A control cabin for a charging vehicle

Abstract

This invention relates to the field of steering control technology for mobile energy storage vehicles, specifically a control cabin for charging vehicles. The invention includes a vehicle frame connecting component and a direction control structure, a steer-by-wire mechanism, and a control module mounted on the vehicle frame connecting component. The direction control structure, steer-by-wire mechanism, and control module are electrically connected. A handlebar drives a steer-by-wire wheel via a belt drive assembly, and signals are transmitted via wire to the control module integrated at the bottom, thereby controlling the steer-by-wire mechanism to achieve precise steering. The direction control structure also includes physical limit blocks on the belt drive path to limit the handlebar rotation angle. This invention, through a highly integrated and compact layout, effectively solves the problems of large space occupation, low control accuracy, and susceptibility to signal interference in existing steering systems. It features a compact structure, simple operation, and precise and reliable control.

Description

Technical Field

[0001] This invention belongs to the field of vehicle steering control technology, and particularly relates to a control cabin for a charging vehicle. Background Technology

[0002] As a crucial mobile carrier for energy storage devices, the steering control module of mobile charging vehicles directly impacts their flexibility, safety, and operational efficiency. Currently, common steering control methods include manual traction, wireless remote control, intelligent following steering, and steer-by-wire. Manual traction is simple in structure but relies on human operation, resulting in laborious and inaccurate steering, making it unsuitable for heavy vehicles and complex road conditions. While wireless remote control improves ease of operation, it is susceptible to signal interference, exhibiting delays and blind spots. Intelligent following steering relies on sensors and environmental perception, resulting in complex and costly devices, and is easily affected by environmental factors leading to control deviations. Steer-by-wire offers rapid response and precise control, but lacks an effective fault-tolerance mechanism in case of malfunction, posing safety hazards.

[0003] Existing control cabins often have a loose structural layout, with transmission components occupying a large space and having low integration, which is not conducive to the compact and lightweight design of the entire vehicle structure. Therefore, there is an urgent need for a direction control module that is compact, precise in control, highly reliable, and has excellent space utilization to improve the overall performance and applicability of mobile charging vehicles. Summary of the Invention

[0004] To address the problems of complex structure, low control precision, low reliability, and poor space utilization in the control cabin of existing charging vehicles, this invention proposes a control cabin for charging vehicles, comprising: a vehicle frame connecting component, a steering control structure, a steer-by-wire mechanism, and a control module; the steering control structure, steer-by-wire mechanism, and control module are mounted on the vehicle frame connecting component; the steering control structure, steer-by-wire mechanism, and control module are electrically connected. The steering control structure includes a handlebar, a belt drive assembly, and a steer-by-wire wheel, wherein the handlebar is connected to the steer-by-wire wheel via the belt drive assembly. The steer-by-wire wheel is electrically connected to the control module via a wired connection; one end of the steer-by-wire mechanism is connected to the vehicle frame connecting component, and the other end is connected to the wheel hub steering bar; after receiving the rotation signal from the steer-by-wire wheel, the control module controls the steer-by-wire mechanism to drive the wheel hub steering bar to rotate.

[0005] According to the above-described control cabin for a charging vehicle, the belt drive assembly includes a drive wheel, a driven wheel, and a drive belt. The drive wheel is fixedly connected to the handlebar shaft, the driven wheel is coaxially arranged with the steering wheel, and the drive belt is sleeved between the drive wheel and the driven wheel.

[0006] According to the control cabin for a charging vehicle described above, the gear ratio between the driving wheel and the driven wheel is 1:1.5~2.5, which is used to proportionally convert the rotation angle of the handlebars into the rotation angle of the driven wheel.

[0007] According to the control cabin for a charging vehicle described above, the drive-by-wire steering wheel is an absolute encoder used to detect the rotation angle of the handlebars in real time and output digital signals to the control module.

[0008] According to the control cabin for a charging vehicle described above, the steer-by-wire mechanism includes: a motor, a connecting arm, and a transmission rod; the motor is connected to the transmission rod; the transmission rod is hinged to the connecting arm; the connecting arm is hinged to the wheel hub steering bar; the transmission rod reciprocates linearly along the axial direction of the transmission rod under the forward and reverse rotation of the motor; the transmission rod drives the connecting arm to swing left and right; thereby causing the wheel hub steering bar connected to the connecting arm to turn left and right.

