An outer rotor generator for range extender

Abstract

The application provides an outer rotor generator for a range extender, comprising: a flywheel shell and a motor shell, a motor rotor, a starting gear ring, a stator core and a rotary transformer arranged in the flywheel shell and the motor shell, the starting gear ring being in transmission connection with the motor rotor; the motor rotor comprises: a rotor spoke, a rotor hub, a rotor core and a permanent magnet; a hollow convex shaft is arranged at the center of the rotor spoke, the inner wall of the rotor hub is fixedly connected with the outer wall of the rotor core, and the permanent magnet is arranged in the rotor core; the stator core is press-fitted on the outer wall of a hollow cylindrical shell in the space surrounded by the rotor hub, the outer wall of the convex shaft is fixedly connected with the inner ring of the rotary transformer, and the outer ring of the rotary transformer is fixedly connected with the hollow cylindrical shell; the outer rotor generator for the range extender has the advantages of short length, light weight, simple overall structure, few fault points and the like, can make the rotor weight lighter under the condition that the rotational inertia is unchanged, and reduces the influence of the rotor weight on the engine bearing bush.

Description

Technical Field

[0001] The present invention belongs to the technical field of generator equipment, and in particular relates to an outer rotor generator for a range extender. Background Art

[0002] Energy conservation and environmental protection are enduring themes in the automotive industry. It's well known that pure electric vehicles, currently hampered by low specific energy and high prices for power batteries, have insufficient range for long-distance travel, leading to range anxiety among consumers. Range extenders effectively address this anxiety and have become a key development trend in new energy vehicles. Range extenders typically consist of an engine and generator, with the generator rotor directly connected to the engine crankshaft and the generator housing mounted on the engine flywheel housing. The generator stator is housed within a hub-shaped rotor, mounted on the inner water jacket of the housing and cooled by internal water jacket cooling. However, the generator's complex structure, including the flywheel, flexible coupling disc, and bearings, results in a large overall length and volume. Furthermore, the excessive rotor mass can impact the engine bearings. Summary of the Invention

[0003] The purpose of the present invention is to provide an outer rotor generator for a range extender, aiming to improve the motor structure, optimize the volume and mass, and make the rotor lighter while keeping the moment of inertia unchanged.

[0004] In order to achieve the above technical objectives and the above technical effects, the present invention is implemented through the following technical solutions:

[0005] The present invention provides an outer rotor generator for a range extender, comprising:

[0006] A flywheel housing and a motor housing, wherein the motor housing is provided with a hollow cylindrical shell, the hollow cylindrical shell is provided with a central through hole, and an annular water channel is embedded in the hollow cylindrical shell; the flywheel housing and the motor housing are fixedly connected by bolts;

[0007] The motor rotor, starting ring gear, stator core and rotary transformer are arranged in the flywheel housing and the motor housing, and the starting ring gear is drivingly connected to the motor rotor; the motor rotor includes: rotor spokes, a rotor hub, a rotor core and permanent magnets; the rotor spokes are disc-shaped structures with a hollow convex shaft at the center; the rotor hub and the rotor core are both annular structures, the inner wall of the rotor hub is fixedly connected to the outer wall of the rotor core, and the permanent magnets are arranged inside the rotor core; the stator core is press-fitted on the outer wall of the hollow cylindrical shell in the space surrounded by the rotor hub, and a winding is also embedded in the stator core. The outer wall of the convex shaft is fixedly connected to the inner ring of the rotary transformer, and the outer ring of the rotary transformer is fixedly connected to the hollow cylindrical shell.

[0008] As a further improvement of the present invention, it also includes: a clutch housing and a bearing, the clutch housing is fixedly connected to the motor housing; the hollow cylindrical shell is a concave structure, the outer wall of the convex shaft is also fixedly connected to the inner ring of the bearing, the outer ring of the bearing is fixedly connected to the hollow cylindrical shell, and the end of the convex shaft passes through the motor housing and extends to the inside of the clutch housing.

[0009] As a further improvement of the present invention, it further comprises: a rear cover and a socket, wherein the rear cover is fixedly connected to the motor housing, and the socket is arranged on the rear cover.

[0010] As a further improvement of the present invention, it further comprises: a water inlet pipe, a water outlet pipe and a junction box, wherein the water inlet pipe and the water outlet pipe are fixedly connected to the stator housing respectively, and the junction box is fixedly connected to the motor housing.

