Generator controller, generator control system and extended-range electric vehicle

Abstract

The present application relates to the technical field of new energy vehicles, and specifically relates to a generator controller, a generator control system and an extended-range electric vehicle. A control module, a generator input / output module, a generator power module and an accessory power module are disposed in the generator controller, such that the operations of an air compressor, a compressor and a heater can be controlled. Compared with independent control in the related art, the waste of electric energy caused by long-distance transmission is reduced, the number of control assemblies and rectifier components is reduced, the reliability of a vehicle is improved, and the service life of the vehicle is prolonged.

Description

A generator controller, a generator control system, and a range-extended electric vehicle

[0001] Cross-reference to related applications

[0002] This application claims priority to Chinese Patent Application No. 2025104650736, filed on April 14, 2025, entitled “A Generator Controller, Generator Control System and Range Extender Electric Vehicle”, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to the field of new energy vehicle technology, specifically to a generator controller, a generator control system, and a range-extended electric vehicle. Background Technology

[0004] Range-extended electric vehicles (REEVs) are based on pure electric vehicles, with the addition of an internal combustion engine to charge the battery or directly drive the electric motor, thus increasing the driving range and overcoming the short driving range of pure electric vehicles. When the battery is fully charged, the battery drives the electric motor to provide the vehicle's driving power, and the engine does not participate in the operation. When the battery charge is depleted to a certain level, the engine starts, the generator generates electricity to drive the electric motor, and the excess power charges the battery. When the battery charge recovers to a set value, the engine shuts off, and the battery drives the electric motor.

[0005] The engine compartment contains an increasing number of electrical components, such as compressors, electronic heaters, and air compressors. Currently, these components are independently controlled, leading to energy waste due to energy conversion issues. Summary of the Invention

[0006] In view of this, this application provides a generator controller, a generator control system, and a range-extended electric vehicle to solve the problem of energy waste caused by energy conversion during the control process of electrical devices.

[0007] In a first aspect, this application provides a generator controller for use in electric vehicles, including a control module, a generator input / output module, a generator power module, and an accessory power module; wherein the control module is used to acquire input commands from the vehicle controller; parse the input commands to obtain the current operating mode and power demand of the electric vehicle; according to the current operating mode and power demand of the electric vehicle, send working signals to the modules in the generator controller that need to work according to preset control logic, and control at least one of the engine and generator to work; the generator input / output module is connected to the generator power module, battery, and accessory power module to provide a current transfer path; the generator power module is also connected to the control module. The module is connected to the control module and, upon receiving a first operating signal from the control module, rectifies the AC power generated by the generator and supplies the rectified DC power to the battery via the generator input / output module; or, upon receiving a first operating signal from the control module, supplies the AC power generated by the generator to the accessory power module via the generator input / output module. The accessory power module is also connected to the control module and, upon receiving a second operating signal from the control module, supplies the AC power generated by the generator to at least one of the compressor and / or accessories via the generator input / output module; and / or inverts the electrical energy in the battery and supplies the inverted AC power to at least one of the compressor and / or accessories via the generator input / output module.

[0008] The generator controller provided in this application essentially realizes the overall functions of the generator assembly, PTC (heater) assembly, compressor assembly, and AC (compressor) assembly in the related technologies. Specifically, the control module 51 and generator power module 53 of the generator controller in this application can realize the functions of the generator assembly in the related technologies; the control module 51 and accessory power module 54 of the generator controller in this application can realize the functions of the PTC assembly, compressor assembly, and AC assembly in the related technologies.

[0009] When multiple assemblies are used for control in related technologies, the standby power is high due to the large number of assemblies; each assembly requires battery power, the total length of the line between the battery and the assembly is large, and the power loss is large; moreover, the conversion efficiency is low because the total number of energy conversion modules (such as rectifier components) in the generator assembly, PTC assembly, compressor assembly and AC assembly is large.

[0010] In electric vehicles, the AC, compressor, and generator are all located on the engine, while the PTC is located in the front engine compartment. The generator controller of this application integrates the generator assembly, PTC assembly, compressor assembly, and AC assembly in related technologies. Therefore, the generator controller of this application uses a centralized node to connect to the AC, compressor, generator, and PTC, which can reduce the total length of the wiring between the battery and the assembly and reduce the loss of electrical energy in the wiring.

[0011] Furthermore, in the generator control of this application, when the generator and accessories work simultaneously, the generator power module and the accessory power module can be directly powered by AC without rectification and inversion, reducing the number of energy conversions and improving conversion efficiency. In addition, the control part in this application is completed independently by the control module, so a uniformly calibrated program control can be built into the control module, which can ensure that the accessories can output power continuously and stably, thereby reducing the loss of switching transistors and making the control more precise.

[0012] In summary, compared with independent control in related technologies, the generator controller provided in this application reduces energy waste caused by long-distance transmission, reduces the number of control assemblies and rectifier components, and improves vehicle reliability and service life.

[0013] In one alternative implementation, the electric vehicle is currently operating in any of the following modes: power generation mode, accessory mode, hybrid mode, or limp mode.

