Emergency direct current generator for transport vehicle

Abstract

The application discloses an emergency direct-current power generation device of a transport vehicle and relates to the technical field of logistics transportation. The emergency direct-current power generation device comprises a base, a diesel engine, a generator, a current transformer, a rotating speed sensor and a controller, the base is installed on the transport vehicle, the diesel engine is installed on the base, a throttle motor, a starting motor and a flameout electromagnetic valve are arranged on the diesel engine, the generator is installed on the base, an input shaft of the generator is in transmission connection with a flywheel disc of the diesel engine through an elastic coupling, so as to form a power generation unit independent of an engine compartment of the transport vehicle, the current transformer collects real-time load current output by the generator, the rotating speed sensor collects a real-time rotating speed signal of the diesel engine, and the controller is in communication connection with the throttle motor, the starting motor, the flameout electromagnetic valve, the current transformer and the rotating speed sensor. The emergency direct-current power generation device has the advantages of simple structure, convenient use, effective improvement of installation convenience and use economy of the power generation device and reduction of economic risks caused by power supply problems.

Description

Technical Field

[0001] This invention relates to the field of logistics and transportation technology, and in particular to an emergency DC power generation device for transport vehicles. Background Technology

[0002] Logistics vehicles, livestock transport vehicles, refrigerated trucks, and similar vehicles are often equipped with high-current electrical equipment. When the power of the added electrical equipment (such as air conditioners, fans, lighting, etc.) is too high (above 6kW), the vehicle's original generator often cannot meet the usage requirements. At present, the main solution is to replace it with a generator with a higher power output.

[0003] The existing technology has the following disadvantages Installation difficulties: Due to the limited space in the engine compartment, replacing the generator is difficult and requires the design of a separate generator bracket; moreover, high-power generators may face the problem of insufficient installation space.

[0004] Excessive energy consumption: When parked, in order to meet the vehicle's power demand, the vehicle engine needs to be started and the throttle is increased to more than 1500 rpm (because the engine's power generation at idle speed is insufficient, the battery will quickly run out of power), resulting in extremely low utilization of the vehicle engine and poor fuel economy.

[0005] Significant risks: Logistics vehicles, such as livestock transport vehicles, heavily rely on chassis generators for power. If the chassis generator malfunctions, livestock could die due to power outages during transport, potentially causing substantial economic losses. Summary of the Invention

[0006] The purpose of this invention is to provide an emergency DC power generation device for transport vehicles to solve the problems existing in the prior art. It has a simple structure, is easy to use, effectively improves the ease of installation and economic efficiency of the power generation device, and reduces the economic risks caused by power supply problems.

[0007] To achieve the above objectives, the present invention provides the following solution: This invention provides an emergency DC power generation device for a transport vehicle, comprising: a base, a diesel engine, a generator, a current transformer, a speed sensor, and a controller. The base is used for mounting on the transport vehicle. The diesel engine is mounted on the base via a diesel engine bracket and includes a throttle motor, a starter motor, and a shutdown solenoid valve. The generator is mounted on the base via a generator bracket, and the input shaft of the generator is connected to the flywheel of the diesel engine via a flexible coupling to form a power generation unit independent of the engine compartment of the transport vehicle. The current transformer is located at the power output terminal of the generator to collect the real-time load current output by the generator. The speed sensor is located at the flywheel of the diesel engine to collect the real-time speed signal of the diesel engine. The controller is communicatively connected to the throttle motor, the starter motor, the shutdown solenoid valve, the current transformer, and the speed sensor.

[0008] Preferably, it also includes a flywheel housing, which is rigidly connected to the connection end of the diesel engine and the generator via a locating pin, and the speed sensor is mounted on the flywheel housing.

[0009] Preferably, the flexible coupling is a gear-type flexible coupling.

[0010] Preferably, it also includes a cooling water tank, which is installed on one side of the diesel engine to cool the diesel engine.

[0011] Preferably, both the diesel engine bracket and the generator bracket are provided with shock-absorbing pads at their bottoms.

[0012] Preferably, it also includes a housing, which is mounted on the base and encloses the diesel engine and the generator.

[0013] Preferably, the top and sides of the enclosure are provided with movable doors for easy maintenance, one end of the enclosure is provided with an air inlet and the other end is provided with an air outlet, and both the air inlet and the air outlet are provided with heat dissipation louvers.

[0014] Preferably, the inner wall of the housing is provided with a layer of sound-absorbing cotton, and the exhaust system of the diesel engine is connected to a muffler.

[0015] Preferably, the throttle motor is a stepper motor.

