Range extender assembly

Abstract

The utility model provides a range extender assembly, which belongs to the technical field of electric automobile range extenders, and comprises an engine, a speed change device, a generator and a range extender shell which are connected in sequence, the range extender shell is used for accommodating the speed change device and the generator, a motor controller is integrated on the range extender shell, and the generator is connected with the motor controller through a connector. According to the range extender assembly, both the engine and the generator work in a high-efficiency area through the speed change device, the external size of the range extender assembly and the occupied cabin space of the range extender assembly are smaller, the heat dissipation and cooling efficiency is higher, and the lubricating effect is better.

Description

Technical Field

[0001] The utility model belongs to the technical field of electric vehicle range extenders, and in particular relates to a range extender assembly. Background Art

[0002] Electric vehicles have the advantages of energy saving, environmental protection, and zero emissions, but their driving range is limited by the amount of electrical energy stored in the onboard power supply. Range extenders can convert other energy into electrical energy and quickly replenish the battery, solving the problem of short driving range of pure electric vehicles.

[0003] The range extender is mainly composed of an engine, a generator, a connecting mechanism and a control system. The output shaft of the engine drives the rotor of the generator to rotate through the input shaft of the generator, and the rotor of the generator rotates relative to the stator of the generator, thereby generating electrical energy that can be used by electric vehicles.

[0004] Existing range extender powertrains basically all use four-cylinder engines, which have relatively large engine power. However, for hybrid or range-extended vehicles, the advantages of four-cylinder engines cannot be brought into play, resulting in redundant power waste.

[0005] Most range extenders are directly connected to the engine and generator, but the high-efficiency zone of small-power engines for micro-cars is generally 2000-3500r / min, and the high-efficiency zone of generators is generally 8000-10000r / min. The corresponding speed of the high-efficiency zone of the small-power engine is quite different from the corresponding speed of the high-efficiency zone of the generator. Therefore, the inconsistency of the corresponding speed of the high-efficiency zone leads to low efficiency of the range extender directly connected to the engine and generator.

[0006] In addition, existing range extenders have complex structures, low heat dissipation and cooling efficiency, high costs, and difficulty in maintenance. Utility Model Content

[0007] In order to solve the above problems in the prior art, the utility model provides a range extender assembly, which aims to improve the output power and heat dissipation efficiency of the range extender, thereby improving fuel economy, optimizing the size of the range extender, and reducing the cost of the range extender.

[0008] In order to achieve the above purpose, the utility model provides the following technical solutions:

[0009] A range extender assembly comprises an engine, a speed change device and a generator connected in sequence, a range extender housing for accommodating the speed change device and the generator, the range extender housing being integrated with a motor controller, and the generator being connected to the motor controller via a connector.

[0010] Furthermore, the generator and the motor controller share a cooling system.

[0011] Furthermore, the cooling system includes a water inlet, a water channel, a water jacket and a water outlet connected in sequence, the water inlet is arranged on the range extender housing corresponding to the position of the motor controller, the water outlet is arranged on the range extender housing corresponding to the position of the generator, and the water jacket is arranged outside the generator.

[0012] Furthermore, the range extender housing includes a front housing, a middle housing and a rear housing which are connected in sequence, and the front housing is connected to the outer shell of the engine.

[0013] Furthermore, the middle shell and the rear shell are both provided with ventilation holes.

[0014] Furthermore, the water inlet is arranged on the rear shell, the water outlet is arranged on the middle shell, and the rear shell and the middle shell are respectively integrated with the water channels connected in series.

[0015] Furthermore, the engine is a two-cylinder four-stroke engine with a compression ratio of 15-17, and the engine is equipped with an EGR exhaust gas recirculation system and a VVT timing system.

[0016] Furthermore, the range extender assembly also includes a torsional damper, the input end of the torsional damper is transmission-connected to the output end of the engine, and the output end of the torsional damper is transmission-connected to the input end of the speed change device.

[0017] Furthermore, the speed change device includes a first bevel gear and a second bevel gear that are meshed with each other, the first bevel gear is connected to the output end of the torsional damper, and the second bevel gear is connected to the input end of the generator. Through the transmission speed ratio of the meshing of the first bevel gear and the second bevel gear, the speed change device can increase the output speed of the engine to within the rated speed range of the generator.

[0018] Furthermore, the torsional damper is spline-connected to the first helical gear, and the second helical gear is spline-connected to the engine.

[0019] Furthermore, the range extender assembly also includes a lubrication system, which includes an oil filling port and an oil drain port arranged on the range extender housing, an oil baffle plate arranged on the inner wall of the range extender, and an oil groove formed by the oil baffle plate.

[0020] Furthermore, the speed change device is oil-stirring lubricating, and the splashing lubricating oil is blocked by the oil baffle plate and guided by the oil groove, thereby lubricating the bearing.

