Hybrid power plant thermal management system and hybrid power plant

Abstract

This application provides a thermal management system and a hybrid power system to address the problems of reducing energy consumption and cost, and improving reliability of hybrid power systems. The thermal management system includes a first cooling loop comprising a first radiator, a first mechanical pump, and a first generator of a first range extender connected in series. The first mechanical pump includes a first end and a second end, and the first radiator includes a third end and a fourth end, with the third end connected to the second end. A portion of the second cooling loop includes a second generator of a second range extender. The two ends of this portion of the second cooling loop are respectively connected to the first end and the fourth end; alternatively, another portion of the second cooling loop includes a second radiator and a second mechanical pump, with the second radiator, second mechanical pump, and second generator connected in series. The thermal management system provided by this application is beneficial for reducing energy consumption and improving the reliability of hybrid power systems.

Description

Technical Field

[0001] This application relates to the field of new energy equipment technology, specifically to a thermal management system for a hybrid power equipment and the hybrid power equipment itself. Background Technology

[0002] With the continuous development of new energy technologies, new energy equipment is becoming increasingly popular among users. For example, the market share of new energy vehicles is rising, primarily driven by pure electric vehicles. However, for equipment with high requirements for load capacity, range, and cost, such as medium-duty trucks, larger batteries are needed to meet range demands, leading to higher costs and weight. Typically, a large-displacement, high-power range extender is required to meet the power requirements; however, such a configuration suffers from high energy consumption, high equipment costs, and difficulties in ensuring effective cooling through a thermal management system. Furthermore, when the range extender malfunctions, the equipment breaks down, impacting operational efficiency. Utility Model Content

[0003] This application provides a thermal management system and a hybrid power device to address the issues of how to reduce the energy consumption and cost of hybrid power devices and how to improve their reliability.

[0004] To achieve the above objectives, the embodiments of this application adopt the following technical solutions:

[0005] In a first aspect, embodiments of this application provide a thermal management system for a hybrid power device, comprising a first cooling loop and a second cooling loop. The first cooling loop includes a first radiator, a first mechanical pump, and a first generator of a first range extender connected in series. The first mechanical pump includes a first end and a second end, and the first radiator includes a third end and a fourth end, with the third end connected to the second end. A portion of the second cooling loop includes a second generator of a second range extender. Specifically, the two ends of a portion of the second cooling loop are respectively connected to the first end and the fourth end, thus reusing the first radiator and the first mechanical pump as another part of the second cooling loop; or, the other part of the second cooling loop includes a second radiator and a second mechanical pump, with the second radiator, the second mechanical pump, and the second generator connected in series.

[0006] In some possible implementations of the first aspect, the second cooling cycle loop further includes a drive motor connected in series between the first radiator and the second generator and located downstream of the second generator.

[0007] In some possible implementations of the first aspect, the first cooling cycle loop further includes a controller group connected in series between the first mechanical pump and the first generator and located upstream of the first generator. The controller group includes a motor controller and / or a range extender controller. The motor controller is electrically connected to the drive motor, and the range extender controller is electrically connected to both the first range extender and the second range extender.

[0008] In some possible implementations of the first aspect, the first cooling circulation loop further includes a steering pump connected in series between the controller group and the first radiator and located downstream of the controller group, the steering pump serving as a power source for the hydraulic power steering system of the hybrid power unit.

[0009] In some possible implementations of the first aspect, the first cooling cycle loop further includes an air compressor connected in series between the controller group and the first radiator and located downstream of the controller group, the air compressor serving as a power source for the pneumatic braking system of the hybrid power equipment.

[0010] In some possible implementations of the first aspect, the controller group further includes a steering pump controller electrically connected to the steering pump; and / or, the controller group further includes an air compressor controller electrically connected to the air compressor.

[0011] In some possible implementations of the first aspect, the thermal management system further includes a third cooling cycle loop and a first air conditioning refrigeration loop. The third cooling cycle loop includes a first heat exchanger, a third mechanical pump, a first heater, and a battery connected in series. The first air conditioning refrigeration loop includes an air conditioning compressor, a second heat exchanger, and an outdoor heat exchanger connected in series, with the second heat exchanger thermally connected to the first heat exchanger so that the refrigerant flowing through the second heat exchanger absorbs heat from the coolant in the first heat exchanger.

[0012] In some possible implementations of the first aspect, the thermal management system further includes a first cooling fan connected to both the first radiator and the outdoor heat exchanger. The first cooling fan is used to drive airflow to cool the coolant flowing through the first radiator and the refrigerant flowing through the outdoor heat exchanger.

[0013] Secondly, embodiments of this application provide a hybrid power device, which includes the thermal management system described in any of the above implementations.

[0014] Thirdly, embodiments of this application provide a hybrid power device, which includes two range extenders and a range extender controller. The two range extenders include a first range extender and a second range extender. The range extender controller is electrically connected to both the first and second range extenders, and is used to: if the hybrid power device requires a power generation P... reqIf the value is less than or equal to the first threshold, then control the actual power generation P of the first range extender. act1 With P req Matching; if P req If the value is greater than the first threshold and less than or equal to the second threshold, then the actual power generation P of the first range extender is controlled. act1 Matching the first threshold and controlling the actual power generation P of the second range extender. act2 With P req The difference between the first threshold and the second threshold is matched. Specifically, the first threshold is less than the maximum power output P of the range extender. max The second threshold is greater than the maximum generating power P of the range extender. max And it is less than the sum of the maximum generating power of the two range extenders.

[0015] In some possible implementations of the third aspect, the range extender controller is also used to: if P req If the actual power generation P of the second range extender is greater than the second threshold, then control the actual power generation P of the second range extender. act2 With the maximum power generation P of the range extender max Matching and controlling the actual power generation P of the first range extender act1 With P req The maximum power output P of the range extender max The difference matches.

