An outer rotor generator for range extender

Abstract

The application provides an outer rotor generator for a range extender, which comprises a stator shell, a motor shell, a stator core, a flywheel rotor, an adapter shaft and a rotary transformer, the adapter shaft is a stepped protruding structure, which is provided with a first boss, a second boss and a third boss; the first boss of the adapter shaft penetrates the flywheel rotor and is fixed with an inner ring of the rotary transformer, an outer ring of the rotary transformer is fixedly connected with the motor shell, the flywheel rotor is sleeved on the second boss of the adapter shaft and is fixed with the third boss through bolts; the stator core is press-fitted on an annular protruding structure of the stator shell in an inner cavity of the flywheel rotor; 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 of their batteries, have a range that's insufficient 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. The generator rotor is directly connected to the engine crankshaft, and the generator housing is 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 connecting 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] The stator housing and the motor housing have a hollow disc structure on the outside and an annular raised structure on the inside. The stator housing and the motor housing are fixedly connected by bolts.

[0007] A stator core, a flywheel rotor, a transfer shaft, and a rotary transformer are arranged in the stator housing and the motor housing, wherein the stator core is embedded with a winding and the flywheel rotor has an inner cavity;

[0008] The adapter shaft is a stepped raised structure having a first boss, a second boss, and a third boss. The first boss of the adapter shaft passes through the flywheel rotor and is fixed to the inner ring of the rotary transformer. The outer ring of the rotary transformer is fixedly connected to the motor housing. The flywheel rotor is sleeved on the second boss of the adapter shaft and is fixed to the third boss by bolts.

[0009] The stator core is press-fitted onto the annular protrusion structure of the stator housing in the inner cavity of the flywheel rotor.

[0010] As a further improvement of the present invention, the stator housing includes an outer shell and an inner shell, and the outer shell is provided with an annular water channel.

[0011] As a further improvement of the present invention, the flywheel rotor includes: a flywheel hub, a flywheel housing and a rotor core. A permanent magnet is also provided inside the rotor core. The flywheel hub is fixedly connected to the flywheel housing, and the rotor core is fixed to the inner wall of the flywheel housing. A central through hole and a weight-reducing hole are provided on the flywheel hub.

[0012] 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.

[0013] 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.

[0014] Advantages of the present invention:

[0015] Compared to traditional standalone motors, the outer rotor generator for range extenders 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, higher efficiency, simpler overall structure, and fewer fault points. Compared to integrated inner rotor range extender generators, this outer rotor generator has a shorter axial dimension. Due to its larger rotor outer diameter, the rotor is lighter while maintaining the same moment of inertia, significantly reducing the impact of the rotor weight on the engine bearings. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a schematic structural diagram of the outer rotor generator of the present invention installed on the range extender;

[0017] Figure 2 Schematic diagram of the cross-sectional structure of the outer rotor generator according to the present invention;

[0018] Figure 3 This is a schematic structural diagram of the stator housing according to the present invention;

[0019] Figure 4 It is a structural schematic diagram of the adapter shaft according to the present invention;

[0020] Figure 5 Schematic diagram of the cross-sectional structure of the flywheel rotor of the present invention;

[0021] Figure 6 It is a structural schematic diagram of the side surface of the flywheel rotor of the present invention;

[0022] Figure 7 This is a schematic structural diagram of the outer rotor generator for the range extender according to the present invention.

[0023] In the figure: 100-engine, 101-crankshaft, 200-outer rotor generator, 201-stator housing, 2011-outer housing, 2012-inner housing, 2013-annular water channel, 202-motor housing, 203-flywheel rotor, 2031-flywheel hub, 2032-flywheel housing, 2033-rotor core, 2034-center through hole, 2035-weight reduction hole, 204-adapter shaft, 2041-first boss, 2042-second boss, 2043-third boss, 2044-first screw hole, 2045-second screw hole, 205-rotating transformer, 206-stator core, 207-back cover, 208-socket, 209-water inlet pipe, 210-water outlet pipe, 211-junction box. DETAILED DESCRIPTION

[0024] 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.