[0016] Preferably, the controller integrates a microprocessor and a data storage module. The microprocessor receives and analyzes the load current signal monitored by the current transformer and the speed signal collected by the speed sensor, and sends adjustment commands to the throttle motor according to preset control logic to control the output power of the diesel engine. At the same time, it realizes the automatic start-stop control of the diesel engine through the starter motor and the shut-off solenoid valve. The data storage module is used to record the operating parameters, fault information and historical data of the generator.

[0017] The present invention achieves the following technical effects compared to the prior art: This invention provides an emergency DC power generation device for transport vehicles. By setting up a power generation unit independent of the transport vehicle's engine compartment, it effectively solves the problems of difficult installation and limited space when replacing high-power generators in existing technologies. The base can be directly installed on the transport vehicle, and the diesel engine and generator are fixed by their respective brackets, forming a modular structure without the need for complex modifications to the original engine compartment. Simultaneously, the device can operate independently when parked, avoiding the problem of excessive energy consumption caused by starting the vehicle engine to meet power demand. The controller automatically adjusts the throttle motor according to the load current and diesel engine speed, matching the output power to the power demand and significantly improving fuel economy. Furthermore, the independent power generation unit design reduces dependence on the vehicle chassis generator. Even if the original vehicle generator fails, the emergency power generation device can still ensure continuous power supply to critical electrical equipment, such as temperature control systems in livestock transport and refrigeration equipment in refrigerated trucks, thereby effectively avoiding major economic risks such as livestock death or cargo damage caused by power outages. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 A forward structural schematic diagram of the emergency DC power generation device for transport vehicles provided by the present invention; Figure 2 A schematic diagram of the structure of the emergency DC power generation device for transport vehicles provided by the present invention from the rear view; Figure 3 An exploded view of the connection between the diesel engine and the generator in the emergency DC power generation device for transport vehicles provided by the present invention; Figure 4 A schematic diagram of the structure of the emergency DC power generation device for transport vehicles provided by the present invention, in which the housing encloses the diesel engine and generator as a whole; Figure 5A schematic diagram of the flexible coupling in the emergency DC power generation device for transport vehicles provided by the present invention; In the diagram: 1. Base; 2. Diesel engine; 21. Throttle motor; 22. Starter motor; 23. Fire shut-off solenoid valve; 24. Flywheel disc; 3. Generator; 4. Speed ​​sensor; 5. Flywheel housing; 6. Flexible coupling; 61. Motor end; 62. Flywheel end of diesel engine; 7. Cooling water tank; 8. Shock-absorbing pad; 9. Housing; 91. Movable door; 92. Heat dissipation louvers. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] The purpose of this invention is to provide an emergency DC power generation device for transport vehicles to solve the problems existing in the prior art. It has a simple structure, is easy to use, effectively improves the ease of installation and economic efficiency of the power generation device, and reduces the economic risks caused by power supply problems.

[0022] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] This invention provides an emergency DC power generation device for transport vehicles, such as... Figures 1-5As shown, the system includes: a base 1, a diesel engine 2, a generator 3, a current transformer, a speed sensor 4, and a controller. The base 1 is used for mounting on a transport vehicle. The diesel engine 2 is mounted on the base 1 via a diesel engine bracket and is equipped with a throttle motor 21, a starter motor 22, and a shutdown solenoid valve 23. The generator 3 is mounted on the base 1 via a generator bracket. The input shaft of the generator 3 is connected to the flywheel disc 24 of the diesel engine 2 via a flexible coupling 6, forming a power generation unit independent of the transport vehicle's engine compartment. By mounting the diesel engine 2 and generator 3 on the base 1 and connecting them via the flexible coupling 6, a power generation unit independent of the transport vehicle's engine compartment is formed. This makes the power generation device flexible in installation, independent of engine compartment space, solving the problem of difficult installation of high-power generator 3 due to engine compartment space limitations. At the same time, the independent unit can better isolate from the original system of the transport vehicle, reduce mutual interference, and improve the stability and reliability of the power generation device. A current transformer is installed at the power output terminal of generator 3 to collect the real-time load current output by generator 3; a speed sensor 4 is installed at the flywheel disc of diesel engine 2 to collect the real-time speed signal of diesel engine 2; the controller is communicatively connected to throttle motor 21, starter motor 22, kill solenoid valve 23, current transformer, and speed sensor 4. The current transformer collects the real-time load current, the speed sensor 4 collects the real-time speed signal of diesel engine 2, and the controller is communicatively connected to each component, enabling the controller to adjust the speed of diesel engine 2 in a timely manner according to the load current, achieving precise control of the output power of generator 3, thereby effectively meeting the power demand under different load conditions and improving the adaptability and working efficiency of the power generation unit.