[0016] In some possible implementations of the third aspect, the range extender controller is also configured to: make the first range extender the first range extender if the cumulative power generation of the first range extender is less than the cumulative power generation of the second range extender.

[0017] The thermal management system and hybrid power equipment provided in this application have the following beneficial effects:

[0018] The thermal management system for the hybrid power equipment provided in this application includes a first cooling loop comprising a first radiator, a first mechanical pump, and a first generator connected in series. This allows the first mechanical pump to drive the coolant in the first cooling loop to cool the first generator, ensuring its efficient operation. Furthermore, by including a second generator in a portion of a second cooling loop, and reusing the first radiator and the first mechanical pump as another part of the second cooling loop, the first mechanical pump can drive the coolant in the second cooling loop to cool the second generator, ensuring its reliability. This also reduces the cost of the thermal management system, thereby lowering the overall cost of the equipment.

[0019] Based on this, by connecting the first cooling loop, which includes the first generator, and the second cooling loop, which includes the second generator, in parallel at the first and fourth ends, the flow paths of the first and second cooling loops are shorter, the water resistance in the cooling loops is smaller, and the cooling effect on the two generators is better. This prevents the coolant from being too hot when flowing through the second generator when the two generators are connected in series in the same cooling loop, thus failing to achieve the desired cooling effect on the second generator, thereby improving the reliability of the hybrid power equipment.

[0020] The hybrid power system provided in this application, compared to configuring a single range extender, utilizes two range extenders. This allows for a smaller displacement and power output of each individual range extender, resulting in a lighter overall weight for the same total power generation, thus contributing to the lightweight design of the hybrid power system. Furthermore, the lower-power range extender has lower performance requirements for its components and more mature manufacturing processes, leading to lower manufacturing, maintenance, and replacement costs, which helps reduce the user's vehicle purchase cost. Simultaneously, the smaller size of the lower-power range extender facilitates its placement in limited spaces. Additionally, it allows for easier adjustment of the power output of the two range extenders according to actual load demands. For example, under low-load conditions, only one range extender needs to operate to prevent inefficiency and high energy consumption at low loads; under high-load conditions, both range extenders can operate simultaneously to meet power requirements. Finally, if one range extender fails, the other can continue operating to ensure the hybrid power system does not break down, thereby improving its reliability. Attached Figure Description

[0021] Figure 1 A side view of a hybrid power device provided for some embodiments of this application.

[0022] Figure 2 for Figure 1 A side view of a portion of the structure of the hybrid power unit shown.

[0023] Figure 3 for Figure 2 Top view of the hybrid power unit shown.

[0024] Figure 4 for Figure 3 A schematic diagram of part of the structure of the hybrid power equipment shown.

[0025] Figure 5 for Figure 3 A schematic diagram of part of the structure of the hybrid power equipment shown.

[0026] Figure 6 for Figure 5 A schematic diagram of part of the structure of the hybrid power device as seen from another perspective.

[0027] Figure 7 for Figure 3 A schematic diagram of part of the structure of the hybrid power equipment shown.

[0028] Figure 8 for Figure 3 The diagram shows a partial structural schematic of the hybrid power equipment.

[0029] Figure 9 for Figure 3 The diagram shows a partial structural schematic of the hybrid power equipment.

[0030] Figure 10 for Figure 3 A partial schematic diagram of the thermal management system of the hybrid power equipment shown.

[0031] Figure 11 for Figure 3 The diagram shows a partial structural diagram of the thermal management system of the hybrid power equipment.

[0032] Figure 12 for Figure 3 A schematic diagram of the air conditioning system of the hybrid power equipment shown.

[0033] Figure 13 for Figure 3 A partial schematic diagram of the thermal management system of the hybrid power equipment shown.

[0034] Figure label:

[0035] Hybrid power unit 1000; Front of vehicle A; Rear of vehicle B;

[0036] Frame 100; First longitudinal beam 110; Second longitudinal beam 120; Crossbeam 130;

[0037] 200 cab;

[0038] First range extender 300; First engine 310; First generator 320;

[0039] Second range extender 400; Second engine 410; Second generator 420;

[0040] Intake system 500; air filter 510; expansion chamber 520; first intercooler 531; second intercooler 532; first piping structure 540; first pipe section 541; second pipe section 542; third pipe section 543;

[0041] Exhaust system 600; First catalytic converter assembly 610; Second catalytic converter assembly 620; Second pipeline structure 630; First exhaust pipe section 631; Second exhaust pipe section 632; Third exhaust pipe section 633; ​​Muffler 640;

[0042] Fuel supply system 700; fuel tank 710; filter 720; carbon canister 730; fourth pipeline structure 740; first fuel supply section 741; second fuel supply section 742; third fuel supply section 743; fourth fuel supply section 744; return gas section 745; gas collection section 746; fifth fuel supply section 747; sixth fuel supply section 748; seventh fuel supply section 749;

[0043] Electrical system 800; Battery 810; Power management system 820; Drive motor 830; Controller group 840; Air conditioning compressor 851; Indoor unit 852; Steering pump 861; Steering oil reservoir 862; Steering gear 863; Air compressor 871;

[0044] Thermal management system A100; first cooling circulation loop A10; second cooling circulation loop A20; first radiator A11; third end A11a; fourth end A11b; first mechanical pump A12; first end A12a; second end A12b; third cooling circulation loop A30; first heat exchange unit A31; third mechanical pump A32; first heater A33; second expansion tank A34; first air conditioning refrigeration loop A40; second heat exchange unit A41; outdoor heat exchanger A42; first cooling fan A50; first expansion tank A60; fourth cooling circulation loop A70; third radiator A71; fifth cooling circulation loop A80; fourth radiator A81; second cooling fan A90; third expansion tank A91. Detailed Implementation

[0045] In the embodiments of this application, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, "connection" can be a detachable connection or a non-detachable connection; it can be a direct connection or an indirect connection through an intermediate medium.

