, engine coolant temperature, driving gear status, and engine oil pressure of the entire welding power station. After the welding power station enters high pressure, the instrument panel displays the READY status. In addition, in case of a fault, the instrument panel can display the fault codes of each system to facilitate the analysis of the cause of the system fault. Under fault conditions, the instrument panel displays the fault light, power battery fault light, power limit indicator light, and engine fault light to prompt the driver to find the cause. When the driver presses the driving gear status, the instrument panel displays the gear. When the driver presses the welding gear, the instrument panel displays the welding status, and the welding power station enters the welding state. When the driver presses the battery correction gear, the engine starts, the instrument panel displays the power battery correction status, and the SOC status of the power battery is corrected, etc.

[0044] Based on the same inventive concept, a second aspect of this application provides a power supply method for a welding power station applied to the first aspect of this application, such as... Figure 2 As shown, the method includes: Step S101: After the welding power station enters the welding state, the welding power requirement under the current welding condition, the SOC state of the power battery, and the actual discharge power of the power battery are obtained through the vehicle controller.

[0045] In this step, after the welding station enters the welding state, the vehicle controller acquires the following key parameters in real time: welding power requirement: the power required by the current welding machine; power battery SOC status: the remaining power of the power battery; and power battery actual discharge power: the maximum discharge power that the power battery can currently provide.

[0046] Step S102: Under the conditions that the actual discharge power of the power battery is greater than the welding power requirement, the SOC state of the power battery is greater than the preset SOC state threshold, and there is no thermal management start-up requirement, the power battery supplies power to the welding machine of the welding power station.

[0047] In this step, under the conditions that the actual discharge power of the power battery is greater than the welding power requirement, the state of charge (SOC) of the power battery is greater than the preset SOC threshold, and there is no thermal management start-up requirement, the power battery is given priority in directly supplying power to reduce engine operation. The engine is in standby mode to reduce fuel consumption and emissions. This can be referenced as follows: Figure 3 The diagram shown illustrates the working principle of pure electric welding. The power of the battery is transmitted to the welding machine through the inverter, thus powering the welding machine.

[0048] Step S103: Under any of the following conditions, the actual discharge power of the power battery is less than the welding demand power, the state of charge (SOC) of the power battery is less than the SOC threshold, and there is a thermal management start-up requirement, the target operating point of the engine is determined based on the welding demand power and the SOC of the power battery. The target operating point includes the first torque and the first speed of the engine. The engine is controlled to operate according to the target operating point so that it drives the generator to generate electricity to power the welding machine of the welding power station. (Refer to...) Figure 4 The diagram shown illustrates the working principle of hybrid welding. The engine runs, driving the generator to generate electricity. The generated electrical power is transmitted sequentially through the motor controller, power battery, and inverter to the welding machine, thus powering the welding machine. In some cases, the motor controller can also transmit the electrical power from the power battery and a portion of the electrical power generated by the generator to the drive motor to enable the drive motor to run.

[0049] In this step, when the power battery cannot fully meet the power supply requirements of the welding machine, the system will switch to engine power supply mode. This mode can be triggered if any of the following conditions are met: the actual discharge power of the power battery is less than the welding power requirement, the SOC state of the power battery is less than the SOC state threshold, or there is a thermal management start-up requirement. In this mode, the vehicle controller determines the target operating point of the engine, namely the first torque and the first speed of the engine, based on the welding power requirement and the SOC state of the power battery.

[0050] Furthermore, the engine is controlled to operate according to the target working point, so that it outputs a preset torque and speed; the engine drives the generator to generate electricity, and the generated electricity is used to power the welding machine.

[0051] This embodiment uses a combination of power battery and engine to provide power, and dynamically switches the power supply mode according to real-time welding needs and battery SOC status. This not only reduces fuel consumption, but also improves the power supply stability of the welding power station under welding conditions.

[0052] In one embodiment, determining the target operating point of the engine based on the welding power requirement and the state of charge (SOC) of the power battery includes: Based on the welding power requirement, the theoretical power requirement of the engine is determined; The actual power demand of the engine is determined based on the SOC state of the power battery and the theoretical power demand of the engine. Based on the actual power demand of the engine, the target operating point of the engine is determined by querying the pre-established engine universal characteristic diagram and the pre-established motor efficiency MAP diagram.