[0014] This allows the generator controller to meet the needs of most application scenarios of electric vehicles.

[0015] In one optional implementation, the control module is specifically configured to: when the electric vehicle is currently in power generation mode, calculate a first power generation power and a first compressor power consumption based on a first power demand; control the engine to start based on the first power generation power and control the engine to input the mechanical energy generated to the generator so that the generator generates alternating current; after the generator generates alternating current, send a first power generation mode operating signal to the generator power module and a second power generation mode operating signal to the accessory power module; after receiving the first power generation mode operating signal from the control module, the generator power module rectifies the alternating current generated by the generator and provides the rectified direct current corresponding to the first power generation power to the battery through the generator input / output module; after receiving the second power generation mode operating signal from the control module, the accessory power module provides the alternating current generated by the generator corresponding to the first compressor power consumption to the compressor through the generator input / output module.

[0016] In other words, in generator mode, the electrical energy generated by the generator is supplied to the battery and compressor. The electrical energy supplied to the battery needs to be rectified, that is, the AC power generated by the generator is first rectified to DC power, and then the DC power is supplied to the battery. The electrical energy supplied to the compressor does not need to be rectified, that is, the AC power generated by the generator is directly supplied to the compressor. This allows for direct AC power supply between the generator power module and the accessory power module in generator mode, reducing the number of energy conversions and improving conversion efficiency. At the same time, since a centralized node is used to connect the AC, compressor, generator and PTC, the total length of the line between the battery and the assembly can be reduced, reducing power loss in the line. Moreover, since the control part is completed independently by the control module, a uniformly calibrated program can be built into the control module to ensure continuous and stable power output of the accessory, thereby reducing switching transistor losses and making the control more precise.

[0017] In one optional implementation, the control module is specifically used to: when the electric vehicle is currently in the accessory mode, calculate the first accessory power consumption based on the second power demand, and send the first accessory mode working signal to the accessory power module; after receiving the first accessory mode working signal sent by the control module, the accessory power module inverts the electrical energy in the battery and inputs the inverted AC power to the accessory corresponding to the second power demand through the generator input / output module.

[0018] In other words, in accessory mode, the electrical energy in the battery is inverted and supplied to the accessory. As mentioned above, since the generator controller is equivalent to integrating the generator assembly, PTC assembly, compressor assembly and AC assembly in related technologies, the generator controller of this application adopts a centralized node connection to the AC, compressor, generator and PTC, which can reduce the total length of the line between the battery and the assembly and reduce the loss of electrical energy in the line. Moreover, since the control part is completed independently by the control module, a uniformly calibrated program control can be built into the control module to ensure that the accessory can provide continuous and stable power output, thereby reducing the loss of the switching transistor and making the control more precise.

[0019] In one optional implementation, the control module is specifically configured to: when the electric vehicle is currently operating in a hybrid mode, calculate the second power generation, the second compressor power consumption, and the second accessory power consumption based on the third power demand; control the engine to start based on the second power generation and control the engine to input the mechanical energy generated to the generator so that the generator generates AC power; after the generator generates AC power, send a first hybrid mode operating signal to the generator power module and a second hybrid mode operating signal to the accessory power module; after receiving the first hybrid mode operating signal from the control module, the generator power module rectifies the AC power generated by the generator and provides the rectified DC power corresponding to the second power generation to the battery through the generator input / output module; after receiving the second hybrid mode operating signal from the control module, the accessory power module provides the AC power generated by the generator corresponding to the second compressor power consumption to the compressor through the generator input / output module, and provides the AC power generated by the generator corresponding to the second accessory power consumption to the accessory corresponding to the third power demand through the generator input / output module.

[0020] In other words, in hybrid mode, the electrical energy generated by the generator is supplied to the battery, compressor, and accessories. The energy supplied to the battery requires rectification; that is, the AC power generated by the generator is first rectified to DC power, which is then supplied to the battery. However, the energy supplied to the compressor and accessories does not require rectification; the AC power generated by the generator is directly supplied to the compressor and accessories. This allows for direct AC power supply between the generator power module and the accessory power module in generator mode, reducing the number of energy conversions and improving conversion efficiency. Furthermore, the centralized node connection to the AC, compressor, generator, and PTC reduces the total length of the wiring between the battery and the assembly, minimizing power loss in the lines. Moreover, since the control section is independently controlled by a control module, a uniformly calibrated program can be built into the control module to ensure continuous and stable power output from the accessories, thereby reducing switching transistor losses and making control more precise.

[0021] In one optional implementation, the control module is configured to calculate a third power generation power based on a fourth power demand when the electric vehicle is currently in limp mode, control the engine to start based on the third power generation power and control the engine to input the mechanical energy generated by the engine to the generator so that the generator generates alternating current; after the generator generates alternating current, it sends a first limp mode operating signal to the generator power module; after receiving the first limp mode operating signal sent by the control module, the generator power module rectifies the alternating current generated by the generator and provides the rectified direct current to the battery through the generator input / output module.