[0046] In the embodiments of this application, it should be understood that the directional terms mentioned, such as "up", "down", "left", "right", "inner", "outer", etc., are only for reference to the direction of the accompanying drawings. Therefore, the directional terms used are for better and clearer explanation and understanding of the embodiments of this application, and are not intended to 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 the embodiments of this application.

[0047] In the embodiments of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" and "second" may explicitly or implicitly include one or more of that feature.

[0048] In embodiments of this application, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus 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 apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0049] In the embodiments of this application, "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0050] In the embodiments of this application, it should be noted that the descriptions of "vertical" and "parallel" respectively indicate approximately vertical and approximately parallel within a certain error range. This error range can be a range with a deviation angle of less than or equal to 5°, 8° or 10° relative to absolute verticality and absolute parallelism, respectively, and is not specifically limited here.

[0051] With the continuous development of new energy technologies, new energy equipment is becoming increasingly popular among users. For example, the market share of new energy vehicles is rising, primarily driven by pure electric vehicles. However, for equipment with high requirements for load capacity, range, and cost, such as medium-duty trucks, larger batteries are needed to meet range demands, leading to higher costs and weight. Related technologies typically require a large-displacement, high-power range extender to meet the power requirements. This configuration suffers from high energy consumption, high equipment costs, and difficulties in ensuring effective cooling through a thermal management system. Furthermore, when the range extender malfunctions, the equipment breaks down, impacting operational efficiency.

[0052] To address this issue, this application provides a thermal management system and a hybrid power system. This hybrid power system, by configuring two range extenders, achieves lower energy consumption and lower cost compared to configuring a single range extender, while maintaining the same power output. Furthermore, the system can continue to operate normally even if one range extender fails, demonstrating good reliability. In addition, by connecting the cooling circuits that cool the generators of the two range extenders in parallel, the cooling effect on the generators of both range extenders is ensured to be good, further improving the reliability of the hybrid power system.

[0053] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings.

[0054] Please see Figures 1-3 , Figure 1 This is a side view of a hybrid power device 1000 provided in some embodiments of this application. Figure 2 for Figure 1 The side view of a portion of the structure of the hybrid power device 1000 shown. Figure 3 for Figure 2 The top view of the hybrid power unit 1000 shown. Figures 1-3 In the illustrated embodiment, the hybrid power equipment 1000 is exemplified as a medium-duty truck logistics vehicle, which should not be construed as a specific limitation of this application. In other embodiments, the hybrid power equipment 1000 may also be a car, bus, fire truck, police car, engineering vehicle, ship, machining equipment, etc.

[0055] Please continue reading. Figures 1-3 The hybrid power unit 1000 includes a frame 100, a cab 200, and two range extenders.

[0056] The frame 100 serves as the structural skeleton of the hybrid power unit 1000. The frame 100 includes a first longitudinal beam 110, a second longitudinal beam 120, and multiple crossbeams 130. The first longitudinal beam 110 and the second longitudinal beam 120 extend from the front A of the hybrid power unit 1000 to the rear B. The multiple crossbeams 130 are approximately perpendicular to the arrangement direction of the front A and rear B, and are spaced apart along this direction. The first longitudinal beam 110 can be the left longitudinal beam of the hybrid power unit 1000, and the second longitudinal beam 120 can be the right longitudinal beam of the hybrid power unit 1000.

[0057] The cab 200 is fixed to the frame 100 and located on the side of the frame 100 facing away from the ground. Specifically, the cab 200 can be fixed to the frame 100 by a semi-floating or fully floating suspension.

[0058] Please see Figure 3 and Figure 4 , Figure 4 for Figure 3 The diagram shows a partial structure of the hybrid power unit 1000. The two range extenders include a first range extender 300 and a second range extender 400. The first range extender 300 and the second range extender 400 are fixed to the frame 100 and located between the first longitudinal beam 110 and the second longitudinal beam 120. The first range extender 300 and the second range extender 400 are located on the ground-facing side of the cab 200. In this way, the overall structure of the hybrid power unit 1000 is relatively compact, the two range extenders do not occupy space on the hybrid power unit 1000 used for equipment or cargo, and the cab 200 can provide protection for the two range extenders, facilitating daily maintenance and upkeep.

[0059] Specifically, the first range extender 300 and the second range extender 400 can be fixed to the frame 100 by a three-point suspension. Figure 3 and Figure 4 In the illustrated embodiment, the first range extender 300 and the second range extender 400 are arranged along the direction of the front A and the rear B of the vehicle. In some other embodiments, the first range extender 300 and the second range extender 400 may not be located entirely between the first longitudinal beam 110 and the second longitudinal beam 120, and the first range extender 300 and the second range extender 400 may be arranged in other directions.

[0060] The first range extender 300 includes a first engine 310, a first generator 320, and a first generator controller (not shown in the figure). The first engine 310 and the first generator 320 are drive-connected, and the first generator controller (not shown in the figure) is integrated into and electrically connected to the first generator 320. The second range extender 400 includes a second engine 410, a second generator 420, and a second generator controller (not shown in the figure). The second engine 410 and the second generator 420 are drive-connected, and the second generator controller (not shown in the figure) is integrated into and electrically connected to the second generator 420.

