CN218952149U - Dynamic compactor hybrid power system - Google Patents
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- CN218952149U CN218952149U CN202223441853.8U CN202223441853U CN218952149U CN 218952149 U CN218952149 U CN 218952149U CN 202223441853 U CN202223441853 U CN 202223441853U CN 218952149 U CN218952149 U CN 218952149U
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Abstract
The utility model belongs to the technical field of engineering machinery, and particularly relates to a dynamic compactor hybrid power system which comprises an engine, a range-extending motor and a main hydraulic pump, wherein the engine drives the range-extending motor to generate power and is used for providing electric energy for an boarding operation mechanism; the engine drives the main hydraulic pump and is used for providing power for the hydraulic action of the get-off operation mechanism, and the clutch is arranged between the engine output shaft and the main hydraulic pump, so that the clutch is disconnected during dynamic compaction operation, and idle loss is avoided.
Description
Technical Field
The utility model belongs to the technical field of engineering machinery, and particularly relates to a dynamic compactor hybrid power system.
Background
The global climate warming and energy shortage problems are increasingly prominent, and engineering machinery is increasingly valued by related departments as an important industry of energy consumption. Based on the national double-carbon strategic target, under the background of policy promotion and environmental protection pressure relief, engineering machinery is developing towards energy conservation, environmental protection, green and low carbon.
At present, the traditional dynamic compactor mostly adopts hydraulic drive or mechanical direct drive, and the hydraulic drive dynamic compactor has low transmission efficiency because of fluid indirect transmission, needs to be matched with a larger engine and has high fuel consumption; or the engine with the same size is matched, so that the operation efficiency is lower. The mechanical direct-drive dynamic compactor system has higher efficiency, but the transmission system is complex, the requirement on the reliability of mechanical parts is high, and the maintenance is inconvenient. The hydraulic driving dynamic compactor and the mechanical direct driving dynamic compactor are both of direct driving essentially, engine power and working condition requirements cannot be decoupled, so that the engine cannot work in a high-efficiency area, fuel economy is poor, energy recovery cannot be achieved in the winch lowering process, and energy waste exists. The engine works in severe working conditions for a long time, and is accompanied with emission of a large amount of harmful gases, so that environmental pollution is caused, and noise during operation can also influence a driver and the surrounding environment.
The existing traditional dynamic compactor is used for releasing gravitational potential energy aiming at the main winch, basically realized through throttling of a balance valve of a hydraulic system, energy is dissipated in a thermal situation, the thermal load of the hydraulic system is increased, the service life of a hydraulic element is prolonged, and meanwhile, additional energy is needed for cooling the hydraulic system, so that energy waste is caused. The energy in the process of lowering the main winch is stored for reuse, and the method has very important significance for improving the fuel economy of the engine and reducing the emission. Although the scheme of storing the released energy by the main winch through the power battery exists, for the working condition that the main winch is frequently released, the situation that the power battery is full of electricity and recharging is not allowed exists, and potential safety hazards exist.
In a patent CN112900413a "hybrid dynamic compactor", the hybrid power system does not have the function of energy recovery and reuse, and the power output by the engine needs to pass through a transfer case, a hydraulic torque converter, a first transmission shaft, a gearbox, a transmission case, a second transmission shaft, a reduction gearbox and the like, so that the transmission chain is long, and efficiency loss exists; the power and the working condition requirements of the engine cannot be completely decoupled, the engine has no stop time, and the fuel economy cannot be optimized. In the patent CN113482521A 'parallel power system of the rotary drilling rig', engine power is split through a transfer case, one part of engine power supplies power to a hydraulic system, the other part of engine power is used for driving a motor to generate power, the engine does not directly drive a main winch, and the main winch is driven by the motor, so that decoupling of engine power and working condition requirements is realized, and energy recovery can be realized. However, according to different working conditions, the connection between the engine, the hydraulic pump and the generator cannot be timely disconnected, the engine cannot be stopped when the whole vehicle has hydraulic requirements, a pure electric driving mode cannot be realized, idle running loss exists, and energy conservation is not facilitated; it is not considered how the energy is dissipated after the energy storage unit is filled.
