A vehicle power take-off power supply system

Abstract

This utility model belongs to the field of power supply technology and relates to a vehicle power take-off power supply system. The utility model includes: a power supply module comprising an AC asynchronous generator, an AC permanent magnet generator, a chassis battery pack, and an additional battery pack; a conversion and control module comprising a power extender, a motor controller, and a display and control box; the power extender communicates with the display and control box and the motor controller, inputting high-voltage DC power to the motor controller through the power extender to achieve power distribution and conversion; and a distribution module comprising a comprehensive control box, which receives power from the motor controller and the AC permanent magnet generator, performs power conversion, and outputs DC power to the load. It has a power extender function; when the vehicle is traveling at low speed, the belt slips, or there is short-term braking, the engine speed is low, and the generator output power is insufficient, which can be compensated for by the power extender.

Description

Technical Field

[0001] This utility model belongs to the field of power supply technology and relates to a power take-off system for vehicles. Background Technology

[0002] With the rapid development of modern technology, the number and functions of various vehicle-mounted devices are constantly increasing, and the requirements for vehicle power supply systems are becoming increasingly stringent. In application scenarios such as engineering vehicles, special vehicles, and communication command vehicles, it is not only necessary to meet the energy needs of the vehicle itself, but also to provide stable and reliable power support for a variety of mission equipment.

[0003] However, when the vehicle is parked or in motion (including complex driving conditions such as low speed, belt slippage, and short-term braking), the engine speed is low when the belt slips or there is short-term braking, resulting in insufficient generator output power and an inability to provide stable power.

[0004] Therefore, there is an urgent need for a vehicle power take-off system to ensure a stable power supply for vehicles. Summary of the Invention

[0005] The purpose of this utility model is to overcome the shortcomings of the prior art and propose a vehicle power take-off power supply system.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A vehicle power take-off system includes:

[0008] Power supply modules include an AC asynchronous generator, an AC permanent magnet generator, a chassis battery pack, and additional battery packs.

[0009] The conversion and control module includes a power amplifier, a motor controller, and a display and control box. The power amplifier communicates with the display and control box and the motor controller, and inputs high-voltage DC power to the motor controller through the power amplifier to realize the distribution and conversion of electrical energy.

[0010] Distribution module: includes an integrated control box, which receives electrical energy from the motor controller and the AC permanent magnet generator, converts the electrical energy, and outputs DC power to the load.

[0011] Furthermore, the power amplifier receives electrical energy from the newly added battery pack and chassis battery.

[0012] Furthermore, the motor controller receives electrical energy from the power amplifier and the AC asynchronous generator, outputs AC power to the integrated control box, and at the same time, the motor controller communicates with the power amplifier.

[0013] Furthermore, the motor controller includes a power generation control module, an inverter module, and a DC-DC module; the power generation control module rectifies and filters the AC power to output DC power, and the DC power is output as AC power through the inverter module.

[0014] Furthermore, the power generation control module includes a first DSP control unit, a three-phase bridge, and a DC filter unit;

[0015] First DSP control unit: Receives detection signals for speed detection, bus voltage, and bus current, performs CAN communication and power supply interaction, and outputs PWM signal control circuit;

[0016] Three-phase bridge full bridge: Receives control from the first DSP control unit and rectifies the AC power output from the generator into DC power;

[0017] DC filter unit: Filters the rectified DC power to output stable DC power.

[0018] Furthermore, the inverter module includes a second DSP control unit, a two-phase full-bridge inverter, and an AC filter unit;

[0019] The second DSP control unit receives the detection signals of output voltage and output current, and performs CAN communication and power supply interaction;

[0020] Two-phase bridge full bridge: receives control from the second DSP control unit and rectifies DC power into AC power;

[0021] AC filtering unit: filters the rectified AC power to output stable single-phase AC power.

[0022] Furthermore, the power amplifier includes a BOOST boosting component, which employs dual-loop control.

[0023] Furthermore, the newly added battery pack is a lithium battery pack.

[0024] Furthermore, the display and control box is equipped with a switch button.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] (1) This utility model adopts a power take-off power generation method to ensure that the vehicle can supply power to the mission equipment when parked and in motion;

[0027] (2) This utility model has a power boosting function. When the vehicle is traveling at low speed, the belt slips or brakes for a short time, the engine speed is low and the generator output power is insufficient. Power can be compensated by the power booster.