[0053] In this embodiment, the theoretical power requirement of the engine is first calculated based on the welding power requirement. The calculation formula for the welding power requirement is shown in the following formula (1): (1) in, Indicates the bus voltage; Indicates the bus current; Indicates generator torque; Indicates the generator speed; Indicates the torque of the drive motor; This indicates the speed of the drive motor.

[0054] Furthermore, after calculating the welding power requirement, the theoretical power requirement of the engine is calculated according to the following formula (2): (2) in, This indicates the power of each accessory in the welding power station; It is a constant.

[0055] Furthermore, after calculating the theoretical power demand of the engine, it is necessary to combine the state of charge (SOC) of the power battery to determine the actual power demand of the engine. For example, if the SOC of the power battery is lower than the preset SOC threshold, the actual power demand of the engine will be appropriately increased according to the actual demand.

[0056] Furthermore, based on the engine's actual power demand, the optimal target operating point is determined by querying pre-established engine universal characteristic diagrams and motor efficiency MAP diagrams.

[0057] In this embodiment, the universal characteristic curve of the engine is as follows: Figure 5 As shown in the figure, the motor efficiency MAP is as follows: Figure 6 As shown, the engine universal characteristic diagram reflects fuel consumption under different speed and torque conditions. The horizontal axis represents engine speed, the vertical axis represents engine torque, and the contour lines represent the fuel consumption rate at different engine operating points (i.e., different speeds and torques). The closer to the center of the contour lines, the lower the fuel consumption rate and the better the fuel economy, which falls within the engine's economic operating range. Figure 7 As shown, the motor efficiency MAP reflects the motor efficiency at different speeds and torques. The horizontal axis represents the motor speed, the vertical axis represents the motor torque, and the contour lines represent the motor efficiency. The closer to the center of the contour line, the higher the motor efficiency.

[0058] This embodiment prioritizes the torque and speed combination with the lowest fuel consumption rate, ensuring the engine operates in its fuel-efficient zone while meeting the engine's actual power requirements. This reduces energy consumption and improves fuel utilization. Since the engine drives a generator to produce electricity, to ensure the generator's energy conversion efficiency is maximized, the optimal operating point of the generator must be selected based on the motor efficiency MAP (Motor Efficiency Mapping) chart. This minimizes energy loss and improves overall electrical output efficiency. By combining the engine's universal characteristic diagram and the motor efficiency MAP chart, the target operating point of the engine—the optimal torque and speed parameters—is finally determined. This target operating point ensures that the engine can meet the welding machine's power requirements while also balancing fuel economy and energy conversion efficiency.

[0059] In some embodiments, determining the target operating point of the engine based on the engine's actual power demand includes: Based on the actual power demand of the engine, the first speed range of the engine is determined by consulting the pre-established universal characteristic diagram of the engine. Based on the first speed range of the engine, the first speed is determined by querying a pre-established motor efficiency MAP. The first torque of the engine is calculated based on the actual power demand of the engine and the first speed. Based on the first rotational speed and the first torque, the target operating point of the engine under the current welding condition is determined.

[0060] In this embodiment, the target operating point of the engine is determined based on the engine's actual power demand by comprehensively analyzing the engine's universal characteristic diagram and the motor efficiency MAP diagram. First, the actual power demand of the engine is calculated based on the welding power requirement and the state of charge (SOC) of the power battery. Then, the first speed range corresponding to this power is queried from the pre-established engine universal characteristic diagram to ensure that the engine operates within a reasonable operating range while meeting the power demand. Next, within this first speed range, the motor efficiency MAP diagram is further queried to select the first speed with the highest motor efficiency, thereby optimizing the overall energy conversion efficiency of the system. After determining the first speed, the first torque required by the engine is calculated in conjunction with the engine's actual power demand, ensuring that the engine can provide sufficient power output. Finally, based on the first speed and the first torque, the target operating point of the engine under the current welding conditions is determined, and the engine's operating state is adjusted through a control strategy to ensure that it always operates within the high-efficiency range, thereby improving energy utilization, reducing unnecessary fuel consumption, and ensuring the stability and reliability of the welding operation.

[0061] In one embodiment, when the current welding condition switches from a first welding condition to a second welding condition, controlling the engine operation according to the target operating point includes: Obtain the torque slope gradient limit of the engine; According to the torque slope gradient limit, the engine is controlled to switch from the target operating point under the first welding condition to the target operating point under the second welding condition.