Disclosure of Invention
In order to solve the problems, the utility model provides a dynamic compactor hybrid power system.
The object of the utility model is achieved in the following way: a dynamic compactor hybrid power system comprises an engine, a range-extending motor and a main hydraulic pump, wherein the engine drives the range-extending motor to generate power and is used for providing electric energy for an boarding mechanism; the engine drives the main hydraulic pump and is used for providing power for the hydraulic action of the get-off operation mechanism, and a clutch is arranged between the engine output shaft and the main hydraulic pump, so that the clutch is disconnected during dynamic compaction operation, and idle loss is avoided.
Further, the engine output shaft is sequentially connected with the range-extending motor and the main hydraulic pump in series, and a fifth clutch is arranged between the range-extending motor and the main hydraulic pump.
Further, the range-extending motor is connected with the main hydraulic pump in parallel, an output shaft of the engine is connected with an input shaft of the transfer case through a first clutch, a first output shaft of the transfer case is connected with the range-extending motor through a second clutch, a second output shaft of the transfer case is connected with the main hydraulic pump through a third clutch, and the first clutch, the second clutch and the third clutch are used for controlling clutch through a master controller.
Further, the boarding operation mechanism comprises a winch motor, an output shaft of the winch motor is connected with an input end of a speed reducer, an output end of the speed reducer is connected with a winding drum through a fourth clutch, and a brake is arranged on the winding drum.
Further, the range-extending motor is electrically connected with a range-extending motor controller, the range-extending motor controller is electrically connected with a high-voltage distribution box, and the high-voltage distribution box is electrically connected with the energy storage device, so that the energy storage device is charged through power generation of the range-extending motor.
Further, the high-voltage distribution box is electrically connected with the winch motor controller and the electric auxiliary oil pump respectively, and the electric auxiliary oil pump is connected with the brake and the clutch through oil ways and used for providing energy.
Furthermore, the high-voltage distribution box is electrically connected with the rectifying cabinet, and the rectifying cabinet is electrically connected with a power grid through an external cable to realize power supply.
Compared with the prior art, the clutch is arranged between the engine output shaft and the main hydraulic pump, so that the clutch is disconnected during dynamic compaction operation, and idle loss is avoided.
Drawings
FIG. 1 is a schematic diagram of one of the embodiments of a dynamic compactor hybrid system;
FIG. 2 is a schematic diagram of a second embodiment of a dynamic compactor hybrid system.
Detailed Description
The following description of the embodiments of the present utility model will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present utility model, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the utility model without making any inventive effort, are intended to be within the scope of the utility model.
In the present utility model, unless explicitly specified and limited otherwise, the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., are used for convenience of description and for simplifying the description only with respect to the orientation or positional relationship shown in the drawings, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the utility model.
A dynamic compactor hybrid power system comprises an engine, a range-extending motor and a main hydraulic pump, wherein the engine drives the range-extending motor to generate power and is used for providing electric energy for an boarding mechanism; the engine drives the main hydraulic pump and is used for providing power for the hydraulic action of the get-off operation mechanism, and a clutch is arranged between the engine output shaft and the main hydraulic pump, so that the clutch is disconnected during dynamic compaction operation, and idle loss is avoided.
As an embodiment, as shown in fig. 1, an engine output shaft is sequentially connected in series with a range-increasing motor and a main hydraulic pump, and a fifth clutch is arranged between the range-increasing motor and the main hydraulic pump.
Further, the range-extending motor is converted into the energy storage device through the range-extending motor controller to charge the energy storage device. The actuating mechanism lifts the hoist and uses the hoist motor to drive, the energy storage device is carried to hoist motor controller, provide the energy input to hoist motor after the conversion, realize hoist work.