[0028] (3) This utility model is easy to operate and can be monitored in real time. The switch button on the display and control box can start and stop the power take-off system from generating electricity. The control panel of the display and control box can display the power generation capacity, load status and various fault conditions in real time.

[0029] (4) The vehicle power take-off power supply system of this utility model has a one-button start-up and shutdown function. Attached Figure Description

[0030] The accompanying drawings are incorporated in and form part of this specification, and together with the description, serve to explain the principles of this invention.

[0031] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is a block diagram of the power take-off system of this utility model;

[0033] Figure 2 This is a block diagram of the motor controller of this utility model;

[0034] Figure 3 This is a block diagram illustrating the principle of the power amplifier of this utility model. Detailed Implementation

[0035] Exemplary embodiments will be described in detail below. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this invention. Rather, they are merely examples consistent with some aspects of this invention as detailed in the appended claims.

[0036] To enable those skilled in the art to better understand the technical solution of this utility model, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. Example

[0037] A vehicle power take-off system includes:

[0038] Power supply modules include an AC asynchronous generator, an AC permanent magnet generator, a chassis battery pack, and additional battery packs.

[0039] The conversion and control module includes a power amplifier, a motor controller, and a display and control box. The power amplifier communicates with the display and control box and the motor controller, and inputs high-voltage DC power to the motor controller through the power amplifier to realize the distribution and conversion of electrical energy.

[0040] Distribution module: includes an integrated control box, which receives electrical energy from the motor controller and the AC permanent magnet generator, converts the electrical energy, and outputs DC power to the load.

[0041] In this embodiment, to minimize the size and weight of the power supply system, a combination of overhead and parking power take-off (PTO) generators is recommended. A 9kW overhead PTO generator is used, along with a 16kW parking PTO generator. The output is managed through a downstream distribution box, ultimately achieving a stable and uninterrupted 9kW overhead PTO power supply and a parking PTO power supply of at least 25kW.

[0042] like Figure 1 As shown:

[0043] Power Input: The newly added battery pack 1 is connected to the power extender; the chassis battery is also connected to the power extender, both providing DC power to the extender; a 9kW AC asynchronous generator is connected to the motor controller; a 16kW AC permanent magnet generator outputs 3-phase 4-wire 380V and is connected to the integrated control box, both providing AC power input to the system. Device Interaction: The power extender and motor controller communicate via CAN bus and high-voltage DC connection; the power extender is connected to the display and control box via CAN communication, and the motor controller outputs AC230V to the integrated control box. Power Output: The integrated control box outputs AC230V and AC380V to power the load, achieving power distribution output.

[0044] The power extender receives electrical energy from the new battery pack and chassis battery, and can also charge the new battery pack in reverse. The power extender is equipped with a CAN communication port, which communicates with the display and control box and the motor controller. The power extender is electrically connected to the motor controller. When the vehicle is traveling at low speed, the belt slips, or there is short-term braking, the engine speed is low and the generator output power is insufficient. The power extender can compensate for the power of the motor controller. The motor controller is electrically connected to the integrated control box. The display and control box and the integrated control box communicate with each other via CAN communication. The integrated control box outputs DC power to the load.

[0045] The vehicle power take-off system mainly consists of a display and control box, a motor controller, a 9kW AC asynchronous generator, a power amplifier, and a set of newly added storage batteries (lithium battery modules).

[0046] Furthermore, the power amplifier receives electrical energy from the newly added battery pack and chassis battery.

[0047] In this embodiment, as Figure 3 As shown, the power booster mainly consists of a DC input relay, isolation diodes, a BOOST boost module (600V), a low-voltage DC / DC charging module, a control board, auxiliary power supply, and filters.

[0048] Power Input: The new battery input and chassis battery input are connected to the system via switches. Specifically, the new battery input is connected to the input terminal of a diode via a switch. The output terminal of the diode is connected to a Boost converter, which outputs DC 600V and interconnects with the motor controller. The battery management module is connected to the chassis battery input and manages the chassis battery. The battery management module's output is also connected to the new battery and manages its charging and discharging.

[0049] Auxiliary power supply: Receives control electrical input, provides auxiliary power to the system, and is connected to the battery management module.

[0050] Boost control board: Receives signals via communication interconnection and connects to the Boost converter. Its purpose is to control the Boost converter and it is connected to the auxiliary power supply.

[0051] Power conversion: The boost converter receives electrical energy from the new battery input (via switches and diodes), boosts it to DC 600V, and interconnects with the motor controller to achieve power output.

