A hybrid power loader power system and loader

Abstract

The utility model relates to hybrid power loader technical field discloses a kind of hybrid power loader power system and loader, including all-in-one controller, power battery, range extender and drive motor, the power battery and range extender are arranged in parallel and are connected all-in-one controller by wiring harness, the all-in-one controller is connected drive motor by wiring harness, to realize range extender direct power supply to drive motor;The utility model adopts big range extension, range extender direct power supply to drive motor, not through power battery transfer, effectively improve energy conversion efficiency, hybrid power loader whole vehicle can not be equipped with external charging port, need not external charging, high-power range extender follows energy following strategy power generation, range extender engine and generator mechanical connection, the performance of both highly coupled, power generation efficiency is high, can guarantee in full operating cycle, power battery SOC is always stable, no power loss concern;Greatly expand airport scene, reduce customer machine cost.

Description

Technical Field

[0001] This utility model relates to the field of hybrid loader technology, and in particular to a hybrid loader power system and loader. Background Technology

[0002] Hybrid loaders boast advantages such as low emissions, energy efficiency, and high energy conversion efficiency, making them highly promising for widespread adoption. Among them, the range extender + battery loader achieves a combination of gasoline and electric power. The battery acts as a "peak shaving and valley filling" mechanism, ensuring the engine continuously operates near its high-efficiency range, thus saving energy and reducing consumption. Powered by the range extender, the loader's range is effectively increased, compensating for the insufficient range of traditional electric loaders and significantly enhancing the customer experience. The battery eliminates the need for external charging, expanding the application scenarios of hybrid loaders.

[0003] Currently, hybrid loaders on the market all adopt a technology route of large-capacity batteries and small-power range extenders. The batteries have external charging ports, and the entire vehicle's power system is mainly powered by the power battery. Charging piles are required to charge the batteries, which limits the operating scenarios and increases the cost of using the vehicle. In addition, the power system layout of hybrid loaders on the market does not divide functional areas and does not effectively isolate the engine heat source. Under continuous high-intensity operation and high-temperature conditions in summer, the engine, radiator, controller and other components are all in a high-temperature environment, which affects the power and lifespan of the equipment and also increases the workload of the radiator, affecting the overall operating performance of the machine. Utility Model Content

[0004] To address the shortcomings of existing technologies, the purpose of this utility model is to provide a hybrid power system and loader for a hybrid loader. This system directly supplies power to the drive motor via a range extender, eliminating the need for a power battery as an intermediary, thus improving energy conversion efficiency. It ensures that the power battery's state of charge (SOC) remains stable throughout the entire operating cycle, eliminating concerns about power depletion. This significantly expands the application scenarios and reduces customer operating costs. Furthermore, the three functional areas on the top of the rear frame are isolated from each other by a compartment structure, effectively isolating the heat source from the range extender area, reducing the impact of heat overflow on other functional areas, improving the operating temperature conditions of electrical equipment, and increasing equipment efficiency.

[0005] To achieve the above objectives, this utility model is implemented through the following technical solution: In a first aspect, a hybrid loader power system includes an all-in-one controller, a power battery, a range extender, and a drive motor. The power battery and the range extender are arranged in parallel and connected to the all-in-one controller via a wiring harness. The all-in-one controller is connected to the drive motor via a wiring harness to enable the range extender to directly supply power to the drive motor.

[0006] As a further implementation, the range extender has a power greater than 150kW.

[0007] As a further implementation, the power battery and the all-in-one controller are connected to the high-voltage box via a wiring harness.

[0008] As a further implementation, the range extender includes a coupled engine and a generator, with the range extender and the generator controller connected via a wiring harness.

[0009] As a further implementation, the drive motor includes a working motor and a walking motor connected in parallel.

[0010] Secondly, a loader, which is a hybrid loader, is equipped with a hybrid loader power system as described above.

[0011] As a further implementation, the hybrid loader includes a rear frame located at the rear of the cab. The top of the rear frame has different sections from front to back, which are separated by a compartment structure. These sections are a high-voltage control area, a range extender area, and a radiator area. The heat source of the range extender area is isolated by the compartment structure. The bottom of the rear frame has a power battery area for arranging the power battery.

[0012] As a further implementation, in the high-voltage control area, a box-type structure is used to arrange the high-voltage box, battery thermal management, multi-function control and generator controller in layers from top to bottom; the range extender area is arranged with the range extender, and the heat dissipation area is arranged with the heat dissipation radiator.

[0013] As a further implementation, the compartment structure is provided with holes for the corresponding wire harness to pass through; the main body of the compartment structure is a plate-like structure.

[0014] As a further implementation, the radiator adopts a dual-water circulation configuration.