[0024] In a preferred embodiment, a flywheel housing 5 is further included, which is rigidly connected to the diesel engine 2 and the generator 3 via locating pins. A speed sensor is mounted on the flywheel housing. The rigid connection of the flywheel housing 5 to the diesel engine 2 and the generator 3 via locating pins ensures precise fixation of the relative positions of the diesel engine 2 and the generator 3, improving installation accuracy and operational stability, guaranteeing reliable power transmission, reducing vibrations and malfunctions caused by component misalignment during operation, and extending the service life of the generator unit.

[0025] In a preferred embodiment, the flexible coupling 6 is a gear-type flexible coupling 6. The gear-type flexible coupling 6 includes a motor end 61 connected to the motor and a flywheel end 62 of the diesel engine connected to the diesel engine 2. In addition to the advantages of ordinary flexible couplings 6 in compensating for radial and angular errors and having low requirements for axial installation accuracy, the gear-type flexible coupling 6 also has the advantages of high transmission efficiency and strong load-bearing capacity, which can better adapt to the working requirements of the power generation unit under high load conditions and ensure stable and efficient power transmission.

[0026] In a preferred embodiment, a cooling water tank 7 is further included, which is installed on one side of the diesel engine 2 to cool the diesel engine 2. The cooling water tank 7 can promptly remove the heat generated by the diesel engine 2 during operation, ensuring that the diesel engine 2 operates within a suitable temperature range, avoiding problems such as power reduction, accelerated component wear, or even damage due to overheating, effectively protecting the diesel engine 2 and extending its service life.

[0027] In a preferred embodiment, both the diesel engine bracket and the generator bracket are provided with vibration damping pads 8 at their bottoms. The vibration damping pads 8 can absorb the vibrations generated during the operation of the diesel engine 2 and the generator 3, reduce the transmission of vibrations to the base 1 and the transport vehicle, reduce the vibration amplitude of the entire power generation unit, improve the stability of equipment operation, and at the same time reduce the failures such as component loosening and wear that may be caused by vibration.

[0028] In a preferred embodiment, the emergency DC power generation device for the transport vehicle further includes a housing 9, which is mounted on the base 1 and encloses the diesel engine 2 and the generator 3. The housing 9 protects the diesel engine 2 and the generator 3 from external debris, dust, moisture, etc., preventing damage to components due to external environmental factors; it also provides sound insulation to a certain extent, reducing the noise generated by the power generation device during operation.

[0029] In a preferred embodiment, the top and sides of the housing 9 are equipped with movable doors 91 for easy maintenance. One end of the housing 9 has an air inlet, and the other end has an air outlet. Both the air inlet and the air outlet are equipped with heat dissipation louvers 92. The movable doors 91 facilitate maintenance personnel to inspect, maintain, and repair the inside of the power generation device. The design of the air inlet, air outlet, and heat dissipation louvers 92 ensures air circulation inside the housing 9, effectively dissipating heat, maintaining a suitable temperature environment inside the power generation device, and ensuring the normal operation of the power generation device.

[0030] In a preferred embodiment, the inner wall of the housing 9 is provided with a sound-absorbing layer, and the exhaust system of the diesel engine 2 is connected to a muffler. The sound-absorbing layer and the muffler can significantly reduce the noise generated by the generator during operation. The sound-absorbing layer absorbs noise reflections within the housing 9, and the muffler reduces the noise generated by the exhaust of the diesel engine 2, effectively reducing noise pollution to the surrounding environment and meeting the noise control requirements of different application scenarios.

[0031] In a preferred embodiment, the throttle motor 21 is a stepper motor. The stepper motor has precise positioning and control accuracy, which can accurately control the throttle opening of the diesel engine 2, thereby achieving more precise adjustment of the output power of the diesel engine 2. It can better adjust the output power of the generator in accordance with load changes, thereby improving the power generation efficiency and energy utilization rate.

[0032] In a preferred embodiment, the controller integrates a microprocessor and a storage module. The microprocessor receives and analyzes the current signal monitored by the current transformer and the speed signal collected by the speed sensor 4, and sends adjustment commands to the throttle motor 21 according to preset control logic to control the output power of the diesel engine 2. Simultaneously, it achieves automatic start-stop control of the diesel engine 2 through the starter motor 22 and the shut-off solenoid valve 23. The storage module records the operating parameters, fault information, and historical data of the generator. The microprocessor enables intelligent control, allowing the generator to automatically adjust the diesel engine power and start / stop according to actual operating conditions, thus improving the automation level and performance of the generator. The storage module records operating parameters, fault information, and historical data, facilitating status monitoring and fault diagnosis by maintenance personnel, and providing a strong basis for subsequent maintenance and troubleshooting.