[0022] In other words, in limp mode, the electricity generated by the generator is only supplied to the battery. This allows the generator to continue operating even if some modules (such as the power accessory module) fail, ensuring the user's emergency power needs are met. Furthermore, the centralized connection to the AC, compressor, generator, and PTC reduces the total length of the wiring between the battery and the assembly, minimizing power loss in the lines. Moreover, since the control section is handled independently by the control module, a uniformly calibrated program can be built into it, ensuring continuous and stable power output from the accessories, thereby reducing switching losses and making control more precise.

[0023] In one alternative implementation, the control module, generator input / output module, generator power module, and accessory power module are located in the same cavity.

[0024] This reduces energy waste caused by long-distance switching and decreases the number of control assemblies and rectifier components, thereby improving vehicle reliability and lifespan.

[0025] In one alternative implementation, the generator input / output module is also used to filter the current passing through the generator input / output module.

[0026] Therefore, the current can be peak-shaving and valley-filling can be performed through the generator input / output module to improve the stability of the current.

[0027] In one alternative implementation, the control module and the generator input / output module are located on the same PCB board.

[0028] This can reduce the manufacturing cost of the generator controller.

[0029] In one alternative implementation, the control module is further configured to control the generator power module and / or accessory power module to be in a wake-up state or a sleep state.

[0030] This allows the generator controller to control the generator power module and / or accessory power module to be in different states in different application scenarios, further reducing power loss.

[0031] Secondly, this application also provides a generator control system, including a vehicle controller and a generator controller as described in the first aspect; the vehicle controller is connected to the generator controller and is used to send input commands to the generator controller, wherein the input commands include the current operating mode of the electric vehicle and the power demand of the electric vehicle.

[0032] The generator control system provided in this application, by setting a control module, a generator input / output module, a generator power module and an accessory power module in the generator controller, can control the operation of the compressor, compressor and heater. Compared with the independent control in related technologies, the generator control system provided in this application reduces the energy waste caused by long-distance conversion, and reduces the number of control assemblies and rectifier components, thereby improving the reliability and service life of the vehicle.

[0033] In one alternative embodiment, the generator control system further includes an engine, a generator, a compressor, and accessories, wherein the engine is connected to the generator controller; the generator is connected to both the generator controller and the engine; the compressor is connected to the generator controller; and the accessories are connected to the generator controller.

[0034] Thus, under the control of the generator control system, the engine mixes oil and air for combustion, generating and outputting mechanical energy. The generator is directly connected to the engine, converting the mechanical energy input from the engine into electrical energy.

[0035] In one alternative implementation, the accessories include at least one of the following: a compressor and a heater.

[0036] This allows the compressor and / or heater to be directly controlled via the generator control system, reducing energy waste caused by long-distance conversion and reducing the number of control assemblies and rectifier components, thereby improving vehicle reliability and service life.

[0037] Thirdly, this application also provides a range-extended electric vehicle, including the generator control system of the second aspect.

[0038] The range-extended electric vehicle provided in this application can control the operation of the compressor, compressor and heater by setting a control module, a generator input and output module, a generator power module and an accessory power module in the generator controller. This reduces the energy waste caused by long-distance transmission and reduces the number of control assemblies and rectifier components, thereby improving the reliability and service life of the vehicle. Attached Figure Description

[0039] To more clearly illustrate the technical solutions in the specific embodiments of this application or the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0040] Figure 1 is a schematic diagram of the generator controller according to an embodiment of this application;

[0041] Figure 2 is a schematic diagram of the generator control system according to an embodiment of this application;

[0042] Figure 3 is a schematic diagram of the working principle of the generator control system according to an embodiment of this application;

[0043] The components include: 1. Engine; 2. Generator; 3. Vehicle controller; 4. Controller area network; 5. Generator controller; 51. Control module; 52. Generator input / output module; 53. Generator power module; 54. Accessory power module; 6. Compressor; 7. Air compressor; 8. Heater. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0045] According to an embodiment of this application, a generator controller is provided, wherein the generator controller is applied to an electric vehicle. Figure 1 is a schematic diagram of the structure of the generator controller according to an embodiment of this application. As shown in Figure 1, the generator controller 5 includes a control module 51, a generator input / output module 52, a generator power module 53, and an accessory power module 54.

[0046] Specifically, the control module 51 is used to acquire input commands from the vehicle controller 3; parse the input commands to obtain the current operating mode of the electric vehicle and the power requirements of the electric vehicle; according to the current operating mode of the electric vehicle and the power requirements of the electric vehicle, send working signals to the modules that need to work in the generator controller 5 according to the preset control logic, and control at least one of the engine 1 and generator 2 to work.

[0047] It should be noted that the power requirements of the electric vehicle can be determined by the control module 51 through a lookup table. For example, the control module 51 can preset multiple operating modes and their respective power requirements, including power generation requirements, compressor power requirements, and accessory power requirements.

[0048] In this embodiment, engine 1 mixes and burns fuel gas with air to generate and output mechanical energy. Generator 2 is directly connected to engine 1, and generator 2 converts the mechanical energy input from engine 1 into electrical energy.