[0015] The beneficial effects of this utility model are as follows: 1. This utility model adopts a large range extender, which differs from the traditional series range extender scheme of "range extender → battery → motor". It directly supplies power to the drive motor through the range extender without going through the power battery, which effectively improves the energy conversion efficiency. The hybrid loader does not need to be equipped with an external charging port and does not require external charging. The high-power range extender generates electricity according to the energy following strategy. The range extender engine and generator are mechanically connected, and their performance is highly coupled, resulting in high power generation efficiency. It can ensure that the power battery SOC remains stable throughout the entire working cycle without any concerns about power depletion. The application scenarios are greatly expanded, and the operating costs for customers are reduced.

[0016] 2. The three functional areas on the top of the rear frame of this utility model are isolated from each other by a partition structure, which can effectively isolate the heat source of the range extender area, reduce the impact of heat overflow on other functional areas, improve the operating temperature conditions of electrical equipment, and improve the working efficiency of the equipment. Attached Figure Description

[0017] The accompanying drawings, which form part of this specification, are used to provide a further understanding of this utility model. The illustrative embodiments of this utility model and their descriptions are used to explain this utility model and do not constitute an improper limitation of this utility model.

[0018] Figure 1 This is a schematic diagram of the hybrid power system of the loader in this embodiment of the present invention; Figure 2 This is a partial structural diagram of the hybrid loader in an embodiment of this utility model; Figure 3 This is a schematic diagram of the energy efficiency zones of the generator and engine in an embodiment of this utility model; Figure 4 This is a schematic diagram of the peak shaving and valley filling principle of the power battery in this embodiment of the utility model; Figure 5 This is a schematic diagram of the arrangement of the box structure in an embodiment of this utility model.

[0019] The diagram exaggerates the spacing or dimensions between parts to show their positions; the diagram is for illustrative purposes only.

[0020] The components include: 1. rear frame, 2. engine cover, 3. power battery, 4. compartment, 5. box-type structure, and 6. shock absorber. Detailed Implementation

[0021] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0022] Example 1 In a typical embodiment of this utility model, refer to Figure 1 As shown, a hybrid loader power system includes an all-in-one controller, a power battery, a range extender, and a drive motor. The power battery and the range extender are arranged in parallel and connected to the all-in-one controller via a wiring harness. The all-in-one controller is connected to the drive motor via a wiring harness, so that the range extender can directly supply power to the drive motor.

[0023] like Figure 1 As shown, the power battery and the all-in-one controller are connected to the high-voltage box via a wiring harness. The range extender includes a coupled engine and generator, and the range extender and the all-in-one controller are connected to the generator controller via a wiring harness.

[0024] The drive motors include a working motor and a travel motor connected in parallel. The multi-functional controller connects the working motor and the travel motor via wiring harnesses. The working motor provides power to the boom and other actuators of the hybrid loader, driving the hydraulic pump to perform lifting, tipping, and other actions, enabling the hybrid loader to operate. The travel motor provides power to the traveling components of the hybrid loader, driving the front and rear axles, enabling the hybrid loader to move. Both motors share a single cooling system with an inlet water temperature ≤65 ℃.

[0025] It is understood that the working motor and the traveling motor are existing technologies, the connection between the working motor and the actuator is existing technology, and the connection between the traveling motor and the traveling assembly is existing technology.

[0026] This embodiment adopts a large range extender with a power of more than 150kW. The engine and generator are highly coupled and operate continuously near the high-efficiency range. The range extender directly supplies power to the drive motor without going through the power battery, which effectively improves the energy conversion efficiency. Compared with the existing small-range, large-battery hybrid loaders, the energy transfer is more efficient. According to real vehicle tests, compared with the same type of fuel vehicle, the fuel saving rate under comprehensive working conditions exceeds 30%.

[0027] Furthermore, this embodiment differs from the traditional series range extender scheme ("range extender → battery → motor") in that it directly supplies power to the drive motor through the range extender, without going through the power battery as an intermediary. The hybrid loader does not need an external charging port or external charging. The high-power range extender generates power according to the energy following strategy. The range extender engine and generator are mechanically connected, and their performance is highly coupled, resulting in high power generation efficiency. This ensures that the power battery SOC remains stable throughout the entire working cycle, eliminating concerns about power depletion. The application scenarios are greatly expanded, reducing the customer's operating costs.

[0028] The power battery can be a lithium titanate battery. A high-power range extender combined with a lithium titanate battery provides power to the entire vehicle. The technical route topology is as follows: Figure 1 As shown.

[0029] The range extender directly supplies power to the drive motor. Under certain operating conditions, such as continuous heavy-load and high-intensity work, it can be supplemented by the power battery. Under other operating conditions, excess power generated by the range extender can be stored in the power battery. The power battery plays a role in "peak shaving and valley filling," ensuring that the engine and generator always operate near their high-efficiency range, saving energy and reducing consumption, and greatly improving the overall vehicle economy.