[0052] Signal Interaction: Communication interconnection is used for signal transmission between the Boost control board and external devices, ensuring system control commands and status feedback. Simply put, after power input, the management and control modules work together to convert electrical energy into power, which is then output to the motor controller by the Boost converter.

[0053] When the vehicle is at low speed, the belt slips, or there is brief braking, and the alternator output power is insufficient, the boost converter uses a boost unit to raise the variable DC power supplied by the additional battery to a stable high-voltage DC power of approximately 600V. This replenishes the high-voltage DC bus inside the motor controller, ensuring sufficient power supply for the DC / AC inverter unit within the motor controller and achieving uninterrupted power supply to AC equipment. To prioritize the alternator's power supply, the boost module employs dual-loop control to regulate output voltage and current, and exchanges data with the motor controller via the CAN bus to adjust the output power in real time.

[0054] The newly added lithium battery module includes a battery management module that charges the new battery and detects the battery voltage balance. When the battery is unbalanced, it reports a fault and reminds the user to replace the new battery.

[0055] Furthermore, the motor controller receives electrical energy from the power amplifier and the AC asynchronous generator, outputs AC power to the integrated control box, and at the same time, the motor controller communicates with the power amplifier.

[0056] Furthermore, such as Figure 2 As shown:

[0057] Power generation control module:

[0058] Input: The output of the alternator (G) is connected to a three-phase full-bridge circuit, and the speed detection signal is connected to the first DSP control unit.

[0059] Internal Interaction: The first DSP control unit communicates with the inverter module via CAN and DC24V, and also receives bus voltage and current detection signals. The first DSP control unit outputs the PWM signal to the three-phase bridge circuit. The output of the three-phase bridge circuit is connected to the DC output filter unit to complete the AC rectification and filtering.

[0060] 2. Inverter module

[0061] Input: The DC output of the power generation control module is connected to the two-phase bridge full bridge.

[0062] Internal Interaction: The second DSP control unit communicates with the power generation control module via CAN and DC24V, receives output voltage and current detection signals, and outputs PWM signals to the two-phase bridge full-bridge circuit. The output of the two-phase bridge full-bridge circuit is connected to the AC filter unit to realize DC power inversion to AC230V AC power output. The AC filter unit outputs AC420V voltage, and its output is connected to the second DSP control unit for output voltage and current detection feedback.

[0063] 3. External connections

[0064] Communication is achieved through CAN and DC24V, connecting the DSP control of the power generation control module and inverter module on one hand, and the DC-DC module (input and output are DC24V) on the other hand, thus constructing a system communication and auxiliary power supply link.

[0065] The motor controller includes a power generation control module, an inverter module, and a DC-DC module; the power generation control module rectifies and filters the AC power to output DC power, and the DC power is output as AC power through the inverter module.

[0066] Furthermore, the power generation control module includes a first DSP control unit, a three-phase bridge, and a DC filter unit;

[0067] First DSP control unit: Receives detection signals for speed detection, bus voltage, and bus current, performs CAN communication and power supply interaction, and outputs PWM signal control circuit;

[0068] Three-phase bridge full-bridge circuit: Receives control from the first DSP control unit and rectifies the AC power output from the generator into DC power;

[0069] DC filter unit: Filters the rectified DC power to output stable DC power.

[0070] In this embodiment: the engine drives the AC generator to generate electricity via a belt. The AC power output is rectified and filtered by the IGBT three-phase bridge circuit to output DC power. The DC power is then output as single-phase AC power by the inverter. By monitoring the generator speed, output voltage and current in real time, the AC output is ensured to meet the power requirements of the task equipment.

[0071] Specifically, the first DSP control unit performs PWM control on the three-phase bridge full-bridge circuit, which is connected to the DC filter circuit, and the DC filter circuit outputs DC power to the inverter module.

[0072] Furthermore, the inverter module includes a second DSP control unit, a two-phase full-bridge inverter, and an AC filter unit;

[0073] The second DSP control unit receives the detection signals of output voltage and output current, and performs CAN communication and power supply interaction;

[0074] Two-phase bridge full bridge: receives control from the second DSP control unit and rectifies DC power into AC power;

[0075] AC filtering unit: filters the rectified AC power to output stable single-phase AC power.

[0076] Specifically, the second DSP control unit performs PWM control on the two-phase bridge full-bridge circuit, which is connected to the AC filter unit.