When the electric quantity is higher, the engine generates electricity at fixed points at the working point with the lowest specific oil consumption, and the residual power is supplemented by the energy storage device. When the electric quantity is reduced to the limit value, the power of the engine is followed, and meanwhile, the fixed-point power generation is performed under the downward working condition, so that the fixed-point power generation duty ratio of the engine in the optimal rotating speed interval is increased. The energy storage device is preferentially used for recovering energy generated by the power generation of the winch motor in the power dropping process, and the energy storage device is used for starting the braking function in the engine cylinder when the recovery power is smaller, so that the range-extending motor drags the engine to consume the energy generated by the power generation of the winch motor.
The range-increasing motor is connected with the main hydraulic pump through a fifth clutch, so that the idle loss of the main hydraulic pump is reduced. In the dynamic compaction operation mode, a fifth clutch between the range-extending motor and the main hydraulic pump is disconnected, the main hydraulic pump stops rotating at the moment, and an electric emergency pump (an electric auxiliary oil pump) supplies power for a hydraulic auxiliary control module (namely, components with small hydraulic demands in an on-board operation mechanism, such as a clutch and a brake of a winding drum), and the main hydraulic pump is only used when a vehicle rotates, walks and changes amplitude.
In the actuating mechanism, the winch motor controller converts electric energy into power for the winch motor, the winch motor is preferably directly driven by a permanent magnet synchronous motor, the input rotating speed is higher, and the construction efficiency is improved in a breakthrough manner; the winch motor drives the winch to rotate, so that the lifting and lowering functions are realized.
The engine drives the range-extending motor to generate electricity, electric energy is provided, the engine can continuously work in an economic area, and specific oil consumption is low. The main working structure of the main winch adopts a motor for direct driving, and the electric transmission replaces hydraulic transmission, so that the transmission efficiency is high. The main hydraulic system is omitted, the maintenance cost of the hydraulic system can be reduced, and the energy consumption is saved by 24%.
As another embodiment, as shown in fig. 2, the solid arrow line in the figure shows electrical connection, the broken arrow line shows control, the output shaft of the engine is connected with the input shaft of the transfer case through a first clutch, the first output shaft of the transfer case is connected with the range-increasing motor through a second clutch, the second output shaft of the transfer case is connected with the main hydraulic pump through a third clutch, and the first clutch, the second clutch and the third clutch control the clutch through a master controller.
The range-extending motor is electrically connected with a range-extending motor controller, the range-extending motor controller is electrically connected with a high-voltage distribution box, and the high-voltage distribution box is electrically connected with the energy storage device, so that the energy storage device is charged through power generation of the range-extending motor.
The high-voltage distribution box is electrically connected with the rectifying cabinet, and the rectifying cabinet is electrically connected with a power grid through an external cable to realize power supply.
The power output by the engine drives the range-extending motor and the main hydraulic pump respectively through the transfer case, and the range-extending motor timely generates power, and forms a power supply system together with an energy storage device (a capacitor, a battery and the like), a rectifying cabinet (an external power grid) and a high-voltage distribution box; the energy storage device (a capacitor, a battery and the like) is used as an energy buffer unit, and when the range extender and the power grid are not in-between, the energy storage device provides electric energy for the whole machine in a limited time and recovers energy under a hoisting braking working condition. When the energy storage device cannot provide energy required by operation, the engine and the range-extending motor generate power to be timely supplemented, and when the electric quantity of the energy storage device is high, the engine and the range-extending motor stop generating power. After the power grid is connected, the power output by the power grid is rectified to provide electric energy for the whole machine, and the energy storage device is charged in time.
The main hydraulic pump provides main power for hydraulic actions (walking, turning, luffing and the like) of the dynamic compactor, the dynamic compactor is operated at a fixed point for most of time, the action time of walking, turning, luffing and the like is small, and the main hydraulic pump is not required to be in a working state for a long time. In order to eliminate the energy loss of the long-time idling of the main hydraulic pump, a third clutch is added between the transfer case and the main hydraulic pump, and when the whole machine does not have hydraulic actions such as walking, rotation, amplitude variation and the like, the third clutch is disconnected, and the main hydraulic pump does not work.