[0061] Please refer to the following: Figure 5 and Figure 6 , Figure 5 for Figure 3 A schematic diagram of a portion of the structure of the hybrid power device 1000 shown. Figure 6 for Figure 5 The diagram shows a partial structural view of the hybrid power system 1000 from another perspective. The hybrid power system 1000 also includes an intake system 500. The intake system 500 includes an air filter 510, an expansion chamber 520, a first intercooler 531, a second intercooler 532, and a first piping structure 540. The air filter 510 can be located on the right side of the frame 100, and the expansion chamber 520 can be fixed to the frame 100 by a mounting bracket. The first piping structure 540 includes a first pipe section 541, multiple second pipe sections 542, and multiple third pipe sections 543.

[0062] The first pipe segment 541 is connected between the air outlet of the air filter 510 and the air inlet of the expansion chamber 520; a second pipe segment 542 is connected between one air outlet of the expansion chamber 520 and the air inlet of the turbocharger of the first engine 310, the air outlet of the turbocharger of the first engine 310 and the air inlet of the first intercooler 531, and the air outlet of the first intercooler 531 and the air inlet of the first engine 310; a third pipe segment 543 is connected between the other air outlet of the expansion chamber 520 and the air inlet of the turbocharger of the second engine 410, the air outlet of the turbocharger of the second engine 410 and the air inlet of the second intercooler 532, and the air outlet of the second intercooler 532 and the air inlet of the second engine 410.

[0063] In this way, after being filtered by the air filter 510, the air enters the expansion chamber 520. After the air velocity and intake resistance are reduced and the intake pressure is stabilized by the expansion chamber 520, a portion of the air can enter the turbocharger of the first engine 310. After being compressed by the turbocharger, the air enters the first intercooler 531 and is cooled by the first intercooler 531 before entering the cylinder of the first engine 310. Similarly, another portion of the air can enter the turbocharger of the second engine 410, be compressed by the turbocharger, enter the second intercooler 532, and be cooled by the second intercooler 532 before entering the cylinder of the second engine 410.

[0064] Please see Figure 7 , Figure 7 for Figure 3 The diagram shows a partial structure of the hybrid power unit 1000. The hybrid power unit 1000 also includes an exhaust system 600. The exhaust system 600 includes a first catalytic converter assembly 610, a second catalytic converter assembly 620, a second piping structure 630, and a muffler 640. The second piping structure 630 includes a first exhaust pipe section 631, a second exhaust pipe section 632, and a third exhaust pipe section 633. The first catalytic converter assembly 610 can be integrated and fixed to the first engine 310 of the first range extender 300. The air intake of the first catalytic converter assembly 610 is connected to the exhaust port of the first engine 310. The first exhaust pipe section 631 is connected between the air outlet of the first catalytic converter assembly 610 and the air intake of the third exhaust pipe section 633. The second catalytic converter assembly 620 can be integrated and fixed to the second engine 410 of the second range extender 400. The air intake of the second catalytic converter assembly 620 is connected to the exhaust port of the second engine 410. The second exhaust pipe section 632 is connected between the air outlet of the second catalytic converter assembly 620 and the air intake of the third exhaust pipe section 633. The air outlet of the third exhaust pipe section 633 is connected to the air intake of the muffler 640.

[0065] In this way, the combustion exhaust gases from the first engine 310 and the second engine 410 can be converted into harmless substances by the first catalytic converter assembly 610 and the second catalytic converter assembly 620, respectively. After passing through the muffler 640, the noise is reduced by physical isolation and sound wave interference before being discharged outside the hybrid power unit 1000. The combustion exhaust gases from both engines are discharged after passing through the same muffler 640, making the overall structure of the exhaust system 600 more compact.

[0066] Please refer to the following: Figure 3 and Figure 8 , Figure 8 for Figure 3 The diagram shows a partial structural schematic of the hybrid power unit 1000. The hybrid power unit 1000 also includes a fuel supply system 700, which supplies fuel to the range extender. Specifically, the fuel can be methanol, an ideal new type of clean and renewable energy source with high combustion efficiency, clean emissions, and low price, comparable to pure electric power in terms of economics, thus making the hybrid power unit 1000 more economical. The fuel supply system 700 includes a fuel tank 710, a filter 720, a carbon canister 730, and a fourth pipeline structure 740. The fuel tank 710 can be fixed to the frame 100 and is located on the left side of the frame 100. The fourth pipeline structure 740 includes a first fuel supply pipe section 741, a second fuel supply pipe section 742, a third fuel supply pipe section 743, a fourth fuel supply pipe section 744, a return gas pipe section 745, a gas collection pipe section 746, a fifth fuel supply pipe section 747, a sixth fuel supply pipe section 748, and a seventh fuel supply pipe section 749.

[0067] The first fuel supply pipe section 741 connects the fuel tank 710 and the fuel inlet of the filter 720; one end of the second fuel supply pipe section 742 is connected to the fuel outlet of the filter 720; the third fuel supply pipe section 743 connects the other end of the second fuel supply pipe section 742 to the first engine 310; and the fourth fuel supply pipe section 744 connects the other end of the second fuel supply pipe section 742 to the second engine 410. Specifically, the third fuel supply pipe section 743 and the fourth fuel supply pipe section 744 can be connected to the second fuel supply pipe section 742 via a tee connector. The return air pipe section 745 connects the air outlet of the filter 720 to the fuel tank 710.

[0068] The gas collection pipe section 746 is connected between the air inlet of the fuel tank 710 and the carbon canister 730; one end of the fifth fuel supply pipe section 747 is connected to the air outlet of the carbon canister 730; the sixth fuel supply pipe section 748 is connected between the other end of the fifth fuel supply pipe section 747 and the second pipe section 542 upstream of the first engine 310; the seventh fuel supply pipe section 749 is connected between the other end of the fifth fuel supply pipe section 747 and the third pipe section 543 upstream of the second engine 410. Specifically, the sixth fuel supply pipe section 748 and the seventh fuel supply pipe section 749 can be connected to the fifth fuel supply pipe section 747 through a tee connector.