[0009] According to the above-described control cabin for a charging vehicle, the control module is located at the bottom of the vehicle frame connecting component and includes a main control board and a signal conditioning circuit. The main control board receives sensor signals and outputs control commands to the steer-by-wire mechanism.

[0010] According to the control cabin for a charging vehicle described above, the direction control structure further includes a physical limiting block disposed on the belt drive path of the belt drive assembly.

[0011] According to the control cabin for a charging vehicle described above, the physical limiting block consists of two symmetrically arranged metal blocks, which respectively limit the maximum rotation angle of the handlebars to the left and right to ±30°.

[0012] According to the control cabin for a charging vehicle described above, the control module further includes a fault detection module for real-time monitoring of the working status of the steer-by-wire mechanism and for initiating an emergency braking procedure in case of an abnormality.

[0013] According to the control cabin for a charging vehicle described above, the direction control structure further includes a tensioning pulley disposed on the outside of the transmission belt to prevent the transmission belt from slipping.

[0014] The beneficial effects of this invention are as follows: 1. High space utilization and compact structure. This invention places the steering control structure at the rear of the vehicle frame connecting component; the steer-by-wire mechanism and control module are located at the front of the vehicle frame connecting component, adopting an integrated design of belt drive and sensors, significantly reducing the space occupied by the external mechanical structure. Compared with the distributed control units in the prior art, the overall layout is more compact, which is conducive to the lightweight and miniaturization design of the vehicle, and improves the mobility and operational flexibility of the mobile charging vehicle in narrow spaces.

[0015] 2. Simple operation and user-friendly human-computer interaction. The physical limit block design of this invention avoids device damage caused by human error, improves the intuitiveness and safety of operation, and is especially suitable for long-term, high-frequency operation needs.

[0016] 3. High control precision and rapid response. The absolute encoder detects the handlebar rotation angle in real time, and combined with wired transmission to avoid signal interference and delay, the control module can output control commands quickly and accurately. The steer-by-wire mechanism uses a "motor + rack and pinion" system with a PID control algorithm to achieve linear control of the front axle steering angle. Steering precision is significantly higher than traditional mechanical or wired control methods, making it suitable for high-precision operating scenarios. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the control compartment for a charging vehicle according to the present invention.

[0018] Figure 2 This is a schematic diagram of the direction control structure of the control compartment for a charging vehicle according to the present invention.

[0019] Figure 3 This is a schematic diagram of the steer-by-wire mechanism for the control compartment of a charging vehicle according to the present invention.

[0020] Figure 4 This is a schematic diagram of a drive-by-wire steering mechanism for the control compartment of a charging vehicle, which drives the wheel hub to move straight, turn left, and turn right.

[0021] Figure 5 This is a schematic diagram of the internal structure of a drive-by-wire steering mechanism for a control compartment of a charging vehicle according to the present invention.

[0022] In the diagram: 1-Bike frame connecting component, 101-Tensioning wheel, 2-Steering control structure, 201-Handlebar, 202-Belt drive assembly, 2021-Drive wheel, 2022-Driven wheel, 2023-Drive belt, 203-Drive-by-wire steering wheel, 204-Physical limit block, 3-Drive-by-wire steering mechanism, 301-Connecting arm, 4-Control module, 5-Motor, 501-Drive rod, 502-Intermediate shaft, 503-Worm gear, 504-Worm. Detailed Implementation

[0023] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0024] like Figures 1 to 4As shown: This embodiment of the present invention provides a control cabin for a charging vehicle, aiming to solve the problems of loose structure, large space occupation, low control accuracy, and insufficient reliability of existing mobile charging vehicle direction control modules. The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0025] This embodiment provides a control compartment for a charging vehicle, including a direction control structure 2, a steer-by-wire mechanism 3, and a control module 4, all mounted on a vehicle frame connecting component 1. The vehicle frame connecting component 1, serving as a basic support structure, is constructed from welded rectangular steel tubing, providing excellent rigidity and load-bearing capacity. The control module 4 includes an ECU (Electronic Control Unit).