[0033] The following are possible usage methods related to the patent for the emergency DC power generation device for this transport vehicle: Start-up phase Connect the power supply: Confirm that the generator is securely installed on the transport vehicle via base 1, the overall electrical connection is normal, all components have been initialized, and the connecting wires between the generator and the transport vehicle's electrical equipment are correctly connected.

[0034] Start-up command input: Send a start-up command to the controller of the power generation unit via the control terminal or corresponding control interface. At this time, the controller has established communication connections with each component and can accurately transmit and execute commands.

[0035] Execute the startup operation: After receiving the startup command, the controller will perform the following sequence of operations: Starting power components: The controller controls the starter motor 22 to be energized, and the starter motor 22 drives the diesel engine 2 to start rotating; at the same time, the controller controls the throttle motor 21 (stepper motor) to pull the throttle to the starting fuel level, providing the diesel engine 2 with the amount of fuel required to start, and ensuring that the diesel engine 2 starts smoothly.

[0036] Power transmission: The flywheel of diesel engine 2 drives the shaft of generator 3 to rotate through flexible coupling 6. Due to the use of gear-type flexible coupling 6, not only is the transmission efficiency high and the load-bearing capacity strong, but it can also compensate for radial and angular errors to a certain extent, ensuring that power is smoothly transmitted to generator 3.

[0037] Monitoring and control of the start-up process: The speed sensor 4 is installed at the flywheel end of the diesel engine 2 to collect the speed signal of the diesel engine 2 in real time and transmit it to the controller. When the controller detects that the engine speed has reached the set value, it controls the starter motor to disconnect; then it controls the throttle motor 21 to pull the throttle to the idle throttle position. After the engine idle speed stabilizes, the throttle motor 21 is adjusted to the rated low speed to complete the start-up process. During this process, the flywheel housing 5 is rigidly connected to the diesel engine 2 and the generator 3 through the locating pin, ensuring that the relative positions of each component are accurately fixed and ensuring reliable power transmission.

[0038] Operational phase Load Connection and Adaptation: When electrical equipment on the transport vehicle is connected, such as air conditioners, fans, and lighting equipment, generator 3 begins to output power to supply the load. At this time, a current transformer is installed at the power output terminal of generator 3 to collect the real-time load current output by generator 3 and transmit the signal to the controller.

[0039] Regulating power generation: After receiving the load current signal monitored by the current transformer and the speed signal collected by the speed sensor 4, the microprocessor in the controller analyzes the current load demand according to the preset control logic and sends an adjustment command to the throttle motor 21. The throttle motor 21 precisely adjusts the throttle opening of the diesel engine 2 according to the command, thereby controlling the output power of the diesel engine 2, so that the speed of the generator 3 is adjusted accordingly to adapt to the load demand and ensure a stable and continuous power supply to the load.

[0040] Equipment Status Monitoring: During the operation of the power generation unit, the water temperature sensor monitors the temperature of diesel engine 2 in real time, and the oil pressure sensor monitors the oil pressure of diesel engine 2. These signals are also transmitted to the controller. If abnormal temperature or pressure conditions occur, the controller will take corresponding measures, such as adjusting the engine operating status or issuing an alarm, to ensure the normal operation of the power generation unit.

[0041] System stability assurance: The cooling water tank 7 is installed on one side of the diesel engine 2, continuously dissipating heat for the diesel engine 2 and ensuring that the diesel engine 2 always operates within a suitable temperature range; the shock-absorbing pads 8 installed at the bottom of the diesel engine bracket and generator bracket effectively absorb operating vibrations, reducing the vibration transmitted to the base 1 and transport vehicle, and improving the operational stability of the equipment; the enclosure 9 encloses the generator unit, not only protecting the internal components from external debris, dust, and moisture, but also the sound-absorbing cotton layer on its inner wall reduces the interference of operating noise to the outside world; the muffler connected to the exhaust system of the diesel engine 2 further reduces the noise generated by the exhaust. In addition, the heat dissipation louvers 92 installed at the air inlet and outlet ensure good air circulation inside the enclosure 9, achieving effective heat dissipation.

