Extended-range hybrid power system and working machine

Abstract

The utility model relates to the technical field of operation machinery, and discloses an extended-range hybrid power system and operation machinery. The extended-range hybrid power system comprises: an engine; the generator is connected with the engine; the electric drive axle is electrically connected with the generator through the first controller; the energy storage device is electrically connected with the first controller through the second controller; the operation motor is electrically connected with the second controller; and the loading operation mechanism is connected with the operation motor. When the range extending type hybrid power system is in a pure electric running mode or a pure electric operation mode, the engine does not work, and zero consumption of fuel oil is achieved; when the extended-range hybrid power system is in the extended-range running mode or the extended-range operation mode, the engine does not directly drive the vehicle to run or operate a motor, the engine does not need to change output power according to the running power requirement, the engine is always in an efficient economic area for power generation, and the engine displacement and power are smaller than those of a traditional fuel vehicle engine. Fuel consumption and tail gas emission are reduced, and energy conservation and emission reduction are achieved.

Description

Technical Field

[0001] This utility model relates to the field of work machinery technology, specifically to a range-extended hybrid power system and work machinery. Background Technology

[0002] As new energy vehicle technology continues to evolve and market demands change, the development direction of new vehicles will also change. Construction machinery also needs to be combined with advanced technologies. As an indispensable part of engineering operations, construction machinery such as cranes should follow the trend of the times and technological development while ensuring the quality and efficiency of engineering operations. New energy technologies need to be applied to construction machinery.

[0003] Traditional construction machinery still relies heavily on fossil fuels. For example, traditional cranes still have problems with high energy consumption and high pollution emissions when they are in motion or working. Their energy is mostly supplied by engines, resulting in excessive carbon emissions. At the same time, the engines of cranes run continuously during operation, generating a lot of noise, which has a negative impact on the environment and the physical and mental health of the drivers.

[0004] To achieve the electrification transformation of cranes, it is necessary to design various new energy system architectures based on crane machinery, such as pure electric and plug-in hybrid models. However, pure electric models are prone to insufficient battery power during driving or operation, which can lead to range issues. Plug-in hybrid models have higher requirements for the operating environment and require stable and engineering machinery-specific power supply equipment during operation. Utility Model Content

[0005] In view of this, the present invention provides a range-extended hybrid power system and a working machine to solve the problem of insufficient battery power that is common in pure electric vehicles.

[0006] In a first aspect, this utility model provides a range-extended hybrid power system, comprising: an engine; a generator connected to the engine; an electric drive axle electrically connected to the generator via a first controller; an energy storage device electrically connected to the first controller via a second controller; a working motor electrically connected to the second controller; and an on-board working mechanism connected to the working motor. The range-extended hybrid power system has a pure electric driving mode, a range-extended driving mode, a pure electric working mode, and a range-extended working mode. When the range-extended hybrid power system is in pure electric driving mode, the energy storage device provides power to the electric drive axle via the second controller and the first controller. When the range-extended hybrid power system is in range-extended driving mode, the engine provides power to the electric drive axle via the generator and the first controller. When the range-extended hybrid power system is in pure electric working mode, the energy storage device provides power to the working motor via the second controller. When the range-extended hybrid power system is in range-extended working mode, the engine provides power to the working motor via the generator, the first controller, and the second controller.

[0007] Beneficial effects: When the range-extended hybrid system is in pure electric driving or pure electric operation mode, the engine does not work, achieving zero fuel consumption. When the range-extended hybrid system is in range-extended driving or range-extended operation mode, since the engine does not need to directly drive the vehicle's driving or operation motor, the engine does not need to change its output power according to the driving power demand. The engine always generates electricity in the high-efficiency and economical range, and its displacement and power are smaller than those of traditional gasoline vehicle engines. Therefore, fuel consumption and exhaust emissions are reduced during driving or operation, resulting in energy saving and emission reduction. During vehicle operation, due to the use of generator drive, the vehicle has strong acceleration performance, low noise, and better driving comfort, which helps to improve engine efficiency, reduce fuel consumption and exhaust emissions, and is environmentally friendly.

[0008] In one alternative implementation, the range-extended hybrid system further includes a third controller, through which the working motor is electrically connected to the second controller.

[0009] Beneficial effects: The third controller manages and regulates the operation of the working motor, ensuring it functions as intended. By precisely controlling the input voltage and current of the working motor, the third controller helps optimize energy use, improve efficiency, and extend battery life. The third controller can control the working motor's speed by adjusting the voltage, frequency, or pulse width modulation signal supplied to it, enabling the machine to maintain the required operating speed under various working conditions.

[0010] In one alternative implementation, the working motor is connected to the upper working mechanism via a hydraulic pump.