[0077] Furthermore, the power amplifier includes a BOOST boosting component, which employs dual-loop control.

[0078] Furthermore, the newly added battery pack is a lithium battery pack.

[0079] Considering the battery's size, weight, and low-temperature characteristics, the newly added storage battery uses lithium battery modules with high capacity density, good low-temperature characteristics, large depth of discharge, and high cycle efficiency.

[0080] The lithium battery pack uses the lithium iron phosphate system:

[0081] (a) It has a high redox potential, which enables the lithium battery to obtain a high output voltage and a high reversible capacity, so as to obtain a sufficiently high energy density;

[0082] (b) The voltage plateau is stable during the reversible embedding / extraction process;

[0083] (c) It has good electronic and ionic conductivity to enable high-current charging and discharging.

[0084] (d) The rated voltage of a single cell is 3.2V. The lithium battery pack adopts 69 series, the rated voltage is 220.8V, and the working voltage range is 172.5V~248V; the specific selection of single cells is shown in Table 4 below.

[0085] Table 1. Selection and Design Results of Individual Cells

[0086]

[0087] The lithium battery pack features overvoltage / undervoltage, overcharge / overdischarge, and reverse connection protection and alarm functions; it also includes overvoltage / undervoltage and low capacity alerts, providing tiered warnings in advance. Furthermore, it has a log management function, capable of uploading system fault records and causes via the CAN bus.

[0088] To reduce the current stress on the boost converter module, increase the input voltage, and reduce the boost duty cycle, the overall design aims to minimize the size and weight of the boost converter and the battery.

[0089] Furthermore, the display and control box is equipped with a switch button.

[0090] Specifically, the display and control box mainly consists of a display and control board and push-button switches. The display and control box communicates with the power amplifier and motor controller via a CAN bus to complete the operation management, data monitoring, and information display of the power supply system.

[0091] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention.

[0092] It should be understood that the present invention is not limited to the content already described above, and various modifications and changes can be made without departing from its scope. The scope of the present invention is limited only by the appended claims.

Claims

1. A power take off system for a vehicle, characterized in that include: Power supply modules include an AC asynchronous generator, an AC permanent magnet generator, a chassis battery pack, and additional battery packs. The conversion and control module includes a power amplifier, a motor controller, and a display and control box. The power amplifier communicates with the display and control box and the motor controller, and inputs high-voltage DC power to the motor controller through the power amplifier to realize the allocation and conversion of electrical energy. The power amplifier also receives electrical energy from newly added battery packs and chassis batteries. Distribution module: includes an integrated control box, which receives electrical energy from the motor controller and the AC permanent magnet generator, converts the electrical energy, and outputs DC power to the load.

2. A power take-off system according to claim 1, wherein, The motor controller receives electrical energy from the power amplifier and the AC asynchronous generator, outputs AC power to the integrated control box, and communicates with the power amplifier.

3. A power take off system as claimed in claim 1 wherein, The motor controller includes a power generation control module, an inverter module, and a DC-DC module; the power generation control module rectifies and filters the AC power to output DC power, and the DC power is output as AC power through the inverter module.

4. A power take off system as claimed in claim 3, wherein, The power generation control module includes a first DSP control unit, a three-phase bridge full-bridge circuit, and a DC filter unit; First DSP control unit: Receives detection signals for speed detection, bus voltage, and bus current, performs CAN communication and power supply interaction, and outputs PWM signal control circuit; Three-phase bridge full-bridge circuit: Receives control from the first DSP control unit and rectifies the AC power output from the generator into DC power; DC filter unit: Filters the rectified DC power to output stable DC power.

5. A power take off system as claimed in claim 3 wherein, The inverter module includes a second DSP control unit, a two-phase bridge full-bridge circuit, and an AC filter unit. The second DSP control unit receives the detection signals of output voltage and output current, and performs CAN communication and power supply interaction; Two-phase bridge full-bridge circuit: Receives control from the second DSP control unit and rectifies DC power into AC power; AC filtering unit: filters the rectified AC power to output stable single-phase AC power.

6. A power take off system as claimed in claim 1, wherein, The power amplifier includes a BOOST boost module, which employs dual-loop control.

7. A power take off system as claimed in claim 1, wherein, The newly added battery pack is a lithium battery pack.

8. A power take off system as claimed in claim 1, wherein, The display and control box is equipped with a power switch button.

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