[0049] Specifically, the generator input / output module 52 is connected to the generator power module 53, the battery, the generator 2, and the accessory power module 54 to provide a current transfer path. Specifically, the generator input / output module 52 is a T-shaped path connected to the generator power module 53, the accessory power module 54, the battery, and the generator 2, for supplying electrical energy generated by the generator to the battery, supplying electrical energy from the battery to at least one of the compressor 7 and accessories, or directly supplying electrical energy generated by the generator to at least one of the compressor 7 and accessories. For example, the accessories include at least one of the following: compressor 6 and heater 8.

[0050] In a first optional embodiment, the generator power module 53 is also connected to the control module 51. Upon receiving a first operating signal from the control module 51, the generator power module 53 rectifies the AC power generated by the generator 2 and supplies the rectified DC power to the battery via the generator input / output module 52. In other words, in this embodiment, the generator 2 converts the mechanical energy input from the engine 1 into AC power, the generator power module 53 rectifies the AC power, and the rectified AC power is then input to the battery via the generator input / output module 52.

[0051] This is because the electrical energy generated by generator 2 cannot be used by the battery, so rectification is required.

[0052] In a second optional embodiment, the generator power module 53 is also connected to the control module 51. Upon receiving a first operating signal from the control module 51, the generator power module 53 supplies the AC power generated by the generator 2 to the accessory power module 54 via the generator input / output module 2. Thus, when the generator and accessory operate simultaneously, the generator power module 53 and the accessory power module 54 can directly supply each other with AC power. This means the AC power generated by the generator 2 can be directly supplied to at least one of the compressor 7 and the accessory, eliminating the need for rectification and inversion, reducing the number of energy conversions, and improving conversion efficiency.

[0053] In a third optional embodiment, the generator power module 53 is also connected to the control module 51. After receiving the first working signal sent by the control module 51, the generator power module 53 rectifies the AC power generated by the generator 2, provides the rectified DC power to the battery through the generator input / output module 52, and directly provides the AC power generated by the generator 2 to the accessory power module 54.

[0054] In other words, while rectifying the AC power generated by the generator 2 and supplying the rectified DC power to the battery through the generator input / output module 52, the generator power module 53 can also directly supply the AC power generated by the generator 2 to the accessory power module 54.

[0055] Corresponding to the first optional implementation of the generator power module 53, the accessory power module 54 is also connected to the control module 51 and is used to invert the electrical energy in the battery after receiving the second working signal sent by the control module 51, and supply the inverted AC power to at least one of the compressor 7 and accessories through the generator input / output module 52.

[0056] Corresponding to the second optional implementation of the generator power module 53, the accessory power module 54 is also connected to the control module 51 and is used to provide the AC power generated by the generator 2 to at least one of the compressor 7 and accessories via the generator input / output module 52 after receiving the second working signal sent by the control module 51. That is, in this embodiment, the operation of at least one of the compressor 7 and accessories is controlled by the accessory power module 54.

[0057] Similarly, when the generator and accessories work simultaneously, the generator power module 53 and the accessory power module 54 can be directly powered by AC. That is, the AC power generated by the generator 2 can be directly supplied to at least one of the compressor 7, compressor 6 and heater 8. This eliminates the need for rectification and inversion, reduces the number of energy conversions, and improves conversion efficiency.

[0058] Corresponding to the third optional implementation of the generator power module 53, the accessory power module 54 is also connected to the control module 51 and is used to provide the AC power generated by the generator 2 to at least one of the compressor 7 and accessories through the generator input / output module 52 after receiving the second working signal sent by the control module 51; at the same time, it inverts the electrical energy in the battery and supplies the AC power obtained after inversion to at least one of the compressor 7 and accessories through the generator input / output module 52.

[0059] Therefore, in this embodiment, the control module 51 controls the generator input / output module 52, generator power module 53, and accessory power module 54 to work according to the preset operating mode. The control module 51, generator power module 53, and accessory power module 54 then control the generator 2, compressor 6, air compressor 7, and heater 8 to work.

[0060] In an optional implementation, the generator input / output module 52 is also used to filter the current passing through it. This allows the generator input / output module to perform peak shaving and valley filling of the current, improving current stability.

[0061] In one alternative implementation, the control module 51 and the generator input / output module 52 are located on the same PCB board. This can reduce the manufacturing cost of the generator controller 5.

[0062] The generator controller provided in this embodiment essentially realizes the overall functions of the generator assembly, PTC (heater) assembly, compressor assembly, and AC (compressor) assembly in related technologies. Specifically, the control module 51 and generator power module 53 of the generator controller in this embodiment can realize the functions of the generator assembly in related technologies; the control module 51 and accessory power module 54 of the generator controller in this embodiment can realize the functions of the PTC assembly, compressor assembly, and AC assembly in related technologies.

