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CN-121989675-A - Global tonnage modularized electrolyte decoupling hybrid power platform and control method

CN121989675ACN 121989675 ACN121989675 ACN 121989675ACN-121989675-A

Abstract

The invention discloses a full-tonnage modularized electrolyte decoupling hybrid power platform and a control method, which are suitable for a 30-99 ton-level large hydraulic excavator. The system comprises four subsystems of a power and transmission unit, an energy storage unit, a high-voltage drive unit and a low-voltage system, wherein a flywheel of a diesel engine is connected with a transfer case, and a double-path drive main hydraulic pump and an ISG start-up power generation integrated machine. The engine deep decoupling, independent electric driving walking and rotation, braking energy recovery, full-electric heat dissipation independent driving, DC-DC independent power supply, intelligent range-increasing energy supplementing and electric starting and stopping are realized, the traditional hydraulic walking, rotation motor, multi-way valve, hydraulic heat dissipation pump and motor are omitted, and the full-tonnage model is adapted in a modularized mode. The whole vehicle controller realizes multi-mode control and global energy scheduling, the fuel saving rate of the comprehensive working condition is 25% -35%, the fuel saving rate of the high idle speed and transition is 35% -45%, and the problems that the existing hybrid coupling degree is large, the heat dissipation depends on the engine and hydraulic pressure, the energy waste and the whole range cannot be expanded are solved.

Inventors

  • WANG YANPO

Assignees

  • 王彦坡

Dates

Publication Date
20260508
Application Date
20260301

Claims (10)

