Four-layer full-stack range-extender control system architecture
Plain Text | SimCar range-extender HIL test bench │ | SimCore energy simulation | Bus recorder │ | EOL production-line test equipmen |├─────────────────────────────────────────────────────────┤ | Dynamic power-generation strategy │ | Engine optimal operating-point mapping │ | Battery charging coordination & protection │ | Vehicle torque coupling control │ | Smooth mode-transition strategy │ | NVH vibration suppression │ | High/low-temperature adaptation logic │ | Fault diagnostics & safety protection|├─────────────────────────────────────────────────────────┤ | U34 full-domain range-extender coordination controller │ | High-precision engine speed/frequency acquisition │ | Generator signal acquisition interface │ | Multi-channel CAN FD communication | High-power I/O drive │ | Automotive-grade wide-temperature hardware design | ├─────────────────────────────────────────────────────────┤ | Hybrid coordinated driving mode | Battery recharging control │ | High-speed steady-state generation │ | Extreme-condition energy fallback protection |└─────────────────────────────────────────────────────────┘ |
System interconnection logic
Engine / generator sensors, throttle actuators, battery system and motor system → range extender control unit (operating-condition recognition, power calculation, start/stop control, torque coordination) → cross-domain linkage with the vehicle central domain controller, BMS, MCU and thermal management unit. The upper-computer toolchain completes the full closed loop of range-extender strategy modeling, automatic code generation, HIL multi-condition simulation, real-vehicle fuel-consumption calibration, production flashing and fault diagnostics.
1. Multi-mode intelligent operating-condition switching.
Supporting pure-electric-priority, hybrid-balanced, fuel-priority and high-speed steady-state modes, it automatically switches the range extender on/off and adjusts generation power according to battery SOC, vehicle speed, load and temperature, achieving adaptive matching of vehicle conditions and balancing range and fuel consumption.
2. Optimal-efficiency operating-point control of the range extender.
With a built-in engine universal characteristic MAP algorithm, it abandons fixed-speed generation logic and dynamically matches the engine's optimal operating point to vehicle energy demand, avoiding low-efficiency, high-fuel-consumption, high-vibration conditions, greatly improving range-extender generation efficiency and reducing charge-sustaining fuel consumption.
3. Coordinated generation and battery charge/discharge protection.
Linked with BMS battery status, it precisely controls generation upper limits and charging rates to avoid over-charging, over-temperature and high-current surges, dynamically balancing range-extender generation power with battery and motor loads, effectively extending battery life and improving system safety.
4. Smooth mode switching and NVH optimization.
With progressive start/stop control and torque buffering strategies, it resolves the jerk, vibration and noise caused by sudden range-extender engagement and disengagement, achieving imperceptible smooth transitions between oil and electric power and greatly improving ride comfort.
5. Full-scenario extreme-condition adaptation.
Adapting to extreme scenarios such as low temperature, high temperature, hill climbing, high speed and heavy load, it supports low-temperature pre-generation, high-temperature power-limiting protection and high-speed steady-state charging logic, thoroughly solving the pain points of high-speed power attenuation, weak charge-sustaining performance and reduced low-temperature range of range-extender vehicles.
6. Model-based rapid development and full-dimension simulation.
Range-extender energy management strategies are quickly built on Simulink, and ECUCoder generates production-grade code with one click. The SimCar range-extender-dedicated HIL bench simulates tens of thousands of combined SOC, vehicle speed and temperature conditions to validate strategy stability in advance, greatly reducing real-vehicle tuning risks.
1. Deep oil-electric coupling, greatly optimizing vehicle energy consumption.
Breaking with traditional fixed generation logic, it achieves dynamic optimal power matching and precisely balances dynamic performance and economy. Compared with traditional range-extender control strategies, charge-sustaining fuel consumption is reduced by 8%~15%, and combined range is significantly improved.
2. Fully self-controlled core technology with no external dependency.
Range-extender energy management, condition strategies, NVH optimization and fault protection algorithms are all developed in-house; the full toolchain has no overseas licensing binding, with fully open low-level code, so customers can iterate strategies themselves and own the core range-extender electronic control IP.
3. Short development cycle and high calibration efficiency.
With reusable same-source software and hardware and full upfront MIL/SIL/HIL verification, a large number of condition and strategy iterations are completed in the virtual phase, greatly reducing real-vehicle calibration rounds; the overall development cycle is shortened by more than 50%.
4. Adaptable to all categories of range-extender vehicle platforms.
The modular architecture flexibly adapts to passenger vehicles, commercial range-extender vehicles and range-extender construction machinery, compatible with small- and large-displacement range-extender engines and with high- and low-voltage generation systems, enabling rapid adaptation to new vehicle platform iterations.
5. Comprehensive upgrade of vehicle smoothness and reliability.
Dedicated jerk suppression, vibration optimization and power buffering logic solve the industry-wide problems of abrupt range-extender engagement, high-speed vibration and weak charge-sustaining power, significantly improving vehicle ride quality and operating-condition stability.
6. Fully meeting automotive-grade mass production requirements.
Strictly following the IATF 16949 quality system and ISO 26262 functional safety development process, it supports the full set of DV/PV endurance, high/low temperature and vibration tests for the range-extender system, directly satisfying OEM mass-production audits and large-scale installation requirements.