The first clutch is added between the engine and the transfer case, and the second clutch is added between the transfer case and the range-extending motor, so that the whole engine has a pure electric driving mode, a mixed electric mode and an engine driving mode.
The high-voltage distribution box is electrically connected with the winch motor controller, the winch motor controller is electrically connected with the winch motor, the output shaft of the winch motor is connected with the input end of the speed reducer, the output end of the speed reducer is connected with the winding drum through the fourth clutch, and the winding drum is provided with a brake.
The high-voltage distribution box is electrically connected with the electric auxiliary oil pump, and the electric auxiliary oil pump is used for providing energy for components with small hydraulic demands in the boarding operation mechanism, wherein the components with small hydraulic demands comprise a first clutch, a second clutch, a third clutch, a fourth clutch and a brake.
The boarding operation mechanism consists of a winch motor, a winch motor controller, a speed reducer, a fourth clutch, a brake and a winding drum, and has two operation modes: dynamic compaction operation mode and power lowering mode.
The dynamic compaction operation mode is divided into a unhooking mode and a unhooking-free mode:
in the unhooking mode, when the rammer is lifted to a set height, the rammer is automatically separated from a lifting hook, the free falling body is smashed to the ground, a fourth clutch between a speed reducer and a winding drum is disconnected, the lifting hook falls to the ground with the free falling body of the winding drum, a brake brakes and decelerates when approaching to the position of the rammer, after the lifting hook is combined with the rammer again, the fourth clutch between the speed reducer and the winding drum is combined, and a winding motor drives the winding drum to lift the rammer again through the speed reducer to reciprocate;
in the unhooking mode, when the rammer is lifted to a set height, the rammer is not separated from the lifting hook, a fourth clutch between the speed reducer and the winding drum is disconnected, the rammer drives the winding drum to fall freely to the ground, a brake brakes and decelerates when approaching the ground, the fourth clutch between the speed reducer and the winding drum is combined, and the winding motor drives the winding drum to lift the rammer again through the speed reducer, so that reciprocating circulation is realized.
The power lowering mode is used for slowly lowering the rammer after the work is completed, the fourth clutch between the speed reducer and the winding drum is combined, the rammer drags the winding motor, the winding motor selects a motor which can be reversely dragged to generate power in the prior art, the winding motor controller controls the lowering speed, the winding motor is in a continuous power generation state at the moment, and the generated power is inverted by the motor controller and is used for charging the energy storage device preferentially. When the energy storage device is full, in order to prevent potential safety hazards caused by overcharging, the first clutch is combined, the engine is started to brake in the cylinder, the range extender motor drags the engine through the transfer case, if the braking power in the cylinder is insufficient, the third clutch between the transfer case and the main hydraulic pump is closed, the range extender motor drags the engine and the main hydraulic pump at the same time, the range extender motor consumes redundant electric quantity, and the energy storage device is ensured to be overcharged.
The extra components are not added, only the resistance provided by the braking and main hydraulic pump in the engine cylinder is utilized, the range-extending motor drags the engine or (and) the main hydraulic pump, the surplus electric quantity generated by the main winch motor in the power lowering process is consumed, the over-charging of the energy storage device is ensured, and the safety and reliability of the whole machine are effectively improved. Meanwhile, in the power lowering mode, the lowering speed is controllable, the power lowering speed is not limited by the state of the energy storage device, and the power system platform can be expanded to be used for a crane.
The control system of the dynamic compactor hybrid power system is composed of a main controller, a sensor and an actuator (a brake and a clutch), wherein the main controller is used for respectively controlling the controllers (a motor controller and an electric auxiliary oil pump) of all the components, so that the coordination actions of the whole machine components in different modes are realized.