[0069] In this way, the fuel from the fuel tank 710 can be supplied to the first engine 310 and the second engine 410 after being filtered for impurities by the filter 720. During this process, the air and / or fuel vapor mixed in the fuel can flow back to the fuel tank 710 through the return air pipe section 745. The fuel vapor from the fuel tank 710 can be absorbed by the carbon canister 730. When the first engine 310 and / or the second engine 410 are started, the fuel vapor in the carbon canister 730 can enter the intake system 500 and then enter the corresponding engine to improve fuel utilization.

[0070] Please refer to the following: Figure 3 and Figure 9 , Figure 9 for Figure 3 The diagram shows a partial structural schematic of the hybrid power system 1000. The hybrid power system 1000 also includes an electrical system 800. The electrical system 800 includes a battery 810, a power management system 820, a drive motor 830, a controller group 840, an air conditioning compressor 851 and an electric heater for the indoor unit 852 (not shown), a steering pump 861, and an air compressor 871, all part of the braking system. Two batteries 810 are used to store electrical energy to power other electrical components and are fixed to the second longitudinal beam 120 of the frame 100 via a housing. In some other embodiments, only one battery 810 may be used. The power management system 820 is electrically connected to the battery 810 to monitor its status, perform equalization management, thermal management, and energy management, provide safety protection for the battery 810, and communicate and exchange information with other components.

[0071] The drive motor 830 is integrated and fixed to an axle and is drive-connected to the axle to convert electrical energy into mechanical energy to drive the hybrid power unit 1000. Specifically, the drive motor 830 may be integrated and fixed to the rear axle. In some other embodiments, the drive motor 830 may also be fixed to the frame 100 and drive-connected to the axle via a transmission device. In still other embodiments, the drive motor 830 may also be integrated and fixed to other axles.

[0072] Based on this, the controller assembly 840 is fixed to the frame 100 and located in the middle of the hybrid power unit 1000 in the front-rear direction. The controller assembly 840 includes a motor controller (not shown in the figure), which is electrically connected to the power management system 820 and the drive motor 830. In this way, the motor controller can interact with the power management system 820 and convert the DC power from the battery 810 into AC power to supply the drive motor 830. In addition, the motor controller can also adjust the output voltage and current, control the speed and torque of the drive motor 830, and perform status monitoring and fault diagnosis of the drive motor 830 to ensure accurate drive of the axle by the drive motor 830, thereby ensuring the reliability of the hybrid power unit 1000.

[0073] The air conditioning compressor 851 of the air conditioning system 850 can be integrated and fixed to the first engine 310 of the first range extender 300. Based on this, the controller group 840 also includes an air conditioning compressor controller (not shown) and a second electric heater controller (not shown). The air conditioning compressor controller is electrically connected to the air conditioning compressor 851 to control and protect the air conditioning compressor 851. The second electric heater controller is electrically connected to the electric heater of the indoor unit 852 integrated in the cab 200 to control and protect the electric heater.

[0074] The steering pump 861 is fixed to a crossbeam 130 of the frame 100 and located between the first range extender 300 and the controller assembly 840. Based on this, the steering system also includes a steering fluid reservoir 862 and a steering gear 863. The steering pump 861, steering fluid reservoir 862, and steering gear 863 can be connected in series via hydraulic lines to form a hydraulic circulation loop to assist the steering of the hybrid power unit 1000. The steering fluid reservoir 862 can be fixed to the frame 100 via a mounting bracket and located below the cab 200. Specifically, the steering fluid reservoir 862 can be integrated and fixed to the same mounting bracket as the aforementioned carbon canister 730. Based on this, the controller assembly 840 also includes a steering pump controller (not shown), which is electrically connected to the steering pump 861 to control the output pressure and speed of the steering pump 861.

[0075] Air compressor 871 can be fixed to a crossbeam 130 of the frame 100 and located between the first range extender 300 and the controller assembly 840. Air compressor 871 serves as the power source for the air braking system. Specifically, air compressor 871 can be integrated with steering pump 861 to save installation space. Based on this, controller assembly 840 also includes an air compressor controller (not shown in the figure), which is electrically connected to air compressor 871 to monitor the parameters of air compressor 871 in real time and adjust the operating status of air compressor 871.

[0076] Building upon the above, the controller assembly 840 also includes a range extender controller (not shown in the figure). The range extender controller is electrically connected to both the first range extender 300 and the second range extender 400 to control the start / stop of the first range extender 300 and the second range extender 400, as well as their output power. In some examples, there may be one range extender controller, electrically connected to both the first range extender 300 and the second range extender 400. In other examples, there may be two range extender controllers, electrically connected to the first range extender 300 and the second range extender 400 respectively. Specifically, all controllers included in the controller assembly 840 can be integrated and fixed to the vehicle frame 100 to save installation space, facilitate signal transmission line routing, and facilitate cooling. In other embodiments, all controllers included in the controller assembly 840 can also be separately installed and fixed to the vehicle frame 100.

[0077] Based on the above, the controller group 840 can be electrically connected to the main controller of the hybrid power equipment 1000 to receive signals from the main controller and send signals to the main controller.

[0078] In some embodiments, the range extender controller is configured to: if the hybrid power unit 1000 requires a power generation P req If the actual power generation P of the first range extender 300 is less than or equal to the first threshold, then the actual power generation P of the first range extender 300 is controlled. act1 With P req Matching; if P req If the actual power generation P of the first range extender 300 is greater than the first threshold and less than or equal to the second threshold, then the actual power generation P of the first range extender 300 is controlled. act1 Matching the first threshold and controlling the actual power generation P of the second range extender 400. act2 With P req The difference between the first threshold and the second threshold is matched.