[0026] The steering control structure 2 includes a handlebar 201, a belt drive assembly 202, a steerable wheel 203, and a physical limit block 204. The handlebar 201 is mounted on the upper front part of the frame connecting component 1 via bearings, and steering is achieved by pushing the handlebar 201. The belt drive assembly 202 consists of a drive pulley 2021, a driven pulley 2022, and a drive belt 2023. The drive pulley 2021 is fixed to the axle of the handlebar 201, and the driven pulley 2022 is coaxially mounted with the steerable wheel 203. The drive belt 2023 is a synchronous belt to ensure no slippage during transmission and improve the accuracy of angle transmission. The gear ratio of the drive pulley 2021 to the driven pulley 2022 is 1:2, used to proportionally convert the rotation angle of the handlebar 201 into the rotation angle of the driven pulley 2022.

[0027] The drive-by-wire steering wheel 203 uses an absolute encoder, whose output signal is wired to the control module 4 via a shielded cable, effectively avoiding common interference and delay problems in wireless signal transmission. Physical limit blocks 204, made of metal, are symmetrically installed on both sides of the belt drive path, limiting the maximum rotation angle of the handlebars 201 to ±30°, preventing mechanical damage or loss of control due to excessive human operation. The handlebars directly drive the belt drive structure, resulting in low operating torque, clear feedback, and ease of use without complex training.

[0028] The output shaft of motor 5 is connected to worm gear 503, which meshes with worm wheel 504. Worm wheel 504 is mounted on intermediate shaft 502, and a gear structure is provided at the lower end of intermediate shaft 502. A rack structure meshing with the gear structure is provided on transmission rod 501. The output shaft of motor 5 drives worm gear 503 to rotate, and the meshing of worm gear 503 and worm wheel 504 drives intermediate shaft 502 to rotate. In turn, the gear structure at the lower end of intermediate shaft 502 and the rack structure of transmission rod 501 drive transmission rod 501 to move left and right. Transmission rod 501 causes connecting arm 301 to swing left and right; thus, the wheel hub steering bar connected to connecting arm 301 turns left and right.

[0029] The control module 4 is integrated into the front bottom space of the vehicle frame connecting component 1, and includes a main control board and a signal conditioning circuit. The main control board is for VCU (Vehicle Controller Unit) chassis control, responsible for receiving digital signals from the steer-by-wire wheel 203, processing them through a PID algorithm, and outputting corresponding control signals to the steer-by-wire mechanism 3. The signal conditioning circuit is used to filter and amplify sensor signals to improve the module's anti-interference capability. In addition, the control module 4 also integrates a fault detection module, which can monitor the current and displacement feedback of the electric push rod in real time. Once an abnormality is detected, such as jamming or power failure, the emergency braking program is immediately activated, cutting off the power output and issuing an audible and visual alarm.

[0030] This invention integrates fault detection and emergency braking functions, enabling timely protection of the module in case of malfunctions in the online steering mechanism. The rational component layout and comprehensive protective measures significantly improve the module's stable operation in harsh environments, reducing maintenance frequency and costs. The device boasts high reliability and a low failure rate.

[0031] The directional control structure also includes a tensioning pulley 101 located on the outside of the drive belt 2032 to prevent the drive belt 2032 from slipping.

[0032] The workflow of this invention is as follows: The handlebars 201 are rotated, and the rotational motion is transmitted to the steer-by-wire wheel 203 via the belt drive assembly 202; the steer-by-wire wheel 203 converts the detected angle value into an electrical signal, which is then transmitted via wire to the control module 4; the control module 4 calculates the required steering angle and direction according to a preset algorithm and sends forward and reverse control commands to the motor 5; the transmission rod 501 reciprocates linearly along its axial direction under the forward and reverse rotation of the motor 5; the transmission rod 501 drives the connecting arm 301 to swing left and right; thereby causing the wheel hub steering bar connected to the connecting arm 301 to turn left and right. The entire process is responsive and precise. This invention places the steering control structure at the rear of the vehicle frame connecting component; the steer-by-wire mechanism and control module are placed at the front of the vehicle frame connecting component, greatly improving space utilization and the compactness of the overall structure. The structure is simplified, transmission efficiency is high, energy consumption is low, and operation is flexible and convenient.