[0030] Explanation of the principle: The range extender's generator employs a power-following strategy, matching its power output based on the current power demand of the working / travel motors, the battery charge level, and the engine's power MAP. The range extender's engine and generator are highly coupled in performance (within the same economic and efficient range), such as... Figure 3 As shown.

[0031] In theory, the range extender (engine and generator) operates continuously at the most economical and efficient point, with a constant speed and the lowest energy consumption; or the speed fluctuation is small, which can also reduce energy consumption; while large speed changes, such as sudden ups and downs, result in the highest energy consumption; however, the nature of loader loading operations determines that the range extender cannot operate at a constant speed, as high-speed power generation consumes more fuel, and low-speed power generation does not meet the usage requirements.

[0032] To save energy and fuel while meeting operational needs, the speed variation of the range extender (engine and generator) needs to be as small as possible; the range extender achieves the best energy-saving effect when operating within the economic and efficient operating range.

[0033] The range extender's power-following generation strategy involves the range extender controller identifying the vehicle's electricity demand and matching the generation power accordingly. To ensure that the generation operation does not exceed the economically efficient range, the generation power is limited, with adjustments made for any discrepancies. When the electricity demand is high, and the range extender's power increases to the maximum generation capacity within the economically efficient range but still falls short of demand, the shortfall is supplemented by the power battery. Conversely, when the electricity demand is low, and the range extender's power decreases to the minimum generation capacity within the economically efficient range but still exceeds demand, the excess power is replenished by the power battery. This overall approach ensures that the range extender's operating range does not exceed or fall outside the economically efficient range, thereby achieving energy-saving effects.

[0034] Function of the device: The generator controller has two functions. First, it receives the vehicle control signal and controls the power output of the range extender generator. Second, it transmits the DC power generated by the generator outward in two paths: 1) through the multi-function controller to the work / walk motor; 2) through the high-voltage box to the power battery.

[0035] The all-in-one controller integrates a working motor controller module, a walking motor controller module, and a DC / DC low-voltage power supply module. It has two main functions: First, the motor controller module inverts high-voltage DC power into AC power and outputs it to the working motor and walking motor. Second, the DC / DC power supply module converts high-voltage DC power into 24V low-voltage DC power and supplies power to the low-voltage electrical components of the vehicle through the battery.

[0036] The high-voltage box is used to distribute and manage the charging and discharging of the power battery. During discharging, it transmits the DC power generated by the power battery to the multi-function controller, which then supplies it to the working and walking motor to power the battery. During charging, it transmits the DC power generated by the generator, controlled by the generator, to the power battery to charge it.

[0037] In contrast, the technology of using large-capacity batteries and low-power range extenders is prone to battery depletion during continuous heavy-load and high-intensity operation. Once the battery is depleted, its power output will be limited, and the range extender will need to be recharged to restore normal power, which will affect the efficiency of operation.

[0038] Example 2 In a typical embodiment of this utility model, refer to Figures 1-5 As shown, a loader is a hybrid loader, and the hybrid loader power system described in Embodiment 1 is arranged on the hybrid loader.

[0039] The hybrid loader includes a rear frame 1, which is located at the rear of the cab. The rear end of the rear frame is connected to an openable hood 2. The top of the rear frame 1 has different sections from front to back, which are separated by a compartment 4 structure. These sections are a high-voltage control area, a range extender area, and a radiator area. The bottom of the frame has a power battery area for housing the power battery 3.

[0040] The power system is arranged in different functional modules. In the high-voltage control area, the high-voltage box, battery thermal management unit, multi-function control and generator controller are arranged in layers from top to bottom; the range extender area is equipped with range extenders, and the heat dissipation area is equipped with radiators.

[0041] The function of battery thermal management is to cool the battery. Water cooling: The battery thermal management unit cools the battery with water. The cooling water enters the water circuit inside the battery pack through the battery inlet via the external heat dissipation water pipe. After absorbing the heat from the battery, it returns to the battery thermal management unit through the battery outlet via the external heat dissipation pipe, forming a loop. The heat generated by the battery charging and discharging will cause the battery to reach a high temperature, which will lead to a decrease in battery efficiency. The battery thermal management unit cools the battery, so that the battery always operates within a reasonable temperature range.

[0042] The high-voltage control area adopts a box-type structure 5 to improve the waterproof and dustproof performance of the electrical control equipment; the bottom support of the box-type structure 5 is equipped with 6 sets of shock absorbers 6 to reduce the impact on electrical equipment during operation, improve stability and reliability, and improve the overall NVH of the machine.

[0043] In the range extender area, the engine and generator are mechanically connected, and their performance is highly coupled. Four sets of shock absorbers are arranged at the bottom of the range extender to reduce the impact of operating conditions on the engine and improve the overall vehicle stability.