[0011] Advantages of the present invention:

[0012] Compared to traditional standalone motors, the external rotor generator for a range extender provided by this invention eliminates the traditional flywheel, flexible connecting plate, and bearings between the generator and the engine. This offers advantages such as shorter length, lighter weight, simpler overall structure, and fewer points of failure. While maintaining the same moment of inertia, it reduces the rotor's weight and its impact on the engine's bearings. Furthermore, it can be connected to a clutch housing to provide external power output. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a schematic structural diagram of the outer rotor generator of the present invention installed on the range extender;

[0014] Figure 2 Schematic diagram of the cross-sectional structure of the outer rotor generator according to the present invention;

[0015] Figure 3 This is a schematic structural diagram of the flywheel housing according to the present invention;

[0016] Figure 4 This is a schematic structural diagram of the annular waterway according to the present invention;

[0017] Figure 5 Schematic diagram of the structure of the motor rotor according to the present invention;

[0018] Figure 6 A side sectional view of the motor rotor according to the present invention;

[0019] Figure 7 This is a schematic structural diagram of the outer rotor generator for the range extender according to the present invention;

[0020] Figure 8 This is a schematic diagram of the installation of the clutch housing of the present invention.

[0021] In the figure: 100 - engine, 101 - crankshaft, 200 - external rotor generator, 201 - flywheel housing, 202 - motor housing, 2021 - hollow cylindrical shell, 2022 - annular water channel, 2023 - central through hole, 203 - motor rotor, 2031 - cam, 2032 - rotor spoke, 2033 - rotor hub, 2034 - rotor core, 2035 - permanent magnet, 204 - stator core, 205 - starting ring gear, 206 - rotary transformer, 207 - rear cover, 208 - socket, 209 - water inlet pipe, 210 - water outlet pipe, 211 - junction box, 212 - bearing, 300 - clutch housing. DETAILED DESCRIPTION

[0022] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below through specific embodiments in conjunction with the accompanying drawings. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0023] In an embodiment of the present invention, an outer rotor generator for a range extender is provided. Figure 1 As shown, the engine 100 and the outer rotor generator 200 can be connected to form a range extender. The overall structure of the range extender depends on the structure of the outer rotor generator 200. Figure 2 As shown, the outer rotor generator 200 includes: a flywheel housing 201 and a motor housing 202, and a hollow cylindrical shell 2021 is provided on the motor housing 202. Figure 3 、 Figure 4 As shown, a central through hole 2023 is opened on the hollow cylindrical shell 2021, and an annular water channel 2022 is embedded in the hollow cylindrical shell 2021. The annular water channel 2022 can be designed in the shape of a "U". The flywheel housing 201 and the motor housing 202 are fixedly connected by bolts. The flywheel housing 201 is also used to be fixedly connected to the housing of the engine 100.

[0024] Please continue to refer to Figure 2 The motor rotor 203, the starting ring gear 205, the stator core 204 and the rotary transformer 206 are arranged in the flywheel housing 201 and the motor housing 202, and the starting ring gear 205 is transmission-connected to the motor rotor 203; Figure 5 、 Figure 6As shown, the motor rotor 203 includes: a rotor spoke 2032, a rotor hub 2033, a rotor core 2034 and a permanent magnet 2035; the rotor spoke 2032 is a disc-shaped structure with a hollow convex shaft 2031 at its center; the rotor hub 2033 and the rotor core 2034 are both annular structures, the inner wall of the rotor hub 2033 is fixedly connected to the outer wall of the rotor core 2034, and the permanent magnet 2035 is arranged inside the rotor core 2034; the stator core 2034 is press-fitted on the outer wall of the hollow cylindrical shell 2021 in the space surrounded by the rotor hub 2033, and a winding is also embedded in the stator core 2034. The outer wall of the convex shaft 2031 is fixedly connected to the inner ring of the rotary transformer 206, and the outer ring of the rotary transformer 206 is fixedly connected to the hollow cylindrical shell 2021 The rotor spoke 2032 is also used to be fixedly connected to the crankshaft 101 of the engine 100 to receive the power output of the engine 100, thereby, the crankshaft 101 of the engine 100, the rotor spoke 2032, the cam 2031 and the rotary transformer 206 will maintain synchronous rotation; it can be seen that the outer diameter of the rotor spoke 2032 determines the outer diameter of the motor rotor 203, and the axial length of the rotor hub 2033 determines the axial size of the motor rotor 203 and the outer rotor generator 200. Therefore, by increasing the outer diameter of the rotor spoke 2032 and reducing the axial length of the rotor hub 2033, the rotational inertia of the motor rotor 203 can still be kept unchanged. Compared with the inner rotor generator in the prior art, the rotor of the generator with the same power can reduce the mass by 20-30%.