1. Mode of operation
1. Pure electric mode
When the electricity quantity of the energy storage device is higher than a design threshold B or an external power grid, a machine operator can select a pure electric mode, at the moment, the master controller controls a first clutch between the engine and the transfer case to be disconnected, the engine is stopped, the whole machine does not have the hydraulic action requirements of walking, turning around, luffing and the like, the master controller disconnects a third clutch between the transfer case and the main hydraulic pump, and controls the electric auxiliary oil pump to provide energy for other parts with small hydraulic requirements of the whole machine. When the whole machine has the hydraulic action demands of walking, turning, luffing and the like, the master controller respectively controls the combination of a second clutch between the transfer case and the range-increasing motor and a third clutch between the transfer case and the main hydraulic pump, and the range-increasing motor drives the main hydraulic pump to supply energy for the hydraulic action of the whole machine through the transfer case. At the moment, the energy storage device or an external power grid provides electric energy for the range-extending motor, the winch motor, the electric auxiliary oil pump and the like.
In the pure electric mode, no fuel consumption exists, the energy is saved, the environment is protected, the response performance of the motor is better, no noise exists, and the driving feeling is better; in the mixed mode, the engine does not directly drive the walking and operating device, the range extender generates power at fixed points, the engine is always in a high-efficiency area for power generation, and compared with a traditional hydraulic dynamic compactor, the electric transmission efficiency is higher, and the fuel consumption can be obviously reduced.
2. Hybrid mode
When the power grid is not connected, and when the manipulator selects the hybrid mode, if the electric quantity of the energy storage device is sufficient, the electric quantity is higher than the design threshold value, and the energy storage device is used as a unique energy source to provide electric energy for the range-extending motor, the winch motor, the electric auxiliary oil pump and the like. When the electric quantity of the energy storage device is lower than the design threshold A, the master controller controls the combination of a second clutch between the transfer case and the range-extending motor, controls the combination of a first clutch between the engine and the transfer case, starts the engine, drives the range-extending motor to generate electricity, inverts the generated electricity through the motor controller and then charges the energy storage device, and simultaneously provides electric energy for other electricity utilization components. When the energy storage device electricity quantity is higher than the design threshold value B, the engine stops working. When the electric quantity of the energy storage device is between the design threshold A and the design threshold B, the engine generates electricity at the working point with the lowest specific oil consumption preferentially, and the power generation power is adjusted in real time according to the power required by the whole machine, so that the power generation working point is always in an optimal working area.
The design threshold A is 45% -55% of the total electric quantity of the energy storage device, and the design threshold B is 75% -85% of the total electric quantity of the energy storage device.
3. Engine drive mode
When the work is finished and long-time walking is needed, the operator selects an engine driving mode, the master controller controls the combination of a third clutch between the transfer case and the main hydraulic pump, the engine is started at the same time, and then the engine drives the main hydraulic pump through the transfer case in combination with the first clutch between the engine and the transfer case to supply energy for the hydraulic system.
4. Limp mode
Because of the two power sources of the engine and the energy storage device, the complete machine can realize the lameness of the complete machine and the repair of the factory by the mode switching. If the engine fails, the vehicle can be driven to walk in a pure electric mode; if the power supply system fails, the walking can be driven in an engine driving mode.
2. Mode switching process control
The first clutch is added between the engine and the transfer case, the second clutch is added between the transfer case and the range-extending motor, so that the whole engine has a pure electric driving mode, a mixed driving mode and an engine driving mode, and the problem of clutch dynamic combination in the mode switching process can be solved. Because the main hydraulic pump does not allow the clutch to be directly and dynamically combined and has no speed regulation capability, the mode switching is realized mainly by means of the speed regulation of the range-extending motor.
First clutch engagement process between engine and transfer case: and after the total controller controls the range-extending motor to regulate the rotating speed of the transfer case input shaft to be consistent with the rotating speed of the engine, the total controller is combined with the first clutch.
A second clutch combining process between the transfer case and the range motor: and after the total controller controls the range-extending motor to regulate the speed until the rotation speed of the range-extending motor and the rotation speed of the transfer case output shaft tend to be consistent, the second clutch is combined.
A third clutch engagement process between the transfer case and the main hydraulic pump: the master controller controls the first clutch and the second clutch to be separated, the third clutch is combined statically, the second clutch is combined statically, and the first clutch is combined finally by utilizing the range-extending motor to regulate speed.