[0063] When multiple assemblies are used for control in related technologies, the standby power is high due to the large number of assemblies; each assembly requires battery power, the total length of the line between the battery and the assembly is large, and the power loss is large; moreover, the conversion efficiency is low because the total number of energy conversion modules in the generator assembly, PTC assembly, compressor assembly and AC assembly is large.

[0064] In electric vehicles, the AC, compressor, and generator are all located on the engine, while the PTC is located in the front engine compartment. In this embodiment, the generator controller integrates the generator assembly, PTC assembly, compressor assembly, and AC assembly from related technologies. Therefore, the generator controller in this embodiment uses a centralized node to connect to the AC, compressor, generator, and PTC, which can reduce the total length of the wiring between the battery and the assembly and reduce the loss of electrical energy in the wiring.

[0065] Furthermore, in the generator control of this embodiment, when the generator and accessories work simultaneously, the generator power module 53 and the accessory power module 54 can directly use AC power for supply without rectification and inversion, reducing the number of energy conversions and improving conversion efficiency. In addition, the control part in this embodiment is independently completed by the control module, so a uniformly calibrated program control can be built into the control module, ensuring continuous and stable power output from the accessories, thereby reducing switching transistor losses and making the control more precise.

[0066] In summary, compared with independent control in related technologies, the generator controller provided in this embodiment reduces energy waste caused by long-distance transmission, and reduces the number of control assemblies and rectifier components, thereby improving the reliability and service life of the vehicle.

[0067] In this embodiment, the electric vehicle is currently operating in any of the following modes: generator mode, accessory mode, hybrid mode, and limp mode. The operating principles of the generator controller 5 in generator mode, accessory mode, hybrid mode, and limp mode are explained below.

[0068] Power generation mode:

[0069] When the electric vehicle is currently in the power generation mode, the control module 51 is specifically used to: calculate the first power generation power and the first compressor power consumption based on the first power demand; control the engine 1 to start based on the first power generation power and control the engine 1 to input the mechanical energy generated to the generator 2 so that the generator 2 generates AC power; after the generator 2 generates AC power, send the first power generation mode working signal to the generator power module 53 and send the second power generation mode working signal to the auxiliary power module 54.

[0070] After receiving the first power generation mode working signal sent by the control module 51, the generator power module 53 rectifies the AC power generated by the generator 2 and provides the rectified DC power corresponding to the first power generation to the battery through the generator input / output module 52.

[0071] After receiving the second power generation mode working signal sent by the control module 51, the power module 54 provides the AC power generated by the generator corresponding to the power consumption of the first compressor to the compressor 7 through the generator input / output module 52.

[0072] In other words, when the electric vehicle is currently in the power generation mode, the generator controller 5 works and the control module 51 calculates the first power generation power and the power consumption of the first compressor 7, starts the generator 2 to generate electricity, controls the engine 1 to start and input mechanical energy to the generator 2, the generator 2 generates alternating current, and provides the alternating current generated by the generator 2, corresponding to the power consumption of the first compressor, to the compressor 7 through the accessory power module 54 and the generator input / output module 52 to provide air intake for the engine 1; the generator power module 53 rectifies the alternating current generated by the generator 2, and provides the rectified direct current corresponding to the first power generation power to the battery through the generator input / output module 52.

[0073] In this embodiment, in power generation mode, the electrical energy generated by the generator is supplied to the battery and the compressor. The electrical energy supplied to the battery needs to be rectified, that is, the AC power generated by the generator is first rectified to obtain DC power, and then the DC power is supplied to the battery. However, the electrical energy supplied to the compressor does not need to be rectified, that is, the AC power generated by the generator is directly supplied to the compressor. Thus, in power generation mode, AC power can be directly used between the generator power module and the accessory power module, reducing the number of energy conversions and improving the conversion efficiency.

[0074] For example, when the user accelerates the vehicle and no accessories (such as air conditioning) are turned on, the vehicle controller 3 determines that the electric vehicle is currently in the power generation mode; or when the vehicle has a low battery level and no accessories are turned on, the vehicle controller 3 determines that the electric vehicle is currently in the power generation mode.

[0075] Attachment format:

[0076] When the electric vehicle is currently in the accessory mode, the control module 51 is specifically used to: calculate the first accessory power consumption based on the second power demand, and send the first accessory mode working signal to the accessory power module 54.

[0077] After receiving the first accessory mode working signal sent by the control module 51, the accessory power module 54 inverts the electrical energy in the battery and inputs the inverted AC power to the accessory corresponding to the second power requirement through the generator input / output module 52.

[0078] For example, the accessories include at least one of the following: compressor 6, heater 8.

[0079] For example, when the electric vehicle is currently in accessory mode, the generator controller 5 operates and the control module 51 calculates the power consumption of the compressor 6. The battery provides power, which is then input to the compressor 6 via the accessory power module 54 and the generator input / output module 52, thereby starting the compressor 6.

[0080] When the electric vehicle is currently in the accessory mode, the generator controller 5 works and the control module 51 calculates the power consumption of the heater 8. The battery provides power, and the power is input to the heater 8 through the accessory power module 54 and the generator input / output module 52, thereby starting the heater 8.