[0025] In one embodiment, Figure 8 As shown, it also includes: a clutch housing 300 and a bearing 212, the clutch housing 300 is fixedly connected to the motor housing 202; the hollow cylindrical housing 2021 is a concave structure, the outer wall of the convex shaft 2031 is also fixedly connected to the inner ring of the bearing 212, the outer ring of the bearing 212 is fixedly connected to the hollow cylindrical shell 2021, and the end of the convex shaft 2031 passes through the motor housing 202 and extends to the inside of the clutch housing 300, thereby the convex shaft 2031 can also drive the transmission device inside the clutch housing 300 to realize power output.

[0026] In one embodiment, Figure 7 As shown, it may further include: a rear cover 207 and a socket 208 , the rear cover 207 is fixedly connected to the motor housing 202 , and the socket 208 is provided on the rear cover 207 .

[0027] In some embodiments, please refer to Figure 7 , and may further include: a water inlet pipe 209 , a water outlet pipe 210 and a junction box 211 , wherein the water inlet pipe 209 , the water outlet pipe 210 and the junction box 211 are fixedly connected to the motor housing 202 respectively.

[0028] References throughout this specification to "some embodiments," "one embodiment," or "an embodiment" mean that a particular feature, structure, or property described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases "in some embodiments," "in one embodiment," or "in an embodiment" in various places throughout this specification do not necessarily refer to the same embodiment. Furthermore, the particular features, structures, or properties may be combined in any suitable manner in one or more embodiments. Furthermore, the elements in the drawings herein are for illustrative purposes only and are not drawn to scale.

[0029] Having thus described several aspects of at least one embodiment of the present invention, it will be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art, and such alterations, modifications, and improvements are intended to be within the spirit and scope of the present invention.

Claims

1. An outer rotor generator for a range extender, characterized in that: include: A flywheel housing and a motor housing, wherein the motor housing is provided with a hollow cylindrical shell, the hollow cylindrical shell is provided with a central through hole, and an annular water channel is embedded in the hollow cylindrical shell; the flywheel housing and the motor housing are fixedly connected by bolts; The motor rotor, starting ring gear, stator core and rotary transformer are arranged in the flywheel housing and the motor housing, and the starting ring gear is drivingly connected to the motor rotor; the motor rotor comprises: a rotor spoke, a rotor hub, a rotor core and a permanent magnet; the rotor spoke is a disc-shaped structure with a hollow convex shaft at its center; the rotor hub and the rotor core are both annular structures, the inner wall of the rotor hub is fixedly connected to the outer wall of the rotor core, and the permanent magnet is arranged inside the rotor core; the stator core is press-fitted onto the outer wall of the hollow cylindrical shell in the space enclosed by the rotor hub, and a winding is also embedded in the stator core. The outer wall of the convex shaft is fixedly connected to the inner ring of the rotary transformer, and the outer ring of the rotary transformer is fixedly connected to the hollow cylindrical shell; The invention also includes: a clutch housing and a bearing, wherein the clutch housing is fixedly connected to the motor housing; the hollow cylindrical housing is a concave structure, the outer wall of the convex shaft is also fixedly connected to the inner ring of the bearing, the outer ring of the bearing is fixedly connected to the hollow cylindrical housing, and the end of the convex shaft passes through the motor housing and extends into the clutch housing; It also includes: a rear cover and a socket, wherein the rear cover is fixedly connected to the motor housing, and the socket is arranged on the rear cover.

2. The outer rotor generator for the range extender according to claim 1, characterized in that: Also includes: A water inlet pipe, a water outlet pipe and a junction box, wherein the water inlet pipe and the water outlet pipe are fixedly connected to the stator housing respectively, and the junction box is fixedly connected to the motor housing.

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