[0062] In this embodiment, when the welding power station switches from the first welding condition to the second welding condition, where there is a sudden power change between the two conditions, the engine's operating state is gradually adjusted based on a preset torque slope gradient limit to ensure smooth engine operation and stable system response. First, the engine's torque slope gradient limit is obtained, which restricts the rate of torque change to prevent sudden torque changes from causing instability in the welding power station. Next, when controlling the engine to switch from the target operating point under the first welding condition to the target operating point under the second welding condition, the engine's torque output is gradually adjusted according to the torque slope gradient limit, ensuring a smooth transition in engine torque and speed, thereby avoiding the impact of drastic fluctuations on welding quality and system lifespan. Ultimately, while meeting the target operating point requirements, the engine ensures a stable and reliable power supply process for the entire welding power station, improving the consistency and safety of welding operations.

[0063] In one embodiment, after the engine operates based on the target operating point, the method further includes: The target operating point is obtained through the motor controller; Based on the target operating point, the adjustment operating point of the generator is determined, and the adjustment operating point includes the second torque and the second speed of the generator; Based on the adjusted operating point, the generator is controlled to operate so that the generator limits the speed of the engine.

[0064] In this embodiment, after the engine operates at the target operating point, adjustments are made to the generator to further optimize the energy management and stability of the welding power station. First, the motor controller acquires the engine's target operating point, which includes the engine's first torque and first speed. Then, based on this target operating point, the motor controller determines the generator's adjustment operating point, which includes the generator's second torque and second speed, to ensure that the generator's operating state matches the engine's needs. Subsequently, the motor controller adjusts the generator's operating state according to the determined adjustment operating point, ensuring it operates within an appropriate operating range and generates a certain amount of negative torque to limit the engine's speed, preventing speed overshoot or excessive fluctuations. This control method helps improve the stability of the entire system, ensuring stable power supply under different operating conditions, while optimizing energy utilization efficiency and improving overall operational performance.

[0065] Among them, refer to, Figure 7The diagram illustrates the lever configuration for welding operation. The single planetary gear set acts as a power distribution mechanism, and the lever torque relationships within it determine the operating state of the welding power station. During welding, a portion of the engine's power is transferred to the generator for energy recovery, while the remaining power is transmitted to the output shaft via the planetary gear mechanism. However, because the vehicle controller always locks the wheel-end output shaft, keeping it stationary, the lever posture within the single planetary gear set adjusts according to the engine's operating state to maintain the torque balance of the entire system.

[0066] In this embodiment, the adjustment operating point of the generator can be calculated using the following formula (3): ; (3) in, Indicates engine speed; This indicates the number of teeth on the ring gear / the number of teeth on the sun gear; Represents a constant; This indicates engine torque.

[0067] In one embodiment, after the engine operates based on the target operating point, the method further includes: The required torque at the wheel end of the output shaft of the welding power station is obtained through the motor controller. Based on the required torque at the wheel end, the suppression operating point of the drive motor of the welding power station is determined, and the suppression operating point includes the third torque and the third speed of the drive motor; Based on the suppression operating point, the drive motor is controlled to suppress the rotation of the wheel-end output shaft.

[0068] In this embodiment, after the engine operates at the target operating point, the drive motor is adjusted accordingly to further optimize the stability and maneuverability of the welding station. First, the motor controller acquires the wheel-end torque requirement of the welding station's wheel-end output shaft. This torque requirement characterizes the travel or braking demand under the current operating condition. Then, based on the wheel-end torque requirement, the motor controller determines the suppression operating point of the drive motor. This suppression operating point includes the third torque and third speed of the drive motor to ensure that the drive motor's operating state meets the control requirements. Next, according to the determined suppression operating point, the motor controller adjusts the operation of the drive motor to apply an appropriate negative torque, thereby suppressing the rotation of the wheel-end output shaft. This control method effectively limits the wheel-end movement of the welding station under specific operating conditions, avoiding unnecessary slippage or speed deviations and improving the stability of the welding process.

[0069] In one embodiment, this application provides a method such as Figure 8 The flowchart of the power supply method for the welding power station is shown in the figure: First, the driver requests the parking controller to enter P gear according to the welding gear requirements; then, based on the welding power requirements, the actual discharge power of the power battery, the SOC state of the power battery, and the start-up requirements of thermal management, the driver selects either pure electric welding mode or hybrid welding mode.