[0081] In this embodiment, the electrical energy in the battery is inverted and provided to the accessory in the accessory mode. As mentioned above, since the generator controller is equivalent to integrating the generator assembly, PTC assembly, compressor assembly and AC assembly in related technologies, the generator controller of this application adopts a centralized node connection to the AC, compressor, generator and PTC, which can reduce the total length of the line between the battery and the assembly and reduce the loss of electrical energy in the line.

[0082] For example, when the user operates the vehicle with a high battery level and turns on the air conditioner, the vehicle controller 3 determines that the electric vehicle is currently in the accessory mode.

[0083] Mixed Mode:

[0084] When the electric vehicle is currently in a hybrid operating mode, the control module 51 is specifically used to: calculate the second power generation power, the second compressor power, and the second accessory power based on the third power demand; control the engine 1 to start based on the second power generation power and control the engine 1 to input the mechanical energy generated to the generator 2 so that the generator 2 generates AC power; after the generator 2 generates AC power, send the first hybrid mode working signal to the generator power module 53 and the second hybrid mode working signal to the accessory power module 54.

[0085] After receiving the first hybrid mode working signal sent by the control module 51, the generator power module 53 rectifies the AC power generated by the generator 2 and provides the rectified DC power corresponding to the second power generation to the battery through the generator input / output module 52.

[0086] After receiving the second hybrid mode operating signal sent by the control module 51, the accessory power module 54 supplies the AC power generated by the generator corresponding to the second compressor power consumption to the compressor 7 through the generator input / output module 52, and supplies the AC power generated by the generator corresponding to the second accessory power consumption to the accessory corresponding to the third power demand through the generator input / output module 52.

[0087] In other words, when the electric vehicle is currently operating in a hybrid mode, the control module 51 calculates the second power generation, the second compressor power consumption, and the second accessory power consumption (e.g., compressor power consumption, heater power consumption, or the total power consumption of the compressor and heater), starts the generator 2 to generate electricity, controls the engine 1 to start and input mechanical energy to the generator 2, the generator 2 generates AC power, the accessory power module 54 provides the AC power generated by the generator 2 corresponding to the second compressor power consumption to the compressor 7 through the generator input / output module 52 to provide air intake for the engine 1; it also provides the AC power generated by the generator 2 corresponding to the second accessory power consumption to the compressor 6 or heater 8, or simultaneously to the compressor 6 and heater 8 through the generator input / output module 52; the generator power module 53 rectifies the AC power generated by the generator 2 and provides the rectified DC power corresponding to the first power generation to the battery through the generator input / output module 52.

[0088] In this embodiment, in hybrid mode, the electrical energy generated by the generator is supplied to the battery, compressor, and accessories. The electrical energy supplied to the battery needs to be rectified, that is, the AC power generated by the generator is first rectified to DC power, and then the DC power is supplied to the battery. However, the electrical energy supplied to the compressor and accessories does not need to be rectified, that is, the AC power generated by the generator is directly supplied to the compressor and accessories. Thus, in power generation mode, AC power can be directly used between the generator power module and the accessory power module, reducing the number of energy conversions and improving conversion efficiency.

[0089] For example, when the battery does not need to be recharged, but the user accelerates the vehicle and opens an accessory, the vehicle controller 3 determines that the electric vehicle is currently in hybrid mode; or when the vehicle has a low battery level, the battery needs to be recharged and an accessory is opened, the vehicle controller 3 determines that the electric vehicle is currently in hybrid mode.

[0090] Limping mode:

[0091] When the electric vehicle is currently in limp mode, the control module 51 is used to calculate the third power generation power based on the fourth power demand, control the engine 1 to start and control the engine 1 to input the mechanical energy generated to the generator 2 so that the generator 2 generates AC power; after the generator 2 generates AC power, it sends the first limp mode working signal to the generator power module 53.

[0092] After receiving the first limp mode operating signal sent by the control module 51, the generator power module 53 rectifies the AC power generated by the generator 2 and supplies the rectified DC power to the battery through the generator input / output module 52.

[0093] In other words, when the electric vehicle is currently in limp mode, the accessory power module 54 is damaged and reports an error. In addition to reporting a fault code and entering limp mode, the control module 51 starts the generator 2 to generate electricity according to the preset third power output, controls the engine 1 to start and input mechanical energy to the generator 2. After being converted by the generator power module 53, the generator 2 provides electrical energy corresponding to the third power output to the battery through the generator input / output module 5251.

[0094] It should be noted that the third power generation in limp mode is the engine output power matched with the intake air volume when the engine does not have intake air compression function. This condition is a pre-calibrated special condition that is only entered after limp mode.

[0095] For example, when a short circuit in the compressor, air compressor, or heater causes an abnormality in the accessory power module, the vehicle controller 3 determines that the electric vehicle is currently in limp mode.

[0096] The generator controller provided in this application embodiment has a limp mode, which allows it to still generate electricity even when some modules are damaged, thus ensuring the user's emergency power needs.