  1. 1. The universal tonnage modularized electrolyte decoupling hybrid power platform and the control method are suitable for 30-99 ton hydraulic excavators and are characterized by comprising a diesel engine, a transfer case, a main hydraulic pump, an ISG (INTEGRATED STARTER-Generator) starting power generation integrated machine, an energy storage unit, an independent electric driving walking module, an independent electric driving rotation module, an all-electric heat dissipation system, a DC-DC power module, an electric air conditioner, an electric transmission operating device and a whole vehicle controller; the flywheel end of the diesel engine is connected with the input end of the transfer case, the transfer case is provided with two independent output shafts, one output shaft drives a main hydraulic pump, the other output shaft drives an ISG to start a power generation integrated machine, so that the ISG is far away from a high-temperature area of the flywheel end, a water cooling loop and a heat dissipation air duct are arranged in sufficient space, the reliability of thermal management is improved, the independent electric driving traveling module, the independent electric driving rotating module, the full electric heat dissipation system and the electric air conditioner are independently powered by an energy storage unit, no mechanical and hydraulic coupling is realized, the independent electric driving traveling module and the independent electric driving rotating module are respectively provided with a bidirectional driving controller, mechanical energy can be converted into electric energy when traveling braking, traveling decelerating, rotating braking or rotating stopping, the electric energy is recovered, the electric energy is directly supplied to the electric air conditioner, the full electric heat dissipation system and the DC-DC power module, the residual electric quantity is supplied to the energy storage unit, the instant power generation is realized, an energy closed loop is formed, the full electric heat dissipation system is not directly fed back to the energy storage unit, the full electric heat dissipation system is formed by an independent driving motor, an electronic fan, an electronic water pump and a heat dissipation controller, the independent power can be regulated according to hydraulic pressure and oil temperature, the independent power, and the independent power can be independently regulated, and independently run under the diesel engine state, the DC-DC power supply high-DC power supply unit is in a power supply unit, the hybrid power platform is in modularized design, and is universal with control logic by adjusting ISG power level, energy storage unit capacity, independent electric drive walking module parameters, independent electric drive rotating module parameters, walking drive controller parameters, rotating drive controller parameters, all-electric heat dissipation system power parameters, DC-DC power module power level and main hydraulic pump matching specifications, so that 30-99 ton-level full-series machine type can be adapted stepwise.
  2. 2. The hybrid platform of claim 1, wherein in a diesel engine flameout state, the independent electric driving walking module, the independent electric driving turning module, the full electric heat dissipation system and the electric air conditioner can independently or cooperatively work to realize pure electric power conversion, pure electric turning, independent heat dissipation, braking energy recovery and zero oil consumption standby.
  3. 3. The hybrid power platform of claim 1, wherein the vehicle controller monitors the energy storage unit SOC in real time in a pure electric mode, automatically starts the diesel engine and supplements energy to the energy storage unit through ISG power generation when the SOC is below a preset lower limit, and automatically stops the diesel engine and resumes pure electric mode when the SOC rises back to a preset upper limit.
  4. 4. The hybrid platform of claim 1, wherein the vehicle controller is configured to instantaneously activate the diesel engine via the ISG to enter a hydraulic mode of operation when the telex operator detects an operator handle command, and wherein the diesel engine automatically extinguishes and returns to a pure mode when the operator handle returns to neutral for a predetermined period of time.
  5. 5. The hybrid platform of claim 1, wherein the vehicle eliminates a conventional hydraulic travel motor, hydraulic swing motor, travel control valve train, swing control valve train, hydraulic motor for hydraulically driving a heat dissipation pump and driving a fan, mechanical fan, and the hydraulic system only retains the main hydraulic pump and working device valve train.
  6. 6. The hybrid power platform according to claim 1, wherein the all-electric heat dissipation system, the electric air conditioner, the diesel engine and the hydraulic system are completely decoupled, and can be independently started and stopped, independently regulated in speed and independently controlled in temperature under any working condition of flameout, pure electric running and hydraulic operation of the diesel engine.
  7. 7. The hybrid platform of claim 1, wherein the ISG start-up and power generation integrated machine is only used for diesel engine start-up and energy storage unit energy supplementing power generation, does not directly drive the main hydraulic pump, and does not output power to the hydraulic system.
  8. 8. The hybrid platform of claim 1, wherein the travel and swing braking energy is recovered and directly supplied to an electric air conditioner, an all-electric heat dissipation system and a DC-DC power module, and the remaining energy is fed back to the energy storage unit to achieve instant use, thereby forming an energy closed loop without being directly fed back to the energy storage unit, and the electric air conditioner operates independently of a diesel engine.
  9. 9. The hybrid platform of claim 1, wherein each tonnage model of 30-99 tons shares the same set of whole vehicle control strategy and energy management logic, and modular expansion and platform versatility is realized only through hardware parameter matching.
  10. 10. A full-tonnage modularized electro-hydraulic decoupling hybrid power platform and a control method applied to the full-tonnage modularized electro-hydraulic decoupling hybrid power platform are characterized by comprising the steps of enabling a system to enter a pure electric standby mode by default after the system is electrified, enabling an independent electric driving traveling module, an independent electric driving rotary module, an all-electric heat dissipation system, an electric air conditioner and a low-voltage system to be independently powered by an energy storage unit and a DC-DC power module, enabling a whole vehicle controller to monitor an SOC in real time when a traveling command is received, enabling a diesel engine to start and stop and continue pure electric traveling when the SOC is lower than the lower limit, enabling the SOC to stop and enable the SOC to reach the upper limit, enabling the energy generated by braking of a traveling motor to be switched to be consumed by a resistance grid when the SOC reaches the upper limit threshold in a long-distance downhill working condition, enabling the traveling motor to automatically enter a power generation mode in a constant speed running reduction and braking process, enabling the traveling driving controller to automatically enter a power generation mode when the whole vehicle is received, enabling the whole diesel engine to automatically enter the power generation mode in a rotary motion energy recovery mode in a rotary motion process in a rotary speed reduction, enabling the rotary motion controller to automatically enter the power generation mode in a rotary motion mode in the process of braking or stopping position, enabling the whole diesel engine to automatically, enabling the whole vehicle to be turned-down when the electric operation device generates a working device signal, enabling the electric operation device to reach the full-tonnage operation device and enabling the full-tonnage operation device to stop and enabling the diesel engine to be in a full-tonnage mode and enabling the full-tonnage operation mode and enabling to be in a full-tonnage mode and stable when the full-tonnage operation mode and not to be matched with the full-mode.