[0070] Under the conditions that the actual discharge power of the power battery is greater than the welding power requirement, the SOC state of the power battery is greater than the preset SOC state threshold, and there is no thermal management start-up requirement, the pure electric welding mode is entered, and the welding machine is powered by the power battery. Under any of the following conditions, the actual discharge power of the power battery is less than the welding power requirement, the state of charge (SOC) of the power battery is less than the SOC threshold, and there is a thermal management start-up requirement, the generator operates at the target operating point to drive the generator to generate electricity: Specifically, the welding machine's required power is calculated based on the actual discharge power of the power battery and the actual power used by the generator and drive motor; then, the engine's required power is calculated based on the welding power requirement and the battery's SOC; then, based on the engine's required power, the pre-established engine universal characteristic curve and motor efficiency MAP are consulted to obtain the engine's speed range and torque range; then, the speed range and torque range are limited, and the engine torque slope gradient is limited to obtain the engine's target torque and target speed (engine target operating point); based on the engine's target torque, the negative torque of the generator used to regulate the engine speed is calculated; combined with the required torque of the wheel-end output shaft and the engine's target torque, the negative torque of the drive motor used to suppress the rotation of the wheel-end output shaft is calculated, and the drive motor's torque is simultaneously limited by efficiency gradient.

[0071] Finally, the engine, generator, and drive motor are controlled to operate according to their respective torques, and the electrical power generated by the generator is transmitted to the welding machine via the inverter.

[0072] This application determines the theoretical power demand of the engine based on the welding power requirements during the operation of the welding power plant, and adjusts the actual power demand of the engine in conjunction with the state of charge (SOC) of the power battery. Subsequently, by consulting the engine's universal characteristic curve, a suitable speed range is determined, and the optimal speed is selected by combining this with the motor efficiency MAP chart. The corresponding torque is then calculated to determine the engine's target operating point, ensuring it operates in the high-efficiency zone and improving fuel economy.

[0073] After the engine operates at the target operating point, the motor controller acquires the target operating point and determines the generator's adjustment operating point to limit the engine speed and prevent it from entering the inefficient zone. Furthermore, when welding conditions change, the engine torque slope gradient limit is acquired to smoothly control the engine's transition from the first welding condition to the second, avoiding unstable operation caused by abrupt changes. Simultaneously, the system also acquires the required torque of the wheel-end output shaft through the motor controller, determines the suppression operating point of the drive motor, and controls the drive motor's operation based on this operating point to suppress the rotation of the wheel-end output shaft, further improving the stability of the welding power station.

[0074] Based on the same inventive concept, a third aspect of this application provides a method such as Figure 9 The illustrated electronic device 100 includes a memory 110, a processor 120, and a program or instructions stored in the memory 110 and executable on the processor 120, wherein the program or instructions, when executed by the processor 120, implement the steps of the power supply method as described in the second aspect of this application.

[0075] Based on the same inventive concept, in a fourth aspect of this application, a readable storage medium is provided, on which a program or instructions are stored, which, when executed by a processor, implement the steps of the power supply method as described in the second aspect of this application.

[0076] Each embodiment in this specification focuses on the differences from other embodiments. For the same or similar parts between the embodiments, please refer to each other.

[0077] Those skilled in the art will understand that embodiments of this application can be provided as methods, apparatus, or computer program products. Therefore, embodiments of this application can take the form of entirely hardware embodiments, entirely software embodiments, or embodiments combining software and hardware aspects. Furthermore, embodiments of this application can take the form of computer program products implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0078] This application describes embodiments with reference to flowchart illustrations and / or block diagrams of methods, terminal devices (systems), and computer program products according to embodiments of this application. It should be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing terminal device to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing terminal device, generate instructions for implementing the flowchart illustrations. Figure 1One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0079] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing terminal device to operate in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0080] These computer program instructions can also be loaded onto a computer or other programmable data processing terminal equipment, causing a series of operational steps to be performed on the computer or other programmable terminal equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable terminal equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0081] Although preferred embodiments of the present application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the embodiments of the present application.

[0082] Finally, it should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or terminal device that includes said element.

[0083] The welding power station, power supply method, electronic equipment, and storage medium provided above have been described in detail. Specific examples have been used to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A welding power station, characterized in that, The welding power station includes at least: an engine, a generator, a power battery, and a welding machine, wherein the engine is mechanically connected to the generator, and the generator is sequentially connected to the power battery and the welding machine via wires; The power battery is used to supply power to the welding machine under the following conditions: the actual discharge power of the power battery is greater than the welding power requirement, the state of charge (SOC) of the power battery is greater than the preset SOC threshold, and there is no thermal management start-up requirement. The engine is used to operate at a target operating point to drive the generator to generate electricity under any of the following conditions: the actual discharge power of the power battery is less than the welding power requirement, the state of charge (SOC) of the power battery is less than the SOC threshold, and there is a thermal management start-up requirement. The generator is used to generate electricity driven by the engine and to supply power to the welding machine.