[0011] Beneficial effects: Precise control of the working mechanism is achieved by regulating oil pressure and flow through a hydraulic pump, providing smooth, continuously variable speed movement to meet the needs of different working conditions. Driving the upper working mechanism with a hydraulic pump enables rapid response to operating commands and provides immediate power output.

[0012] In one alternative implementation, the range-extended hybrid system further includes an on-board charger electrically connected to a second controller.

[0013] Beneficial effects: When the work site has access to electricity, after inserting the charging gun from the external power source into the charging port of the vehicle-mounted charger, the power from the external power source is transmitted to the working motor, thereby driving the on-board working mechanism to perform operations. At the same time, the external power source can charge the energy storage device, making full use of the charging time and replenishing the battery's energy in a timely manner.

[0014] In one alternative implementation, the first controller is a dual-motor controller that controls the generator and the electric drive axle.

[0015] Beneficial effects: The dual-motor controller can simultaneously manage and optimize the operating states of two motors to achieve higher efficiency, better performance, and more flexible operation. By coordinating the operation of the generator and the electric drive axle, the dual-motor controller can select the optimal operating mode under different operating conditions, such as pure electric mode or range-extending mode, thereby improving the overall system efficiency.

[0016] In one alternative implementation, the second controller is an all-in-one controller.

[0017] Beneficial effects: The all-in-one controller integrates a high-voltage junction box, DC-DC converter, and other controllers. It adopts a modular design, allowing different functional modules to be selected and combined according to actual needs. It has a high degree of integration, reduces intermediate links through centralized control, and improves the system's response speed and overall efficiency.

[0018] Secondly, this utility model also provides a working machine, including: the above-mentioned range-extended hybrid power system.

[0019] In one alternative embodiment, the working machinery includes an upper vehicle and an lower vehicle. The lower vehicle includes an engine, generator, electric drive axle, first controller, second controller, energy storage device, and working motor of a range-extended hybrid power system. The upper vehicle includes an upper vehicle working mechanism of a range-extended hybrid power system.

[0020] In one alternative implementation, the onboard working mechanism includes a slewing mechanism, a hoisting mechanism, a telescopic mechanism, and a luffing mechanism.

[0021] In one alternative implementation, the working machinery is a crane. Attached Figure Description

[0022] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0023] Figure 1 This is a structural block diagram of a crane according to an embodiment of the present utility model.

[0024] Explanation of reference numerals in the attached figures:

[0025] 1. Engine;

[0026] 2. Generator;

[0027] 3. Electric drive axle;

[0028] 4. Dual motor controller;

[0029] 5. All-in-one controller;

[0030] 6. Power battery;

[0031] 7. Operating motor;

[0032] 8. Hydraulic oil pump;

[0033] 901. Slewing mechanism; 902. Hoisting mechanism; 903. Telescopic mechanism; 904. Luffing mechanism;

[0034] 10. Third controller;

[0035] 11. On-board charger. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0037] In related technologies, the biggest obstacle for crane chassis using pure electric power sources, especially when charging infrastructure is still underdeveloped, is the limited driving range. To achieve unlimited driving range, the main unit must install more power batteries, which inevitably increases the cost of batteries significantly, making it unacceptable to customers. Due to the limited battery range, pure electric cranes have poor adaptability to road travel and on-board operations. Plug-in hybrid electric vehicle cranes overcome the high cost of pure electric vehicles while also achieving good fuel economy, qualifying for green license plates, and enjoying road rights advantages. They represent the mainstream direction for the future development of engineering vehicles. However, the chassis engine often cannot operate at its highest efficiency range when operating on-board.

[0038] To solve the above problems, the following will combine... Figure 1 The following describes embodiments of the present invention.

[0039] According to an embodiment of this utility model, a range-extended hybrid power system is provided, comprising: an engine 1, a generator 2, an electric drive axle 3, an energy storage device, a work motor 7, and an on-board work mechanism. The generator 2 is connected to the engine 1; the electric drive axle 3 is electrically connected to the generator 2 via a first controller; the energy storage device is electrically connected to the first controller via a second controller; the work motor 7 is electrically connected to the second controller; and the on-board work mechanism is connected to the work motor 7. The range-extended hybrid power system has a pure electric driving mode, a range-extended driving mode, a pure electric work mode, and a range-extended work mode. When the range-extended hybrid power system is in pure electric driving mode, the energy storage device provides power to the electric drive axle 3 via the second controller and the first controller. When the range-extended hybrid power system is in range-extended driving mode, the engine 1 provides power to the electric drive axle 3 via the generator 2 and the first controller. When the range-extended hybrid power system is in pure electric work mode, the energy storage device provides power to the work motor 7 via the second controller. When the range-extended hybrid power system is in range-extended work mode, the engine 1 provides power to the work motor 7 via the generator 2, the first controller, and the second controller.