[0097] This application embodiment also provides a generator control system, as shown in FIG2, including a vehicle controller 3 and a generator controller 5 of the first aspect; the vehicle controller 3 is connected to the generator controller 5 and is used to send input commands to the generator controller 5, wherein the input commands include the current operating mode of the electric vehicle and the power demand of the electric vehicle.

[0098] The generator control system provided in this embodiment, by setting a control module 51, a generator input / output module 52, a generator power module 53 and an accessory power module 54 in the generator controller 5, can control the operation of the compressor 7, the compressor 6 and the heater 8. Compared with the independent control in related technologies, the generator control system provided in this embodiment reduces the energy waste caused by long-distance transmission, and reduces the number of control assemblies and rectifier components, thereby improving the reliability and service life of the vehicle.

[0099] In one alternative embodiment, the generator controller 5 system further includes an engine 1, a generator 2, a compressor 7, and an accessory, wherein the engine 1 is connected to the generator controller 5; the generator 2 is connected to both the generator controller 5 and the engine 1; the compressor 7 is connected to the generator controller 5; and the accessory is connected to the generator controller 5.

[0100] Thus, under the control of the generator control system, engine 1 mixes oil and gas with air and burns them to generate and output mechanical energy. Generator 2 is directly connected to engine 1 and converts the mechanical energy input from engine 1 into electrical energy.

[0101] In one alternative implementation, the accessories include at least one of the following: compressor 6, heater 8.

[0102] This allows the compressor 6 and / or heater 8 to be directly controlled via the generator control system, reducing energy waste from long-distance conversion and decreasing the number of control assemblies and rectifier components, thereby improving vehicle reliability and service life.

[0103] Figure 3 is a schematic diagram of the working principle of the generator control system according to an embodiment of this application. As shown in Figures 2 and 3, the generator control system includes a vehicle controller 3, a generator controller 5, an engine 1, a generator 2, a compressor 6, an air compressor 7, and a heater 8. The generator controller 5 includes, but is not limited to, a control module 51, a generator input / output module 52, a generator power module 53, and an accessory power module 54. The control module 51, the generator input / output module 52, the generator power module 53, and the accessory power module 54 are located in the same cavity.

[0104] The vehicle controller 3 transmits signals and other information to CAN 4. Specifically, in the control method, after the user operates the vehicle compressor 6 or heater 8, or their components, the signal is acquired and transmitted to CAN 4. CAN 4 is the signal transmission line within the vehicle, transmitting information about the aforementioned components in this example. The generator controller 5 responds to the instructions from the vehicle controller 3. Its control module 51 calculates and operates the generator power module 53 and accessory power module 54 according to a preset mode, further controlling the generator 2, compressor 6, compressor 7, and heater 8 to operate normally. As shown in Figure 3, the working principle of the generator control system is as follows: In response to user operation of the vehicle, after the vehicle controller 3 inputs instructions, the control module 51 of the generator controller 5 calculates and controls the generator power module 53 and accessory power module 54 to operate according to a preset mode, thereby controlling the generator 2, compressor 6, compressor 7, and heater 8 to operate accurately and meet user needs. For example, as shown in Figure 3, the vehicle controller (VCU) 3 generates input commands based on user operation information and battery level, and sends the input commands to the generator controller (PEU) 5 via CAN 4; the generator controller 5 operates, and the control module 51 obtains the current operating mode of the electric vehicle and the power demand of the electric vehicle based on the input commands; according to the current operating mode of the electric vehicle and the power demand of the electric vehicle, it controls the generator power module and accessory power module to operate respectively; after the vehicle controller (VCU) obtains new operations and battery level, it controls the operating mode to switch or exit operation.

[0105] This application also provides a range-extended electric vehicle, including a generator control system as a second aspect.

[0106] The range-extended electric vehicle provided in this application can control the operation of the compressor 7, compressor 6 and heater 8 by setting a control module 51, a generator input / output module 52, a generator power module 53 and an accessory power module 54 in the generator controller 5. Compared with the independent control and rectification conversion in the current industry, the process control is more accurate after unified calibration. The conversion is carried out inside the generator controller 5, which reduces the energy waste of long-distance conversion and reduces the original multiple control and rectification components, thereby improving the reliability and service life of the vehicle.

[0107] Although embodiments of this application have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of this application, and all such modifications and variations fall within the scope defined by the appended claims.

Claims

1. A generator controller characterized by, Applied to electric vehicles, it includes a control module (51), a generator input / output module (52), a generator power module (53), and an accessory power module (54); The control module (51) is used to acquire input instructions from the vehicle controller, parse the input instructions to obtain the current operating mode of the electric vehicle and the power requirements of the electric vehicle; according to the current operating mode of the electric vehicle and the power requirements of the electric vehicle, it sends working signals to the modules that need to work in the generator controller according to the preset control logic, and controls at least one of the engine (1) and generator (2) to work. The generator input / output module (52) is connected to the generator power module (53), the battery, the generator (2) and the accessory power module (54) to provide a path for current transfer; The generator power module (53) is also connected to the control module (51) and is used to rectify the AC power generated by the generator (2) after receiving the first working signal sent by the control module (51), and provide the rectified DC power to the battery through the generator input / output module (2); and / or provide the AC power generated by the generator (2) to the accessory power module (54) through the generator input / output module (2) after receiving the first working signal sent by the control module (51); The accessory power module (54) is also connected to the control module (51) and is used to provide the alternating current generated by the generator (2) to the compressor (7) and / or at least one of the accessories through the generator input / output module (52) after receiving the second working signal sent by the control module (51); and / or to invert the electrical energy in the battery and provide the inverted alternating current to the compressor (7) and / or at least one of the accessories through the generator input / output module (52).