[0025] 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 stator housing 201 and a motor housing 202. The outer side of the stator housing 201 is a hollow disc structure, and the inner side of the stator housing 201 is an annular protrusion structure. The stator housing 201 and the motor housing 202 are fixedly connected by bolts. The stator housing 201 is also used to be fixedly connected to the outer casing of the engine 100; a stator core 206, a flywheel rotor 203, an adapter shaft 204 and a rotary transformer 205 are arranged in the stator housing 201 and the motor housing 202. The stator core 206 is embedded with a winding, and the flywheel rotor 203 has an inner cavity. Figure 4As shown, the adapter shaft 204 is a stepped raised structure, which is provided with a first boss 2041, a second boss 2042 and a third boss 2043; the first boss 2041 of the adapter shaft 204 passes through the flywheel rotor 203 and is fixed to the inner ring of the rotary transformer 205, the first boss 2041 is used to transmit power to the rotary transformer 205, the outer ring of the rotary transformer 205 is fixedly connected to the motor housing 202, the front end of the third boss 2043 is provided with a first screw hole 2044, the rear end of the third boss 2043 is provided with a second screw hole 2045, the flywheel rotor 203 is sleeved on the second boss 2042 of the adapter shaft 204 and is fixed to the third boss 2043 It is fixed by bolts at the first screw hole 2044, and the second boss 2042 is used to transmit power to the flywheel rotor 203; the third boss 2043 is fixedly connected to the crankshaft 101 of the engine 100 through the second screw hole 2045 at the rear end to receive the power output of the engine 100, thereby, the crankshaft 101 of the engine 100, the adapter shaft 204, the flywheel rotor 203 and the rotary transformer 205 will maintain synchronous rotation; the stator core 206 is pressed onto the annular protrusion structure of the stator housing 201 in the inner cavity of the flywheel rotor 203, and the inner cavity of the flywheel rotor 203 can accommodate part of the annular protrusion structure located on the inner side of the stator housing 201.

[0026] In one embodiment, Figure 3 As shown, the stator housing 201 includes an outer shell 2011 and an inner shell 2012 , and the outer shell 2011 is provided with an annular water channel 2013 for heat dissipation.

[0027] In some embodiments, as Figure 5 、 Figure 6 As shown, the flywheel rotor 203 includes: a flywheel hub 2031, a flywheel housing 2032 and a rotor core 2033. A permanent magnet is also provided inside the rotor core 2033. The flywheel hub 2031 is fixedly connected to the flywheel housing 2032, and the rotor core 2033 is fixed to the inner wall of the flywheel housing 2032. The flywheel hub 2031 is provided with a central through hole 2034 for inserting the adapter shaft 204 and a weight-reducing hole 2035 for reducing the overall mass. It can be seen that the axial length of the flywheel housing 2032 determines the length of the flywheel rotor. 203 and the axial size of the outer rotor generator 200, the outer diameter of the flywheel hub 2031 determines the outer diameter of the flywheel rotor 203. Therefore, by increasing the outer diameter of the flywheel hub 2031 and reducing the axial length of the flywheel housing 2032, the rotational inertia of the flywheel rotor 203 can still be kept unchanged. Compared with the inner rotor generator of the prior art, the rotor of the generator with the same power can reduce the mass by 20-30%. The flywheel hub 2031 and the flywheel housing 2032 can also adopt an integrated structure and be made by stamping or casting.

[0028] In some embodiments, as Figure 7As 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 arranged on the rear cover 207 .

[0029] 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 , the water inlet pipe 209 and the water outlet pipe 210 are fixedly connected to the stator housing 201 respectively, and the junction box 211 is fixedly connected to the motor housing 202 .

[0030] 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.

[0031] 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: The stator housing and the motor housing have a hollow disc structure on the outside and an annular raised structure on the inside. The stator housing and the motor housing are fixedly connected by bolts. A stator core, a flywheel rotor, a transfer shaft, and a rotary transformer are arranged in the stator housing and the motor housing, wherein the stator core is embedded with a winding and the flywheel rotor has an inner cavity; The adapter shaft is a stepped raised structure having a first boss, a second boss, and a third boss. The first boss of the adapter shaft passes through the flywheel rotor and is fixed to the inner ring of the rotary transformer. The outer ring of the rotary transformer is fixedly connected to the motor housing. The flywheel rotor is sleeved on the second boss of the adapter shaft and is fixed to the third boss by bolts. The stator core is press-fitted onto the annular raised structure of the stator housing in the inner cavity of the flywheel rotor; The stator housing comprises an outer shell and an inner shell, wherein the outer shell is provided with an annular water channel; The flywheel rotor comprises: a flywheel hub, a flywheel housing and a rotor core. A permanent magnet is further provided inside the rotor core. The flywheel hub is fixedly connected to the flywheel housing, and the rotor core is fixed to the inner wall of the flywheel housing. The flywheel hub is provided with a central through hole and a weight-reducing hole. 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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