[0021] Compared with the prior art, the utility model has at least the following beneficial effects:

[0022] 1. The speed regulation of the speed change device enables both the engine and the generator to operate in the high efficiency zone;

[0023] 2. The motor controller is integrated in the rear housing of the range extender, and the three-phase AC power generated by the generator is directly connected to the motor controller through a connector, eliminating the need for high-voltage wiring harnesses, saving costs, and reducing the space occupied by the range extender assembly in the cabin;

[0024] 3. By designing connecting water channels in the front and rear housings of the range extender, the generator and motor controller share a cooling system, shortening the coolant flow path, improving heat exchange efficiency, eliminating cooling pipes, and reducing the external dimensions of the range extender assembly;

[0025] 4. By arranging oil baffle plates on the inner walls of the front housing and the middle housing of the range extender, the oil baffle plates form oil grooves, and the speed change device stirs the oil for lubrication. The gears of the speed change device stir up the lubricating oil during the meshing process. The splashing lubricating oil is blocked by the oil baffle plates and guided by the oil grooves, thereby splashing lubrication on rotating parts such as bearings, thereby improving lubrication efficiency and achieving better lubrication effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 The figure is a schematic diagram of the principle of a range extender assembly according to an embodiment of the utility model, in which the letter G represents a generator, C represents a motor controller, and B represents a battery;

[0027] Figure 2 This is a schematic structural diagram of a range extender assembly according to an embodiment of the utility model (front view);

[0028] Figure 3 This is a schematic structural diagram of a range extender assembly according to an embodiment of the utility model (back side);

[0029] Figure 4 A schematic diagram of a water jacket according to an embodiment of the utility model;

[0030] Figure 5 This is a schematic diagram of a shell water channel of an embodiment of the utility model. DETAILED DESCRIPTION

[0031] In order to make the purpose, technical solution and advantages of the implementation of the utility model clearer, the technical solution in the implementation of the utility model will be clearly and completely described below in conjunction with the drawings in the implementation of the utility model. Obviously, the described implementation is a part of the implementation of the utility model, not all of the implementations. Based on the implementation of the utility model, all other implementations obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0032] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in the field without creative work are within the scope of protection of the present invention.

[0033] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected or indirectly connected through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0034] In order to better understand the purpose, structure and function of the present invention, a range extender assembly of the present invention is further described in detail below in conjunction with the accompanying drawings.

[0035] like Figure 1-5 As shown, the range extender in some embodiments of the utility model includes a low-power engine 1, a generator 4 and a speed change device 3, wherein the low-power engine 1 consumes fuel to generate heat energy, the heat energy is converted into mechanical energy to drive the generator 4 to move, the generator 4 consumes mechanical energy and converts it into electrical energy to drive the vehicle, and the excess electricity is stored in the battery; the speed change device 3 enables the low-power engine 1 and the generator 4 to have a speed ratio during the transmission process, so that the low-power engine 1 and the generator 4 work in the high-efficiency zone at the same time, thereby achieving the purpose of improving fuel economy; when the low-power engine 1 is in a stopped state, the battery supplies power to drive the generator 4 to rotate, and drives the crankshaft of the low-power engine 1 to rotate, thereby achieving the effect of starting the low-power engine 1.

[0036] In some embodiments of the present invention, the low-power engine 1 is a two-cylinder engine with high thermal efficiency, a high compression ratio of 15-17, and is equipped with an EGR exhaust gas recirculation system and a VVT timing system.

[0037] In some embodiments of the utility model, the low-power engine 1 is equipped with a torsional vibration damper 12 to adjust the speed unevenness caused by the reciprocating motion of the piston, so that the transmission process is smoother and the vibration and noise of the range extender in the utility model are reduced; the torsional vibration damper 12 is connected to the flywheel in the low-power engine 1 by screws, and the end of the flywheel in the low-power engine 1 is provided with unevenly distributed locating pins that cooperate with the locating holes in the torsional vibration damper 12 to prevent misinstallation and simplify the installation process.

[0038] In some embodiments of the utility model, the low-power engine 1 and the large helical gear 31 are connected with the external splines at the end of the large helical gear 31 through the internal splines at the center of the torsional vibration damper 12; the speed change device 3 is composed of a large helical gear 31 and a small helical gear 32, and a fixed speed ratio transmission is realized through the meshing of the large helical gear 31 and the small helical gear 32. The meshing of the helical gears has the characteristics of low impact noise, high load-bearing capacity and smooth transmission.

[0039] In some embodiments of the present invention, the small helical gear 32 and the generator 4 are connected through the internal splines at the center of the generator rotor 42 and the external splines at the end of the small helical gear 32, which can transmit a large torque.

[0040] In some embodiments of the present invention, both the range extender middle housing 22 and the range extender rear housing 23 are provided with vent holes for removing the pressure change caused by the temperature difference.

[0041] like Figure 2-3 As shown, in some embodiments of the utility model, a motor controller 5 is integrated in the rear housing 23 of the range extender, and the three-phase alternating current generated by the low-power engine 1 driving the generator 4 through the crankshaft and the speed change device 3 is directly connected to the motor controller 5 through a connector (connector), eliminating the cumbersomeness and risk of wiring and reducing hardware costs; the three-phase alternating current is converted into two-phase direct current after passing through the motor controller 5, and the battery is charged through the two-phase direct current connector 9.