2. The generator controller of claim 1, wherein, The electric vehicle is currently operating in any of the following modes: power generation mode, accessory mode, hybrid mode, or limp mode.

3. The generator controller according to claim 2, characterized in that: The control module (51) is specifically used for: when the electric vehicle is currently in the power generation mode, calculating the first power generation power and the first compressor power consumption based on the first power demand, controlling the engine (1) to start based on the first power generation power and controlling the engine (1) to input the generated mechanical energy to the generator (2) so that the generator (2) generates the AC power; after the generator (2) generates the AC power, sending the first power generation mode working signal to the generator power module (53) and sending the second power generation mode working signal to the accessory power module (54); After receiving the first power generation mode working signal sent by the control module (51), the generator power module (53) rectifies the AC power generated by the generator (2) and provides the DC power obtained after rectification corresponding to the first power generation to the battery through the generator input / output module (52). After receiving the second power generation mode working signal sent by the control module (51), the accessory power module (54) provides the AC power generated by the generator (2) corresponding to the power consumption of the first compressor to the compressor (7) through the generator input / output module (52).

4. The generator controller according to claim 2, characterized in that: The control module (51) is specifically used to: when the electric vehicle is currently in the accessory mode, calculate the first accessory power consumption according to the second power demand, and send the first accessory mode working signal to the accessory power module (54); After receiving the first accessory mode working signal sent by the control module (51), the accessory power module (54) inverts the electrical energy in the battery and inputs the inverted AC power to the accessory corresponding to the second power requirement through the generator input / output module (52).

5. The generator controller according to claim 2, characterized in that: The control module (51) is specifically used for: when the electric vehicle is currently in a hybrid mode, calculating the second power generation power, the second compressor power, and the second accessory power according to the third power demand; controlling the engine (1) to start and controlling the engine (1) to input the mechanical energy generated to the generator (2) so that the generator (2) generates the AC power; after the generator (2) generates the AC power, sending the first hybrid mode working signal to the generator power module (53) and the second hybrid mode working signal to the accessory power module (54); After receiving the first hybrid mode working signal sent by the control module (51), the generator power module (53) rectifies the AC power generated by the generator (2) and provides the DC power obtained after rectification, which corresponds to the second power generation, to the battery through the generator input / output module (52). After receiving the second hybrid mode working signal sent by the control module (51), the accessory power module (54) provides the AC power generated by the generator (2) corresponding to the second compressor power consumption to the compressor (7) through the generator input / output module (52), and provides the AC power generated by the generator (2) corresponding to the second accessory power consumption to the accessory corresponding to the third power demand through the generator input / output module (52).

6. The generator controller according to claim 2, characterized in that: The control module (51) is used to calculate the third power generation power according to the fourth power demand when the electric vehicle is currently in the limp mode, and control the engine (1) to start and control the engine (1) to input the mechanical energy generated to the generator (2) so that the generator (2) generates the AC power; after the generator (2) generates the AC power, it sends the first limp mode working signal to the generator power module (53); After receiving the first limp mode working signal sent by the control module (51), the generator power module (53) rectifies the AC power generated by the generator (2) and provides the rectified DC power to the battery through the generator input / output module (52).

7. The generator controller of claim 1, wherein: The control module (51), the generator input / output module (52), the generator power module (53), and the accessory power module (54) are located in the same cavity.

8. The generator controller of claim 1, wherein, The generator input / output module (52) is also used to filter the current passing through the generator input / output module (52).

9. The generator controller of claim 1, wherein, The control module (51) and the generator input / output module (52) are located on the same PCB board.

10. The generator controller of claim 1, wherein: The control module (51) is also used to control the generator power module (53) and / or the accessory power module (54) to be in a wake-up state or a sleep state.

11. A generator control system characterized by, include: The generator controller according to any one of claims 1 to 10; The vehicle controller, connected to the generator controller, is used to send input commands to the generator controller, wherein the input commands include the current operating mode of the electric vehicle and the power requirements of the electric vehicle.

12. The generator control system of claim 11, wherein, Also includes: Engine (1), connected to the generator controller; A generator (2) is connected to the generator controller and the engine (1); Compressor (7), connected to the generator controller; The attachment is connected to the generator controller.

13. The generator control system of claim 12, wherein, The accessories include at least one of the following: a compressor (6) and a heater (8).

14. A range extended electric vehicle, characterized by, Includes the generator control system as described in claim 11.

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