[0079] Among them, the first threshold is less than the maximum power generation P of the range extender. max The second threshold is greater than the maximum generating power P of the range extender. max And it is less than the sum of the maximum generating power of the two range extenders. For example, the first threshold could be the maximum generating power P of the range extender. max 3 / 5, the second threshold can be the maximum power generation P of the range extender. max 8 / 5 of them.

[0080] This allows both range extenders to operate within their most economical speed range and also ensures good NVH performance. NVH performance refers to the combined effects of noise, vibration, and the discomfort these factors cause to passengers during operation.

[0081] Based on this, the range extender controller is also used to: if P req If the actual power generation P of the second range extender 400 is greater than the second threshold, then control the actual power generation P of the second range extender 400. act2 With the maximum power generation P of the range extender max Matching and controlling the actual power generation P of the first range extender 300 act1 With P req The maximum power output P of the range extender max The difference matches.

[0082] This allows the total power generation of the first range extender 300, which starts first, and the total power generation of the second range extender 400, which starts later, to be as close as possible, facilitating simultaneous maintenance of both range extenders. Furthermore, it simplifies the overall control strategy for both the first and second range extenders 300.

[0083] Based on this, the range extender controller is also used to: if the cumulative power generation of the first range extender is less than the cumulative power generation of the second range extender, then make the first range extender the first range extender.

[0084] This further makes the total power generation of the first range extender 300 and the total power generation of the second range extender 400 as close as possible, so as to facilitate the simultaneous maintenance of the two range extenders.

[0085] In some other embodiments, the required power generation P of the hybrid power unit 1000 may also be [the required power generation P]. req When the value is greater than zero, the actual power generation P of the two range extenders is increased. act It remains a constant value. In other embodiments, the required power generation P of the hybrid power unit 1000 can also be [value missing]. req When it is greater than zero, the power generation capacity P is determined according to demand. req Simultaneously adjust the actual power generation P of the two range extenders act And make both have the same power value.

[0086] Based on the above, please refer to Figure 10 , Figure 10 for Figure 3This is a partial schematic diagram of the thermal management system A100 of the hybrid power device 1000. The hybrid power device 1000 also includes the thermal management system A100. The thermal management system A100 includes a first cooling circulation loop A10 and a second cooling circulation loop A20. The first cooling circulation loop A10 includes a first radiator A11, a first mechanical pump A12, and a first generator 320 of a first range extender 300 connected in series. The first mechanical pump A12 includes a first end A12a and a second end A12b, and the first radiator A11 includes a third end A11a and a fourth end A11b, with the third end A11a connected to the second end A12b.

[0087] A portion of the second cooling circulation loop A20 includes the second generator 420 of the second range extender 400. The two ends of the aforementioned portion of the second cooling circulation loop A20 are respectively connected to the aforementioned first end A12a and fourth end A11b, so that the first radiator A11 and the first mechanical pump A12 are reused as another part of the second cooling circulation loop A20.

[0088] In this way, the hybrid power equipment 1000 provided in this application, compared to configuring a single range extender, can have two range extenders, resulting in a smaller displacement and power output of each individual range extender. Consequently, with the same total power generation, the total weight of the two range extenders is lighter, which is beneficial for the lightweight design of the hybrid power equipment 1000. Furthermore, the performance requirements for the components of the lower-power range extender are lower, and the manufacturing process is more mature, resulting in lower manufacturing, maintenance, and replacement costs, thus reducing the user's vehicle purchase cost. At the same time, the smaller size of the lower-power range extender facilitates its placement in limited spaces. In addition, it is easier to adjust the power output of the two range extenders according to actual load requirements. For example, under low-load conditions, only one range extender needs to operate to prevent inefficiency and high energy consumption at low loads; under high-load conditions, both range extenders can operate simultaneously to meet power demands. Finally, if one of the two range extenders fails, the other can continue to operate to ensure that the hybrid power equipment 1000 does not break down, thereby improving the reliability of the hybrid power equipment 1000.

[0089] Based on this, the thermal management system A100 provided in this application includes a first cooling circulation loop A10 comprising a first radiator A11, a first mechanical pump A12, and a first generator 320 connected in series. This allows the first mechanical pump A12 to drive the coolant in the first cooling circulation loop to cool the first generator 320, ensuring the efficient operation of the first generator 320. Furthermore, by including a second generator 420 in a portion of the second cooling circulation loop A20, and reusing the first radiator A11 and the first mechanical pump A12 as another part of the second cooling circulation loop A20, the first mechanical pump A12 can drive the coolant in the second cooling circulation loop A20 to cool the second generator 420, ensuring the reliability of the second generator 420. Simultaneously, this reduces the cost of the thermal management system A100, thereby reducing the overall cost of the equipment.

[0090] Based on this, by connecting a portion of the first cooling circulation loop including the first generator 320 and a portion of the second cooling circulation loop including the second generator 420 in parallel to the first end A12a and the fourth end A11b, the flow paths of the first cooling circulation loop and the second cooling circulation loop A20 are shorter, the water resistance in the cooling loop is smaller, and the cooling effect on the two generators is better. This can prevent the coolant from being too hot when flowing through the second generator when the two generators are connected in series in the same cooling circulation loop, thus failing to achieve the cooling effect on the second generator.

[0091] In some other embodiments, the second cooling loop A20 may also include a second radiator (not shown) and a second mechanical pump (not shown), with the second radiator, the second mechanical pump, and the second generator 420 connected in series. In this way, the second cooling loop A20 and the first cooling loop A10 are independent of each other, while still ensuring the cooling effect on the two generators.

