A generator system integrated structure for extended-range electric vehicles

Abstract

The application relates to a generator system integrated structure for a range-extended electric vehicle, which comprises a motor controller, a casing assembly and a rotor assembly, the motor controller comprises a box body and a box cover, and a supporting capacitor, a power assembly and a filter assembly are arranged in the box body, the box body is a disc-shaped cavity structure, an annular rotary variable structure (RVDT) boss is arranged at the center of the outer surface, the casing assembly comprises a casing, a stator assembly, an RVDT support, an RVDT and an RVDT pressing plate, the stator assembly is in interference fit after being shrink-fitted with the casing, the RVDT support is fixed on the RVDT boss of the box body, the RVDT is fixed on the rear end surface of the RVDT support through the RVDT pressing plate, and the box body is fixedly connected with the rear end surface of the casing. Compared with the prior art, the application has the advantages of reducing the vibration interference of the unbalanced mass of the engine cylinder and reducing the volume of the generator system.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of range-extender electric vehicle generator systems, in particular to a range-extender electric vehicle generator system integrated structure. BACKGROUND

[0002] In recent years, the concept of "energy saving and emission reduction, green travel" has been widely recognized in society, and new energy vehicles have accounted for a large share in the domestic market. However, pure electric vehicles are difficult to match traditional fuel vehicles in a long period of time due to the bottleneck of battery technology development at this stage. At present, vehicle manufacturers claim that the pure electric vehicle can travel 400-600km. However, in actual use, especially in high-speed driving, the energy consumption of auxiliary electrical equipment, wind resistance and tire rolling resistance loss are greatly improved, and the actual driving range is often much less than the test range, causing great range anxiety for drivers and passengers. Range-extender electric vehicles use a small engine and a range-extender to generate electricity in the engine compartment of the whole vehicle, and store energy in the power battery, thereby alleviating the contradiction between power battery capacity and driving range.

[0003] Chinese patent CN213413503U discloses a generator system directly connected to an engine, which places the motor controller directly above the generator. The generator adopts a conventional motor stator-rotor integrated motor scheme, and one end of the generator is provided with a cavity for accommodating the engine flywheel. The engine flywheel is connected to the generator shaft by spline connection to drive the generator to generate electricity for the vehicle power battery. The main development purpose is to design a two-in-one generator system integrated with a directly connected engine. However, the influence of the sinusoidal vibration load generated by the unbalanced mass of the engine cylinder on the motor controller is not fully considered when the motor controller is placed above the generator. Secondly, the generator adopts a stator-rotor integrated structure, which requires strict concentricity of the mounting hole of the flywheel and the generator shaft, increasing the machining and installation precision of the engine and the generator mating surface, which is not suitable for mass production and assembly.

[0004] Chinese patent CN111002843A discloses a driving and generating system integrated structure for range-extender electric vehicles, which divides two cavities in the transmission case for the generator gear box and the driving motor reduction box, respectively. The driving motor and the generator are placed side by side on one side of the transmission case, the engine is placed on the other side of the transmission case, and the integrated controller assembly is placed in the cavity outside the side wall of the transmission case. The gear box volume of this scheme is too large, and its projection area along the engine axis needs to cover the generator, driving motor and engine, which is not convenient for the installation of the assembly in the engine compartment of the whole vehicle. Secondly, the controller assembly is placed in the cavity outside the side wall of the transmission case, so that the internal electronic components of the controller are affected by the double vibration sources from the engine and the transmission.

[0005] Chinese patent CN112240381A discloses a coaxially arranged transmission mechanism for a range-extending hybrid system, specifically an integrated mechanism of a coaxially arranged generator, drive motor and parking mechanism. The deficiency is that the integrated mechanism has a long overall layout, a complex internal structure, a large demand for vehicle assembly space, and is not convenient for assembly. SUMMARY

[0006] The purpose of the present application is to provide a generator system integrated structure for range-extending electric vehicles, which reduces the vibration interference of engine cylinder unbalanced mass by integrating the motor controller assembly into the rear end cover of the generator. At the same time, the generator adopts a stator-rotor separated structure, the stator, the housing and the controller assembly are integrated, the rotor and the engine flywheel disc are integrated, the volume of the generator system is reduced, the integration degree of the system assembly is improved, the assembly precision of the generator housing and the engine is reduced, the demand for the installation space of the vehicle engine compartment is reduced, and it is suitable for mass production and assembly.