[0042] Downtime Upon receiving a shutdown command: When the electrical equipment on the transport vehicle no longer requires power from the generator, the operator sends a shutdown signal to the controller of the generator through the control terminal.

[0043] Reduce engine speed: After receiving the shutdown signal, the controller first controls the throttle motor 21 to adjust the speed of diesel engine 2 to idle speed; Engine shutdown: Subsequently, the controller controls the shutdown solenoid valve 23 to cut off the fuel supply to the diesel engine 2, causing the diesel engine 2 to stop and the generator to stop generating power.

[0044] Maintenance and overhaul phase Routine inspection: Operators regularly check whether the connections of each part of the generator are secure, check for any signs of damage to the internal components of the housing 9, check the water level and oil level in the cooling water tank 7, and check the operating parameters, fault information and historical data through the controller's data storage module to determine whether the generator is working properly.

[0045] Maintenance and Repair: If the generator malfunctions, maintenance personnel can enter the interior for inspection and repair through the easily accessible access doors 91 located on the top and sides of the housing 9. Based on the fault information recorded by the data storage module and the on-site inspection results, the cause of the fault can be determined and repairs performed. When maintenance is required on critical components such as the diesel engine 2, the access doors 91 can be easily opened for maintenance operations.

[0046] This power generation device not only meets the emergency power supply needs of vehicles, but also has the advantages of flexible installation, stable operation, good noise control, and easy maintenance.

[0047] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. An emergency DC power generation device for a transport vehicle, characterized in that: include: Base (1), said base (1) is used for mounting on a transport vehicle; The diesel engine (2) is mounted on the base (1) via a diesel engine bracket. The diesel engine (2) is equipped with a throttle motor (21), a starter motor (22) and a shutdown solenoid valve (23). The generator (3) is mounted on the base (1) by a generator bracket. The input shaft of the generator (3) is connected to the flywheel disc (24) of the diesel engine (2) by a flexible coupling (6) to form a power generation unit independent of the engine compartment of the transport vehicle. A current transformer is installed at the power output terminal of the generator (3) to collect the real-time load current output by the generator (3); A speed sensor (4) is disposed at the flywheel disc (24) of the diesel engine (2) to collect the real-time speed signal of the diesel engine (2); and The controller is communicatively connected to the throttle motor (21), the starter motor (22), the shut-off solenoid valve (23), the current transformer, and the speed sensor (4).

2. The emergency DC power generation device for transport vehicles according to claim 1, characterized in that: It also includes a flywheel housing (5), which is rigidly connected to the diesel engine (2) and the generator (3) by a positioning pin, and the speed sensor (4) is installed on the flywheel housing (5).

3. The emergency DC power generation device for transport vehicles according to claim 1, characterized in that: The flexible coupling (6) is a gear-type flexible coupling (6).

4. The emergency DC power generation device for transport vehicles according to claim 1, characterized in that: It also includes a cooling water tank (7), which is installed on one side of the diesel engine (2) to cool the diesel engine (2).

5. The emergency DC power generation device for transport vehicles according to claim 1, characterized in that: Both the diesel engine bracket and the generator bracket are equipped with shock-absorbing pads (8) at their bottoms.

6. The emergency DC power generation device for transport vehicles according to claim 1, characterized in that: It also includes a housing (9), which is mounted on the base (1) and encloses the diesel engine (2) and the generator (3) inside.

7. The emergency DC power generation device for transport vehicles according to claim 6, characterized in that: The top and sides of the housing (9) are provided with movable doors (91) for easy maintenance. One end of the housing (9) is provided with an air inlet and the other end is provided with an air outlet. Both the air inlet and the air outlet are provided with heat dissipation louvers.

8. The emergency DC power generation device for transport vehicles according to claim 7, characterized in that: The inner wall of the housing (9) is provided with a sound-absorbing cotton layer, and the exhaust system of the diesel engine (2) is connected to a muffler.

9. The emergency DC power generation device for transport vehicles according to claim 1, characterized in that: The throttle motor (21) is a stepper motor.

10. The emergency DC power generation device for transport vehicles according to claim 1, characterized in that: The controller integrates a microprocessor and a data storage module. The microprocessor is used to receive and analyze the load current signal monitored by the current transformer and the speed signal collected by the speed sensor (4), and send adjustment commands to the throttle motor (21) according to the preset control logic to control the output power of the diesel engine (2). At the same time, the automatic start and stop control of the diesel engine (2) is realized through the start motor (22) and the shut-off solenoid valve (23). The data storage module is used to record the operating parameters, fault information and historical data of the power generation device.

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