[0092] Please continue reading. Figure 10 The second cooling circulation loop A20 also includes the aforementioned drive motor 830, which is connected in series between the first radiator A11 and the second generator 420, and is located downstream of the second generator 420. In this way, the first mechanical pump A12 can drive the coolant cooled by the first radiator A11 to cool the second generator 420 and then the drive motor 830. This allows for the efficient use of the circulating coolant to cool different components sequentially, based on the different coolant inlet temperatures required by the generator and drive motor 830, thus simplifying the structure of the thermal management system A100.

[0093] Please continue reading. Figure 10The first cooling circulation loop A10 also includes the aforementioned controller group 840, which is connected in series between the first mechanical pump A12 and the first generator 320, and is located upstream of the first generator 320. In this way, the first mechanical pump A12 can drive the coolant cooled by the first radiator A11 to cool each controller in the low-temperature sensitive controller group 840 before cooling the first generator 320. This allows for the efficient use of circulating coolant to cool different components sequentially, based on their varying requirements for the coolant's inlet temperature, thus simplifying the structure of the thermal management system A100.

[0094] Please continue reading. Figure 10 The first cooling circulation loop A10 also includes the aforementioned steering pump 861, which is connected in series between the controller group 840 and the first radiator A11 and is located downstream of the controller group 840.

[0095] The first cooling circulation loop A10 also includes the aforementioned air compressor 871, which is connected in series between the controller group 840 and the first radiator A11 and is located downstream of the controller group 840. Specifically, the steering pump 861 and the air compressor 871 are located upstream of the first generator 320.

[0096] In this way, the first mechanical pump A12 can drive the coolant cooled by the first radiator A11 to cool the low-temperature sensitive controller group 840, then cool the steering pump 861 and the air compressor 871, and then cool the first generator 420. It can make full use of the circulating coolant to cool different components in sequence according to the different requirements of the coolant inlet temperature of different components and the layout of the components in the overall equipment, so as to simplify the structure of the thermal management system A100.

[0097] In some other embodiments, the steering pump 861 and the air compressor 871 may also be located downstream of the first generator 320.

[0098] The thermal management system A100 also includes a first expansion tank A60, which is connected to the pipeline between the first mechanical pump A12 and the first radiator A11.

[0099] Based on the above, please refer to Figure 11 and Figure 12 , Figure 11 for Figure 3 The diagram shows a partial structural diagram of the thermal management system A100 of the hybrid power equipment 1000. Figure 12 for Figure 3The diagram shows the air conditioning system 850 of the hybrid power unit 1000. The thermal management system A100 also includes a third cooling circulation loop A30 and a first air conditioning refrigeration loop A40. The third cooling circulation loop A30 includes a first heat exchanger A31, a third mechanical pump A32, a first heater A33, and the aforementioned battery 810 connected in series. The third cooling circulation loop A30 also includes a second expansion tank A34, which is connected to the pipeline between the third mechanical pump A32 and the first heat exchanger A31. The second expansion tank A34, the first expansion tank A60, the carbon canister 730, and the power steering fluid reservoir 862 can be integrated and fixed on the same bracket.

[0100] The first air conditioning refrigeration circuit A40 includes the aforementioned air conditioning compressor 851, the second heat exchanger A41, and the outdoor heat exchanger A42, which are connected in series. The second heat exchanger A41 is thermally connected to the first heat exchanger A31, so that the refrigerant flowing through the second heat exchanger A41 can absorb the heat of the coolant flowing through the first heat exchanger A31. Based on this, the controller group also includes a first electric heating controller (not shown in the figure), which is electrically connected to the first heater to control and protect the first heater.

[0101] In this way, when it is necessary to heat the battery 810, the first heater A33 can be activated to heat the coolant in the third cooling circulation loop A30, so that the coolant can heat the battery 810 after heating. When it is necessary to cool the battery 810, the first heater A33 can be stopped, and the air conditioning compressor 851 can be activated to make the refrigerant flow in the first air conditioning refrigeration loop A40 and exchange heat with the first heat exchange loop A31 at the second heat exchange loop A41, so as to cool the coolant in the third cooling circulation loop A30, so that the cooled coolant can cool the battery 810. In this way, the battery 810 can be kept within its optimal operating range.

[0102] Based on the above, the thermal management system A100 also includes a second air conditioning refrigeration circuit, which includes an air conditioning compressor 851, an indoor heat exchanger of an indoor unit 852, and an outdoor heat exchanger A42 connected in series. The air conditioning compressor 851 and the outdoor heat exchanger A42 of the first air conditioning refrigeration circuit A40 are reused as part of the second air conditioning refrigeration circuit. The first air conditioning refrigeration circuit A40 and the second air conditioning refrigeration circuit together form the air conditioning system 850.

[0103] In this way, by using an air conditioning compressor 851 and an outdoor heat exchanger A42, the cab 200 can be cooled, and the coolant in the third cooling loop A30 can also be cooled, simplifying the structure of the air conditioning system 850.

[0104] Please refer to the following: Figure 10 and Figure 12The thermal management system A100 also includes a first cooling fan A50. The first cooling fan A50 is connected to both the first radiator A11 and the outdoor heat exchanger A42. The first cooling fan A50 drives airflow to cool the coolant flowing through the first radiator A11 and the refrigerant flowing through the outdoor heat exchanger A42. Specifically, the first cooling fan A50, the first radiator A11, and the outdoor heat exchanger A42 can be integrated and fixed to a bracket, and then fixed to the first longitudinal beam 110 of the frame 100 via the bracket.