2. The welding power station according to claim 1, characterized in that, Also includes: Vehicle controller; The vehicle controller is used to acquire the welding power requirement, the SOC state of the power battery, and the actual discharge power of the power battery, respectively. The vehicle controller is also used to determine the target operating point of the engine based on the welding power requirement and the SOC state of the power battery.

3. The welding power station according to claim 1, characterized in that, Also includes: A single planetary gear set is disposed between the engine and the generator, and the single planetary gear set includes at least a first gear set and a second gear set. The first gear set is used to transmit the torque of the engine to the generator so that the engine drives the generator to generate electricity; The second gear set is used to transmit the first negative torque of the generator to the engine so that the generator regulates the speed of the engine.

4. The welding power station according to claim 3, characterized in that, Also includes: Motor controller and drive motor; The motor controller is electrically connected to the drive motor and the generator respectively, and the drive motor is mechanically connected to the wheel end output shaft of the welding power station; The motor controller is used to acquire the target operating point of the engine and determine the adjustment operating point of the generator based on the target operating point of the engine, so as to control the generator to operate based on the adjustment operating point; The motor controller is further configured to acquire the wheel end required torque of the wheel end output shaft, and determine the suppression operating point of the drive motor based on the wheel end required torque of the wheel end output shaft, so as to control the drive motor to operate based on the suppression operating point; The generator is configured to operate based on the adjusted operating point to generate the first negative torque; The drive motor is configured to operate based on the suppression operating point to generate a second negative torque, which is used to suppress the rotation of the wheel-end output shaft.

5. A power supply method for a welding power station as described in any one of claims 1-4, characterized in that, The method includes: After the welding station enters the welding state, the vehicle controller obtains the welding power required under the current welding conditions, the SOC state of the power battery, and the actual discharge power of the power battery. Under the conditions that the actual discharge power of the power battery is greater than the welding power requirement, the SOC state of the power battery is greater than the preset SOC state threshold, and there is no thermal management start-up requirement, the power battery supplies power to the welding machine of the welding power station. Under any of the following conditions: the actual discharge power of the power battery is less than the welding demand power, the state of charge (SOC) of the power battery is less than the SOC threshold, and there is a thermal management start-up requirement, the target operating point of the engine is determined based on the welding demand power and the SOC of the power battery. The target operating point includes the first torque and the first speed of the engine. The engine is controlled to operate based on the target operating point so that the engine drives the generator to generate electricity to power the welding machine of the welding power station.

6. The power supply method according to claim 5, characterized in that, Determining the target operating point of the engine based on the welding power requirement and the state of charge (SOC) of the power battery includes: Based on the welding power requirement, the theoretical power requirement of the engine is determined; The actual power demand of the engine is determined based on the SOC state of the power battery and the theoretical power demand of the engine. Based on the actual power demand of the engine, the target operating point of the engine is determined by querying the pre-established engine universal characteristic diagram and the pre-established motor efficiency MAP diagram.

7. The power supply method according to claim 5, characterized in that, After the engine operates based on the target operating point, the method further includes: The target operating point is obtained through the motor controller; Based on the target operating point, the adjustment operating point of the generator is determined, and the adjustment operating point includes the second torque and the second speed of the generator; Based on the adjusted operating point, the generator is controlled to operate so that the generator limits the speed of the engine.

8. The power supply method according to claim 5, characterized in that, After the engine operates based on the target operating point, the method further includes: The required torque at the wheel end of the output shaft of the welding power station is obtained through the motor controller. Based on the required torque at the wheel end, the suppression operating point of the drive motor of the welding power station is determined, and the suppression operating point includes the third torque and the third speed of the drive motor; Based on the suppression operating point, the drive motor is controlled to suppress the rotation of the wheel-end output shaft.

9. An electronic device, characterized in that, It includes a processor, a memory, and a program or instructions stored in the memory and executable on the processor, wherein the program or instructions, when executed by the processor, implement the steps of the power supply method as described in any one of claims 5-8.

10. A readable storage medium on which a program or instructions are stored, characterized in that, When the program or instructions are executed by the processor, they implement the steps of the power supply method as described in any one of claims 5-8.

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