[0040] In the range-extended hybrid system of this embodiment, when the system is in pure electric driving mode or pure electric operation mode, engine 1 does not operate, achieving zero fuel consumption. When the system is in range-extended driving mode or range-extended operation mode, since engine 1 does not need to directly drive the vehicle or the operation motor 7, engine 1 does not need to change its output power according to driving power demand. Engine 1 always generates electricity in the high-efficiency economic zone, and since engine 1's displacement and power are smaller than those of a traditional gasoline vehicle engine 1, fuel consumption and exhaust emissions are reduced during driving or operation, resulting in energy saving and emission reduction. During vehicle operation, due to the use of generator 2 for driving, the vehicle has strong acceleration performance, low noise, and better driving comfort, which helps to improve the working efficiency of engine 1, reduce fuel consumption and exhaust emissions, and is environmentally friendly.

[0041] Furthermore, the electric drive axle 3 integrates the motor, transmission, differential, etc. The electric drive axle 3 has the advantages of compact structure, high efficiency, and fast response, reducing the transmission and drive shaft, and effectively reducing mechanical losses from engine 1, transmission, drive shaft, and axle.

[0042] It should be noted that the electric drive axle 3 can adopt the structure of existing technology, and will not be described in detail here.

[0043] In one embodiment, the range-extended hybrid system further includes a third controller 10, through which the work motor 7 is electrically connected to the second controller. The third controller 10 manages and regulates the operation of the work motor 7, ensuring that it operates as intended. By precisely controlling the input voltage and current of the work motor 7, the third controller 10 helps optimize energy use, improve efficiency, and extend battery life. The third controller 10 can control the speed of the work motor 7 by adjusting the voltage, frequency, or pulse width modulation signal supplied to it, enabling the work machinery to maintain the required operating speed under different working conditions.

[0044] In one embodiment, the working motor 7 is connected to the upper working mechanism via a hydraulic pump 8. The hydraulic pump 8 regulates oil pressure and flow to achieve precise control of the working mechanism, providing smooth, continuously variable speed motion to meet the needs of different working conditions. Driving the upper working mechanism with the hydraulic pump 8 enables rapid response to operating commands and provides immediate power output.

[0045] In one embodiment, the range-extended hybrid system further includes an on-board charger 11, which is electrically connected to a second controller. When the work site has access to electricity, the charging gun from an external power source is inserted into the charging port of the on-board charger 11. Power from the external power source is then transmitted to the working motor 7, which in turn drives the on-board working mechanism to perform its tasks. Simultaneously, the external power source can charge the energy storage device, making full use of the charging time and instantly replenishing the battery's energy.

[0046] It should be noted that the English abbreviation for On-board Charger 11 is OBC.

[0047] In one embodiment, the first controller is a dual-motor controller 4 that controls the generator 2 and the electric drive axle 3. The dual-motor controller 4 can simultaneously manage and optimize the operating states of the two motors to achieve higher efficiency, better performance, and more flexible operation. By coordinating the operation of the generator 2 and the electric drive axle 3, the dual-motor controller 4 can select the optimal operating mode under different operating conditions, such as pure electric mode or range-extending mode, thereby improving the overall system efficiency.

[0048] In one embodiment, the second controller is an all-in-one controller 5. The all-in-one controller 5 integrates controllers for high-voltage junction boxes, DC-DC converters, etc., and adopts a modular design, allowing for the selection and combination of different functional modules according to actual needs; it has a high degree of integration, and through centralized control, reduces intermediate links, improving the system's response speed and overall efficiency.

[0049] In one embodiment, the energy storage device is a power battery 6, which has advantages such as long cycle life and environmental sustainability. It is understood that the power battery 6 can also be replaced with other energy storage devices, converting other forms of energy into electrical energy and storing it in the energy storage device.

[0050] According to an embodiment of the present invention, another aspect provides a working machine, including the above-described range-extended hybrid power system.

[0051] In one embodiment, the working machinery includes an upper vehicle and an lower vehicle. The lower vehicle includes an engine 1, a generator 2, an electric drive axle 3, a first controller, a second controller, an energy storage device, and a working motor 7 of a range-extended hybrid power system. The upper vehicle includes an upper vehicle working mechanism of a range-extended hybrid power system.