[0033] This invention features a simplified structure, high transmission efficiency, and lower energy consumption than traditional hydraulic or pneumatic steering modules. All electrical components are powered by low-voltage DC, eliminating the need for additional hydraulic oil or high-pressure air sources and avoiding environmental pollution and leakage risks. It is suitable for various mobile energy storage platforms, logistics vehicles, AGVs, and other electric vehicles, and has high potential for widespread adoption.

[0034] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A control capsule for a charging trolley, characterized in that, include: The vehicle frame connecting component (1), the steering control structure (2), the steer-by-wire mechanism (3), and the control module (4) are mounted on the vehicle frame connecting component (1); the steering control structure (2), the steer-by-wire mechanism (3), and the control module (4) are electrically connected. The steering control structure (2) includes a handlebar (201), a belt drive assembly (202), and a steerable wheel (203), wherein the handlebar (201) is connected to the steerable wheel (203) via the belt drive assembly (202); The steer-by-wire (203) is electrically connected to the control module (4) via a wired connection; one end of the steer-by-wire mechanism (3) is connected to the vehicle frame connecting component (1), and the other end is connected to the wheel hub steering bar; after receiving the rotation signal of the steer-by-wire (203), the control module (4) controls the steer-by-wire mechanism (3) to drive the wheel hub to rotate.

2. A control capsule for a charging cart as defined in claim 1, wherein: The belt drive assembly (202) includes a drive pulley (2021), a driven pulley (2022), and a drive belt (2023). The drive pulley (2021) is fixedly connected to the shaft of the handlebar (201). The driven pulley (2022) is coaxially arranged with the steering wheel (203). The drive belt (2023) is sleeved between the drive pulley (2021) and the driven pulley (2022).

3. A control capsule for a charging cart as defined in claim 2, wherein: The gear ratio of the driving wheel (2021) to the driven wheel (2022) is 1:1.5~2.5, which is used to convert the rotation angle of the handlebar (201) into the rotation angle of the driven wheel (2022) proportionally.

4. A control capsule for a charging trolley as claimed in claim 3, characterised in that: The drive-by-wire steering wheel (203) is an absolute encoder used to detect the rotation angle of the handlebars (201) in real time and output digital signals to the control module (4).

5. A control capsule for a charging trolley as claimed in claim 4, characterised in that: The steer-by-wire mechanism (3) includes: a motor (5), a connecting arm (301), and a transmission rod (501); the motor (5) is connected to the transmission rod (501); the transmission rod (501) is hinged to the connecting arm (301); the connecting arm (301) is hinged to the wheel hub steering bar; the transmission rod (501) moves linearly back and forth along the axis of the transmission rod (501) under the forward and reverse rotation of the motor (5); the transmission rod (501) drives the connecting arm (301) to swing left and right; thereby causing the wheel hub connected to the connecting arm (301) to turn left and right.

6. A control capsule for a charging trolley as claimed in claim 5, characterised in that: The control module (4) is located at the bottom of the body frame connecting component (1) and includes a main control board and a signal conditioning circuit. The main control board receives sensor signals and outputs control commands to the steer-by-wire mechanism (3).

7. A control capsule for a charging trolley as claimed in claim 6, characterised in that: The direction control structure (2) also includes a physical limit block (204) disposed on the belt drive path of the belt drive assembly (202).

8. A control capsule for a charging trolley as claimed in claim 7, characterised in that: The physical limiting block (204) consists of two symmetrically arranged metal blocks that limit the maximum rotation angle of the handlebars to the left and right to ±30° respectively.

9. A control capsule for a charging trolley as claimed in claim 8, characterised in that: The control module (4) also includes a fault detection module, which is used to monitor the working status of the steer-by-wire mechanism (3) in real time and to start the emergency braking procedure when there is an abnormality.

10. A control capsule for a charging trolley as claimed in claim 9, characterised in that: The direction control structure further comprises a tension pulley (101) arranged outside the transmission belt (2023) to prevent the transmission belt (2023) from slipping.

Images