By means of the clutch dynamic switching strategy, the instantaneous impact of a transmission system can be reduced, and the service life is prolonged.
3. Unhooking process
When the winch is lifted to the highest point and the rammer unhooks, the load of the winch motor suddenly withdraws to 0, and the motor is easy to overspeed. Therefore, by adding the tension sensor at the bottom end of the unhooking rope, the master controller predicts unhooking in advance according to the tension value of the tension sensor, and reduces the rotating speed of the winch motor to be close to 0 in time before lifting to the highest point.
4. Power down process control
The winch motor is dragged by the rammer, the lowering speed is controlled by the winch motor controller, the power generation power of the winch motor and the state of the energy storage device are detected in real time by the master controller, when the energy storage device is full, the master controller controls the engine to start in-cylinder braking, the range extender motor drags the engine through the transfer case, and the power generation power of the winch motor is dynamically followed by the braking power in the cylinder through controlling the rotating speed of the range extender. If the braking power in the cylinder is insufficient, a third clutch between the transfer case and the main hydraulic pump is closed, the range-extending motor drags the engine and the main hydraulic pump at the same time, and the range-extending motor consumes redundant electric quantity to ensure that the energy storage device is over-charged.
The foregoing is merely a preferred embodiment of the present utility model, and it should be noted that it will be apparent to those skilled in the art that several changes and modifications can be made without departing from the general inventive concept, and these should also be regarded as the scope of the utility model.
Claims (7)
1. A dynamic compactor hybrid power system comprises an engine, a range-extending motor and a main hydraulic pump, wherein the engine drives the range-extending motor to generate power and is used for providing electric energy for an boarding mechanism; the engine drives the main hydraulic pump for the hydraulic motion of operation mechanism provides power, its characterized in that: the clutch is arranged between the engine and the main hydraulic pump, so that the clutch is disconnected during dynamic compaction operation, and idle loss is avoided.
2. The dynamic compactor hybrid system of claim 1, wherein: the engine output shaft is sequentially connected with the range-extending motor and the main hydraulic pump in series, and a fifth clutch is arranged between the range-extending motor and the main hydraulic pump.
3. The dynamic compactor hybrid system of claim 1, wherein: the range-extending motor is connected with the main hydraulic pump in parallel and is connected with the engine, an output shaft of the engine is connected with an input shaft of the transfer case through a first clutch, a first output shaft of the transfer case is connected with the range-extending motor through a second clutch, a second output shaft of the transfer case is connected with the main hydraulic pump through a third clutch, and the first clutch, the second clutch and the third clutch are used for controlling clutch through the master controller.
4. The dynamic compactor hybrid system according to claim 3, wherein: the boarding operation mechanism comprises a winch motor, an output shaft of the winch motor is connected with an input end of a speed reducer, an output end of the speed reducer is connected with a winding drum through a fourth clutch, and the winding drum is provided with a brake.
5. The dynamic compactor hybrid system according to claim 4, wherein: the range-extending motor is electrically connected with a range-extending motor controller, the range-extending motor controller is electrically connected with a high-voltage distribution box, and the high-voltage distribution box is electrically connected with the energy storage device, so that the energy storage device is charged through power generation of the range-extending motor.
6. The dynamic compactor hybrid system according to claim 5, wherein: the high-voltage distribution box is respectively and electrically connected with the winch motor controller and the electric auxiliary oil pump, and the electric auxiliary oil pump is connected with the brake and the clutch through oil ways and used for providing energy.
7. The dynamic compactor hybrid system according to claim 5, wherein: the high-voltage distribution box is electrically connected with the rectifying cabinet, and the rectifying cabinet is electrically connected with the power grid through an external cable to realize power supply.
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| CN202223441853.8U CN218952149U (en) | 2022-12-22 | 2022-12-22 | Dynamic compactor hybrid power system |
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| CN202223441853.8U CN218952149U (en) | 2022-12-22 | 2022-12-22 | Dynamic compactor hybrid power system |
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