[0044] In the radiator area: The radiator is located at the rear of the vehicle and uses 8 sets of electric fans, integrating engine cooling, hydraulic cooling, and motor & controller cooling. It features dual water circulation and independent transmission oil-water plate heat exchange; it also has automatic and manual dust removal modes for more reliable heat dissipation.

[0045] One cooling circuit: Generator cooling core outlet → Water pump → Multi-function controller → Working motor → Generator → Generator cooling core inlet.

[0046] Two cooling circuits: water outlet of the walking motor cooling core → water pump → generator controller → walking motor → water inlet of the walking motor cooling core.

[0047] A transmission oil heat exchanger is connected in parallel between the walking motor and the core water inlet via a T-junction for cooling the transmission oil of the gearbox.

[0048] Automatic dust removal: The motor radiator is equipped with 8 brushless electronic fans. The radiator controller has a built-in program that automatically reverses the electronic fans for a certain period of time according to the preset dust removal cycle. The reverse rotation of the fans blows away the dust accumulated on the radiator. Manual dust removal: The settings interface has a manual dust removal icon. Clicking it will activate manual dust removal. Manual dust removal has two functions: forward strong blowing and reverse dust removal. Click on the dust removal mode and the radiator will start dust removal. It will automatically stop when the preset dust removal time is reached.

[0049] The power battery is located in the power battery area. The power battery uses three sets of high-rate batteries, which do not require external charging. It is located in the original rear fuel tank position of traditional fuel vehicles. The battery, high-voltage wiring harness and cooling pipes are encapsulated in a box frame to improve space utilization and enhance waterproof, dustproof and corrosion resistance.

[0050] The rear frame features two sets of compartment 4 structures at the top, which isolate the high-voltage controller area from the range extender area, and the range extender area from the radiator area. The main body of the compartment structure is plate-like, and its dimensions are adapted to the cross-sectional dimensions of the corresponding positions on the engine hood. When the engine hood is closed, a gap is formed between the compartment 4 structure and the engine hood, and heat insulation cotton is installed in the gap, creating a relatively enclosed space for the three functional areas. This effectively divides the powertrain area into three functional zones, achieving heat source isolation.

[0051] For heat dissipation in functional areas: the high-pressure control area dissipates heat through two water channels via the radiator, and the first set of partitions blocks the heat source input to the range extender area; the range extender area dissipates heat through the radiator; the radiator area blocks the heat source input to the range extender area through the second set of partitions, thus improving the temperature conditions in the radiator area.

[0052] Understandably, the compartment structure has holes for the corresponding wire harnesses to pass through.

[0053] In this embodiment, the three functional areas on the top of the rear frame are isolated from each other by a partition structure, which can effectively isolate the heat source of the range extender area, reduce the impact of heat overflow on other functional areas, improve the operating temperature conditions of electrical equipment, and improve the working efficiency of the equipment.

[0054] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A hybrid power loader power system, characterized in that, It includes an all-in-one controller, a power battery, a range extender, and a drive motor. The power battery and the range extender are arranged in parallel and connected to the all-in-one controller through a wiring harness. The all-in-one controller is connected to the drive motor through a wiring harness, so that the range extender can directly supply power to the drive motor.

2. The hybrid power system for a loader according to claim 1, characterized in that, The range extender has a power greater than 150kW.

3. The hybrid power system for a loader according to claim 1, characterized in that, The power battery and the all-in-one controller are connected to the high-voltage box via a wiring harness.

4. The hybrid power system for a loader according to claim 1, characterized in that, The range extender includes a coupled engine and a generator, and the range extender and the all-in-one controller are connected via a wiring harness to the generator controller.

5. The hybrid power system for a loader according to claim 1, characterized in that, The drive motor includes a working motor and a traveling motor connected in parallel.

6. A loader, characterized in that, The loader is a hybrid loader, and the hybrid loader is equipped with a hybrid loader power system as described in any one of claims 1-5.

7. A loader according to claim 6, characterized in that, The hybrid loader includes a rear frame located at the rear of the cab. The top of the rear frame has different sections from front to back, which are separated by a compartment structure. These sections are a high-voltage control area, a range extender area, and a radiator area. The heat source of the range extender area is isolated by the compartment structure. The bottom of the rear frame has a power battery area for housing the power battery.

8. A loader according to claim 7, characterized in that, In the high-voltage control area, a box-type structure is used to arrange the high-voltage box, battery thermal management, multi-function control and generator controller from top to bottom; the range extender area is used to arrange the range extender and the heat dissipation area is used to arrange the heat dissipation radiator.

9. A loader according to claim 8, characterized in that, The compartment structure has holes for the corresponding wire harnesses to pass through; the main body of the compartment structure is a plate-like structure.

10. A loader according to claim 9, characterized in that, The radiator adopts a dual-water circulation system.

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