[0052] Furthermore, when the vehicle is in pure electric mode, the power battery 6 drives the electric drive axle 3 via the multi-function controller 5 and the dual-motor controller 4. When the vehicle is in range-extended mode, the engine 1 provides power to drive the generator 2, which generates electricity and drives the electric drive axle 3 via the dual-motor controller 4. Simultaneously, the power battery 6 is charged via the dual-motor controller 4 and the multi-function controller 5. When the power provided by the power battery 6 is insufficient, the engine 1 starts, driving the generator 2 to provide additional power to the electric drive axle 3 via the dual-motor controller 4. When the vehicle is in pure electric mode, the power battery 6 drives the working motor 7 via the multi-function controller 5 and the third controller 10, which in turn drives the hydraulic pump 8 to provide hydraulic power to the vehicle. When the vehicle is in range-extended mode, the engine 1 provides power to drive the generator 2, which generates electricity and drives the working motor 7 via the dual-motor controller 4, the multi-function controller 5, and the third controller 10. Simultaneously, the power battery 6 is charged via the dual-motor controller 4 and the multi-function controller 5. Both vehicle operation and driving have pure electric and range-extended modes, with the engine 1 always operating in the high-efficiency economic zone.

[0053] In one embodiment, the upper-mounted working mechanism includes a slewing mechanism 901, a hoisting mechanism 902, a telescopic mechanism 903, and a luffing mechanism 904. The slewing mechanism 901 includes a slewing motor and a slewing bearing, etc., and is used to achieve 360-degree rotation of the upper part relative to the lower part, allowing the boom or hook to move freely in the horizontal plane, expanding the working range. The hoisting mechanism 902 includes a hoisting motor and a drum, etc., and is responsible for lifting and lowering goods or the boom. The telescopic mechanism 903 includes a telescopic cylinder, etc., and is used to change the length of the boom, expanding the working range, especially for flexible operation in confined spaces. The luffing mechanism 904 includes a variable-speed cylinder, etc., and is used to adjust the angle of the boom, changing the working range and lifting height, ensuring optimal working conditions under different operating circumstances.

[0054] It should be noted that the slewing mechanism 901, the hoisting mechanism 902, the telescopic mechanism 903, and the luffing mechanism 904 can all adopt the existing structures, and will not be described in detail here.

[0055] In one embodiment, the working machinery is a crane. It is understood that in another embodiment, the working machinery may also be a pile driver, a mixer, etc., and is not limited thereto.

[0056] Although embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A range-extended hybrid power system, characterized in that, include: Engine (1); A generator (2) is connected to the engine (1); The electric drive axle (3) is electrically connected to the generator (2) via a first controller; The energy storage device is electrically connected to the first controller via a second controller; The working motor (7) is electrically connected to the second controller; The onboard working mechanism is connected to the working motor (7); The range-extended hybrid system has a pure electric driving mode, a range-extended driving mode, a pure electric operation mode, and a range-extended operation mode. When the range-extended hybrid system is in the pure electric driving mode, the energy storage device provides power to the electric drive axle (3) through the second controller and the first controller; When the range-extended hybrid system is in the range-extended driving mode, the engine (1) provides power to the electric drive axle (3) through the generator (2) and the first controller; When the range-extended hybrid power system is in the pure electric operation mode, the energy storage device provides power to the working motor (7) through the second controller; When the range-extended hybrid system is in the range-extended operation mode, the engine (1) provides power to the working motor (7) through the generator (2), the first controller, and the second controller.

2. The range-extended hybrid power system according to claim 1, characterized in that, The range-extended hybrid power system also includes a third controller (10), and the working motor (7) is electrically connected to the second controller through the third controller (10).

3. The range-extended hybrid power system according to claim 1 or 2, characterized in that, The working motor (7) is connected to the upper working mechanism via a hydraulic oil pump (8).

4. The range-extended hybrid power system according to claim 1 or 2, characterized in that, The range-extended hybrid system also includes an on-board charger (11), which is electrically connected to the second controller.

5. The range-extended hybrid power system according to claim 1 or 2, characterized in that, The first controller is a dual-motor controller (4) that controls the generator (2) and the electric drive axle (3).

6. The range-extended hybrid power system according to claim 1 or 2, characterized in that, The second controller is an all-in-one controller (5).

7. A type of operating machinery, characterized in that, include: The range-extended hybrid power system according to any one of claims 1 to 6.

8. The operating machinery according to claim 7, characterized in that, The working machinery includes an upper vehicle and an lower vehicle. The lower vehicle includes the engine (1), generator (2), electric drive axle (3), first controller, second controller, energy storage device, and working motor (7) of the range-extended hybrid power system. The upper vehicle includes the upper vehicle working mechanism of the range-extended hybrid power system.

9. The operating machinery according to claim 8, characterized in that, The upper working mechanism includes a slewing mechanism (901), a hoisting mechanism (902), a telescopic mechanism (903), and a luffing mechanism (904).

10. The operating machinery according to claim 9, characterized in that, The operating machinery is a crane.

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