[0042] like Figure 1-3 As shown, in some embodiments of the utility model, a cooling system is also included. The cooling system of the low-power engine 1 is a cooling system designed by the engine itself. The utility model does not change it and still adopts one of the prior art; the cooling system also includes a cooling system for the generator 4 and the motor controller 5. Thanks to the integration of the motor controller 5 in the rear housing 23 of the range extender, a set of motor controller molds is saved, and the generator 4 and the motor controller 5 share a cooling system. Reasonable water channel design connects the water channels on the housing 22 in the range extender and the rear housing 23 of the range extender in series, eliminating the external rubber water pipe, reducing the size of the range extender, and facilitating the generation of The engine compartment is arranged, the cooling component of the generator 4 includes a water jacket 41 and a water outlet 62, and the cooling component of the motor controller 5 includes a water inlet 61. The water inlet 61 is arranged on the rear shell 23 of the range extender, and the water outlet 62 is arranged on the middle shell 22. The cooling water enters the cooling system from the water inlet 61, and first cools the IGBT power module of the motor controller 5, etc., and enters the water jacket 41 of the generator 4 through the water channel. The cooling water enters the water jacket 41 of the generator 4, circulates once, and flows out from the water outlet 62. Since the IGBT power module of the motor controller 5 generates a large amount of heat, the water inlet 61 of the cooling water is arranged on the rear shell 23 of the range extender.

[0043] In some embodiments of the utility model, a lubrication system is also included. The lubrication system of the low-power engine 1 is a lubrication system designed for the engine itself. This solution does not change it and still adopts one of the prior arts. The lubrication system also includes lubrication for the speed change device 3 and the bearings. The lubrication method of the speed change device 3 is splash lubrication. The large bevel gear 31 and the small bevel gear 32 are lubricated by stirring the oil during the meshing process. By reasonably reinforcing the inner walls of the range extender front housing 21 and the range extender middle housing 22, an oil baffle plate and an oil groove are formed. The oil stirred up by the meshing of the large bevel gear 31 and the small bevel gear 32 splashes onto the oil baffle plate. The splashed lubricating oil is blocked by the oil baffle plate and guided by the oil groove, thereby splashing lubrication on other rotating parts such as bearings. The lubrication system components also include an oil filling screw 81 and an oil drain screw 82. The lubricating oil is replaced by unscrewing the oil filling screw 81 and the oil drain screw 82.

[0044] The above description is only a preferred embodiment of the utility model and is not intended to limit the utility model. For those skilled in the art, the utility model may have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the utility model are included in the protection scope of the utility model.

Claims

1. A range extender assembly, characterized in that: The invention comprises an engine, a speed change device and a generator which are connected in sequence, and a range extender housing for accommodating the speed change device and the generator. The range extender housing is integrated with a motor controller, and the generator is connected to the motor controller through a connector.

2. The range extender assembly according to claim 1, characterized in that: The generator and the motor controller share a cooling system.

3. The range extender assembly according to claim 2, characterized in that: The cooling system includes a water inlet, a water channel, a water jacket and a water outlet connected in sequence, the water inlet is arranged on the range extender housing corresponding to the position of the motor controller, the water outlet is arranged on the range extender housing corresponding to the position of the generator, and the water jacket is arranged outside the generator.

4. The range extender assembly according to claim 3, characterized in that: The range extender housing comprises a front housing, a middle housing and a rear housing which are connected in sequence, the front housing is connected to the outer shell of the engine, and the middle housing and the rear housing are both provided with ventilation holes.

5. The range extender assembly according to claim 4, characterized in that: The water inlet is arranged on the rear shell, the water outlet is arranged on the middle shell, and the rear shell and the middle shell are respectively integrated with the water channels connected in series.

6. The range extender assembly according to claim 1, characterized in that: The engine is a two-cylinder four-stroke engine with a compression ratio of 15-17. The engine is equipped with an EGR exhaust gas recirculation system and a VVT timing system.

7. The range extender assembly according to claim 1, characterized in that: The range extender assembly also includes a torsional damper, an input end of the torsional damper is transmission-connected to an output end of the engine, and an output end of the torsional damper is transmission-connected to an input end of the speed change device.

8. The range extender assembly according to claim 7, characterized in that: The speed change device includes a first helical gear and a second helical gear meshing with each other, the first helical gear is connected to the output end of the torsion damper, and the second helical gear is connected to the input end of the generator. Through the transmission speed ratio of the meshing of the first helical gear and the second helical gear, the speed change device can increase the output speed of the engine to within the rated speed range of the generator.

9. The range extender assembly according to claim 8, characterized in that: The torsional damper is spline-connected to the first helical gear, and the second helical gear is spline-connected to the engine.

10. The range extender assembly according to claim 1, characterized in that: The range extender assembly also includes a lubrication system, which includes an oil filling port and an oil drain port arranged on the range extender housing, an oil baffle plate arranged on the inner wall of the range extender, and an oil groove formed by the oil baffle plate.

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