[0105] In this way, the first cooling fan A50 can cool the coolant flowing through the first radiator A11 and the refrigerant flowing through the outdoor heat exchanger A42, making the structure of the thermal management system A100 more compact and also making the heat dissipation efficiency of the thermal management system A100 higher.

[0106] Based on the above, please refer to the following: Figure 6 and Figure 13 , Figure 13 for Figure 3 This is a partial schematic diagram of the thermal management system A100 of the hybrid power unit 1000. The thermal management system A100 also includes a fourth cooling loop A70 and a fifth cooling loop A80. The fourth cooling loop A70 includes a third radiator A71, a fourth mechanical pump (not shown), and a first engine 310 connected in series. The fifth cooling loop includes a fourth radiator A81, a fifth mechanical pump (not shown), and a second engine 410 connected in series. Specifically, the third radiator A71 and the fourth radiator A81 can be integrated with the aforementioned first intercooler 531 and second intercooler 532. In this way, the coolant in the two cooling loops cools the first engine 310 and the second engine 410 respectively.

[0107] The thermal management system A100 also includes a second cooling fan A90. The second cooling fan A90 is connected to both the third radiator A71 and the fourth radiator A81, and is used to drive airflow to cool the coolant flowing through the third radiator A71 and the fourth radiator A81.

[0108] The thermal management system A100 also includes a third expansion tank A91, which is connected to the piping between the fourth mechanical pump and the third radiator A71, and to the piping between the fifth mechanical pump and the fourth radiator A81.

[0109] In the description of this specification, specific features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments or examples.

[0110] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A thermal management system for a hybrid power equipment, characterized in that, include: The first cooling circulation loop includes a first radiator, a first mechanical pump, and a first generator of a first range extender connected in series; the first mechanical pump includes a first end and a second end, and the first radiator includes a third end and a fourth end, wherein the third end is connected to the second end. A second cooling cycle loop, a portion of which includes a second generator of the second range extender; Wherein, the two ends of the portion of the second cooling circulation loop are respectively connected to the first end and the fourth end, so as to reuse the first radiator and the first mechanical pump as another part of the second cooling circulation loop; or, Another part of the second cooling circulation loop includes a second radiator and a second mechanical pump, which are connected in series.

2. The thermal management system according to claim 1, characterized in that, The second cooling circulation loop also includes a drive motor, which is connected in series between the first radiator and the second generator and is located downstream of the second generator.

3. The thermal management system according to claim 2, characterized in that, The first cooling circulation loop further includes a controller group, which is connected in series between the first mechanical pump and the first generator and is located upstream of the first generator. The controller group includes a motor controller and / or a range extender controller. The motor controller is electrically connected to the drive motor, and the range extender controller is electrically connected to both the first range extender and the second range extender.

4. The thermal management system according to claim 3, characterized in that, The first cooling circulation loop also includes a steering pump, which is connected in series between the controller group and the first radiator and is located downstream of the controller group. The steering pump is used as the power source for the hydraulic power steering system of the hybrid power equipment.

5. The thermal management system according to claim 4, characterized in that, The first cooling cycle loop also includes an air compressor, which is connected in series between the controller group and the first radiator and is located downstream of the controller group. The air compressor is used as the power source for the pneumatic braking system of the hybrid power equipment.

6. The thermal management system according to claim 5, characterized in that, The controller group further includes a steering pump controller, which is electrically connected to the steering pump; and / or, The controller group also includes an air compressor controller, which is electrically connected to the air compressor.

7. The thermal management system according to any one of claims 1-5, characterized in that, The thermal management system also includes: The third cooling circulation loop includes a first heat exchange unit, a third mechanical pump, a first heater, and a battery connected in series. The first air conditioning refrigeration circuit includes an air conditioning compressor, a second heat exchange section and an outdoor heat exchanger connected in series. The second heat exchange section is thermally connected to the first heat exchange section so that the refrigerant flowing through the second heat exchange section absorbs heat from the coolant in the first heat exchange section.

8. The thermal management system according to claim 7, characterized in that, The thermal management system also includes: The first cooling fan is connected to both the first radiator and the outdoor heat exchanger. The first cooling fan is used to drive airflow to cool the coolant flowing through the first radiator and the refrigerant flowing through the outdoor heat exchanger.

9. A hybrid power device, characterized in that, include: A thermal management system, wherein the thermal management system is any one of claims 1-8.

10. A hybrid power device, characterized in that, include: Two range extenders, the two range extenders including a first range extender and a second range extender; Range extender controller, electrically connected to both the first and second range extenders, is configured to: if the required power generation P of the hybrid power equipment... req If the actual power generation P of the first range extender is less than or equal to the first threshold, then control the actual power generation P of the first range extender. act1 With the P req Matching; if the P req If the power output P of the first range extender is greater than the first threshold and less than or equal to the second threshold, then the actual power generation P of the first range extender is controlled. act1 Matching the first threshold and controlling the actual power generation P of the second range extender. act2 With the P req The difference between the first threshold and the first threshold are matched; Wherein, the first threshold is less than the maximum power generation P of the range extender. max The second threshold is greater than the maximum power generation P of the range extender. max And less than the sum of the maximum power output of the two range extenders.

11. The hybrid power equipment according to claim 10, characterized in that, The range extender controller is further configured to: if the P req If the actual power generation P of the second range extender is greater than the second threshold, then control the actual power generation P of the second range extender. act2 With the maximum power generation P of the range extender max Matching and controlling the actual power generation P of the first range extender act1 With the P req The maximum power output P of the range extender max The difference matches.

12. The hybrid power device according to claim 10, characterized in that, The range extender controller is further configured to: if the cumulative power generation of the first range extender is less than the cumulative power generation of the second range extender, then make the first range extender the first range extender.

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