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I、 Significant temperature fluctuations can cause multiple damages to electrical components of construction machinery
The impact of temperature changes on electrical components can be divided into three categories: high temperature, low temperature, and alternating cold and hot shock. Under high temperature conditions, the internal carrier activity of semiconductor devices increases, device parameters drift, capacitor electrolyte evaporation accelerates, and insulation material aging rate accelerates. Long term high-temperature operation can reduce the service life of components, resulting in inaccurate signal acquisition and misjudgment of electrical control conditions. In low-temperature environments, the opposite is true. The conductivity characteristics of components change, some capacitance capacity decays, sensor response slows down, and equipment during the cold start phase is prone to action lag.
The impact of the cold and hot cycle caused by the alternation of day and night is often overlooked. Metal, plastic, and circuit board substrates have different coefficients of thermal expansion, and repeated thermal expansion and contraction can cause stress fatigue at circuit board solder joints and result in virtual soldering; The metal spring inside the connector repeatedly expands and contracts, causing an increase in contact resistance and intermittent signal interruption. This type of malfunction is sporadic and extremely difficult to troubleshoot. After the equipment is sent to the maintenance workshop and the temperature rises, the malfunction disappears, making it difficult to reproduce the problem and consuming a lot of maintenance time.
The electrical system of fuel engineering machinery is relatively simple, with only engine control and basic sensors; The electric loader is equipped with a VCU vehicle controller, BMS battery management system, motor controller, dozens of pressure, temperature, and position sensors, and the number of electrical components has doubled. Once the temperature tolerance range of the components is insufficient, the probability of failure in a temperature difference environment will significantly increase. Many electric loaders use consumer grade or ordinary industrial grade components, which are only suitable for constant temperature indoor environments and placed in exposed material yards. Faced with temperature differences of tens of degrees between winter and summer, long-term stability is difficult to guarantee.
II、 Selection criteria for wide temperature range components and the product landing strategy of Jining Xinghang
During the component selection stage, Jining Xinghang abandoned ordinary commercial grade components and chose wide temperature industrial grade components for the core electronic control motherboard, signal acquisition chip, pressure sensor, and wiring harness connector. The working temperature range of the core chip covers the low to high temperature range, meeting the requirements of temperature fluctuations in outdoor environments. All sensors do not only focus on static accuracy indicators, but also synchronously assess the changes in measurement accuracy under high and low temperature environments, ensuring that there will be no significant deviation in pressure, temperature, and position data collected under low-temperature refrigeration and high-temperature full load conditions. The vehicle controller relies on accurate signals to complete power adjustment.
Wiring harnesses and connectors are equally important in wide temperature range design. Ordinary plastic sheaths become hard and brittle in low temperature environments, and are prone to cracking during vibration during operation, as well as the invasion of water vapor and dust; Softening and deformation under high temperature environment. Jining Xinghang uses high and low temperature resistant special materials for the sheath, and the internal terminals are treated with gold plating to improve contact stability in alternating cold and hot environments and reduce the probability of terminal oxidation. The insulation layer of the wiring harness is made of weather resistant materials, taking into account both high and low temperature characteristics, while also being resistant to oil and corrosion, making it suitable for complex environments on construction sites.
Component selection is not just about selecting wide temperature devices, but also conducting cold and hot cycle durability testing simultaneously. The prototype is placed in a high and low temperature chamber in the laboratory, repeatedly simulating temperature changes day and night, continuously collecting electrical control signals and sensor data, observing changes in component performance, and screening components with significant performance degradation under temperature fluctuations. In addition to static testing, synchronous loading and unloading composite action testing will be carried out under high and low temperature conditions to verify the consistency of power output and action response of the equipment under cold start and high temperature full load, ensuring that the components will not affect the overall operation feel when the temperature changes.
III、 Wide temperature range devices combined with overall machine strategy to reduce the risk of using temperature difference conditions
Wide temperature range components are the hardware foundation, and Jining Xinghang's supporting electronic control strategy further buffers the impact of temperature fluctuations. During the device startup phase, BMS and VCU will collect the temperature of each module and execute differentiated startup logic based on the temperature status. When starting at low temperature, the power output will not immediately reach full load. First, complete the battery preheating and hydraulic oil preheating, wait for the core component temperature to enter a reasonable range, and then gradually release the rated power; Working in high-temperature environments, the system dynamically limits peak power to avoid continuous overheating of components.
At the same time, the electronic control has a built-in temperature drift compensation algorithm, and the sensor's collected signals will be calibrated in real time based on its own temperature, offsetting the measurement deviation caused by temperature changes in the components themselves. Even if there is a slight temperature drift in the sensor itself, the data provided to the vehicle controller through algorithm compensation is still accurate, avoiding false triggering of protection and power abnormalities due to temperature. This combination of software and hardware solution is different from relying solely on components and hardware to withstand temperature changes. Through software and hardware collaboration, it further expands the temperature range within which the equipment can operate stably.
IV、 The actual value brought to end users
The most intuitive benefit for cross seasonal operations in material yards and factory areas is to reduce occasional electrical failures during seasonal transitions. Many devices operate normally in summer, but frequently experience cold start abnormalities and lagging actions after winter; After being exposed to sunlight in summer, there is a power jump, and the root cause is the insufficient temperature resistance of the components. Jining Xinghang uses wide temperature range components to significantly reduce the probability of such occasional failures, minimize equipment downtime for maintenance, and ensure stable attendance throughout the year.
Extend the service life of electrical components. The aging and virtual soldering caused by alternating cold and heat are chronic damages. Wide temperature devices have stronger resistance to temperature stress, and the service life of electronic controls, sensors, and connectors is longer, reducing the cost of replacing electrical components in the later stage. The residual value of the equipment will also benefit, as long-term use in areas with large temperature differences will result in slower aging of the electrical system.
At the same time, it reduces the difficulty of troubleshooting for operation and maintenance personnel. Occasional electrical failures are the most headache inducing problem in the maintenance of construction machinery, and the symptoms of these failures are intermittent. Wide temperature range components reduce the problems of virtual soldering and signal drift caused by cold and hot cycles, reduce these difficult to reproduce faults, and lower on-site maintenance workload.
Conclusion
Electric loaders are electrical intensive construction machinery, and the lower limit of overall reliability is determined by the environmental tolerance of each component. Many product promotions focus on the two core components of batteries and motors, but ignore basic components such as sensors, chips, and connectors. The temperature difference between day and night, as well as the significant fluctuations in winter and summer temperatures, are environmental challenges that outdoor work equipment cannot avoid. Jining Xinghang electric loader adheres to the selection of wide temperature range components, cooperates with electronic control temperature compensation algorithm, and works together with software and hardware to resist the performance drift and stress aging of components caused by temperature fluctuations, ensuring that the equipment switches between outdoor material yards and factory areas, regardless of cold or hot weather, maintaining stable signal acquisition and power output, and reducing the risk of hidden electrical system failures.