Description

Global tonnage modularized electrolyte decoupling hybrid power platform and control method Technical Field The invention relates to the technical field of engineering machinery hybrid power, in particular to a full-domain tonnage modularized electrolyte decoupling hybrid power platform with traveling and rotation braking energy recovery and a control method, which are suitable for a 30-ton to 99-ton large hydraulic excavator and are constructed based on four subsystems of a power system, an energy storage unit, a high-voltage power drive system and a low-voltage system. Background The existing large hydraulic excavator mostly adopts a pure hydraulic drive or traditional parallel hybrid power configuration, and the heat dissipation, air conditioning, low pressure, walking and rotation systems all depend on mechanical drive or hydraulic drive of an engine, so that the coupling degree of power and transmission is high, parasitic loss is large, idle energy consumption is high, and energy-saving space is limited. The traditional heat radiation system depends on the mechanical driving of the engine, the rotation speed of the heat radiation fan passively changes along with the working condition of the engine, the heat radiation system cannot be independently regulated, the adaptability of the working condition of high temperature and low temperature is poor, and the effective power of the engine is continuously consumed. The traditional parallel mixed operation only realizes electric drive rotation, the energy recovery mode is single, the instant use cannot be realized, the energy utilization rate is low, the cost is high, the single machine type customized design is adopted, and the multi-machine type platform coverage is difficult to realize. Meanwhile, low-voltage power supply can not be maintained independently under the flameout state of the engine, an auxiliary system is strongly bound with the engine, and zero oil consumption standby and pure electric transition can not be realized in a real sense. The walking and slewing mechanism has a large amount of inertial energy in the braking, decelerating and slewing stopping processes, and the traditional hydraulic system consumes braking energy in an overflow and throttling mode, so that the braking energy is converted into heat waste, and the heat load of the hydraulic system and the energy consumption of the whole machine are further increased. The part of coaxial integration scheme arranges an ISG (INTEGRATED STARTER-Generator) at the flywheel end of the engine, and has the problems of strong high-temperature radiation, difficult arrangement of cooling pipelines, high thermal management risk and the like. The prior art lacks a set of unified mixing platform which can be seamlessly expanded from 30 tons to 99 tons, independently electrically driven to walk and revolve, walk and revolve to brake energy recovery, independently control full-electric heat dissipation, intelligently increase range and supplement energy, independently supply power for a low-voltage system, deeply decouple electrohydraulic, cool and friendly ISG and can realize mass production and landing. Disclosure of Invention The invention constructs a full-tonnage modularized electrolyte decoupling hybrid power platform, which is suitable for a 30-to 99-ton full-series large hydraulic excavator and realizes a set of architecture, full-scale coverage and modularized building block type expansion. The platform is integrally composed of four subsystems, namely a power system, an energy storage unit, a high-voltage electric drive system and a low-voltage system, wherein the core framework of the system comprises a diesel engine flywheel end connected with a transfer case, the transfer case is provided with two independent output shafts, one output shaft drives a main hydraulic pump, the other output shaft drives an ISG to start a power generation integrated machine, so that the ISG is far away from a flywheel end high-temperature area, a cooling pipeline is arranged in sufficient space, the thermal management is safer and more reliable, and the intelligent power generation and stop can be realized by matching with the deep decoupling of engine operation, the independent electric drive of a walking and rotating mechanism, the independent electric drive of a walking and rotating braking energy recovery system, the independent drive of a full-electric heat dissipation system, the intelligent range increase and energy supplement, the overall energy closed-loop scheduling, the independent power supply of a high-voltage to low-voltage DC-DC power supply module and the electric transmission control. The key components are designed in a standardized and modularized way, and comprise a diesel engine, a transfer case, a main hydraulic pump, an ISG starting and generating integrated machine, a power battery pack, an independent electric driving walking module, an independent electric driving revolving module, a