[0007] The purpose of the present application can be achieved by the following technical solutions:

[0008] A generator system integrated structure for range-extending electric vehicles, comprising a motor controller, a housing assembly and a rotor assembly,

[0009] The motor controller comprises a box body and a box cover matched with each other, and a support capacitor, a power assembly, a filter assembly and an AC plastic package in the box body, the box body is a disc-shaped cavity structure, an annular rotary variable protrusion is arranged at the center of the outer surface, a plurality of first fixing screw holes are arranged near the edge,

[0010] The housing assembly comprises a housing, a stator assembly, a rotary variable support, a rotary variable and a rotary variable press plate,

[0011] The stator assembly is in interference fit with the housing after hot fitting, the rotary variable support is fixed on the rotary variable protrusion of the box body, the rotary variable is fixed on the rear end face of the rotary variable support through the rotary variable press plate, the second fixing screw hole corresponding to the first fixing screw hole is arranged on the rear end face of the rotary variable support, and the box body and the rear end face of the housing are fixedly connected through the bolts matched with the first fixing screw hole and the second fixing screw hole.

[0012] A first platform, a second platform and an AC end cavity are arranged on the inner surface of the box body, the second platform and the AC end cavity are respectively located on the two sides of the first platform, and a side platform is arranged on the outer side of the box body near the AC end cavity,

[0013] The box cover is in a disc-shaped structure, the outer surface is provided with a protrusion, the inside of the protrusion is a cavity, and the inside of the cavity is provided with a mounting leg;

[0014] The power component bottom is smeared with heat-conducting silicon grease and is fixed on the first platform, the supporting capacitor is fixed on the second platform, the AC plastic package is installed on the upper end face of the AC end cavity, the filter assembly is installed on the installation support in the boss of the box cover, the input terminal of the supporting capacitor is electrically connected with the output terminal of the filter assembly, the output terminal of the supporting capacitor is electrically connected with the input terminal of the power component, the output terminal of the power component is electrically connected with the copper bar of the AC plastic package, and the three-phase winding of the stator assembly is electrically connected with the AC plastic package of the motor controller.

[0015] The boss is provided with an upper cover plate.

[0016] The side platform is provided with a side cover plate.

[0017] The first platform is provided with a heat dissipation cover plate, a heat dissipation pool with a cavity structure is arranged below the heat dissipation cover plate, a first water inlet is arranged on the outer side of the box body near the second platform, a first water outlet is arranged on the bottom of the box body near the AC end cavity, a side water pumping channel is arranged on the back of the second platform, and the side water pumping channel is in communication with the first water inlet and the heat dissipation pool.

[0018] The heat dissipation cover plate is a rectangular flat plate structure, one side of the flat plate structure is provided with an elliptical heat dissipation fin, and the long axis of the heat dissipation fin is 6 mm and the short axis is 4 mm.

[0019] The machine shell is also provided with a second water inlet and a second water outlet, the second water inlet is arranged on the rear end face of the machine shell and is connected with the first water outlet.

[0020] The rotor assembly comprises a rotor hub and a rotor core, the rotor hub is in the shape of a wheel, a frustum is arranged in the inside, a plurality of circular holes are arranged on the frustum, the circular holes are mechanically connected with the engine flywheel, and an axle shoulder for fixing the rotor of the rotary transformer is arranged on the other side of the rotor hub.

[0021] The first platform is rectangular, and the AC end cavity is in the shape of a cuboid.

[0022] The rotor assembly is fixed on the engine flywheel disc, and the motor controller and the machine shell assembly are assembled and fixed on the flange surface of the engine.

[0023] Compared with the prior art, the present application has the following beneficial effects:

[0024] 1) By integrating the motor controller assembly to the generator rear end cover, the vibration interference of engine cylinder unbalanced mass is reduced; at the same time, the generator adopts a separate stator and rotor structure, the stator, the shell and the controller assembly are integrated, the rotor is integrated with the engine flywheel disc, the volume of the generator system is reduced, the integration of the system assembly is improved, the assembly precision of the generator shell and the engine is reduced, the demand for the installation space of the engine compartment of the whole vehicle is reduced, and batch production and assembly are suitable.

[0025] 2) The generator system adopts a separate stator and rotor structure, the rotor assembly is directly connected to the engine flywheel through bolts, the bearing, front and rear end covers and the shaft coupling in the traditional motor are cancelled, and the eccentric problem in the assembly process of the generator shaft and the engine crankshaft is avoided, the manufacturing and assembly precision of the engine and the generator flange surface is reduced, and batch production is suitable.

[0026] 3) The motor controller is arranged axially at the rear end cover of the generator, the influence of mechanical impact vibration of the engine cylinder unbalanced mass on the controller is reduced, the integration of the extended range generator system assembly is improved, the use of the connecting wire harness and the adapter water pipe between the motor controller and the generator is reduced, the volume of the extended range generator system assembly is reduced, and the demand for the engine compartment layout space of the whole vehicle is reduced.

[0027] 4) The motor electric control adopts an integrated water channel structure design, which can simultaneously cool the support capacitor, power components and generator stator in the motor controller, thereby realizing effective thermal management of the extended range generator system, avoiding the influence of system self-heating and engine cooling on the generator assembly. At the same time, the integrated cooling water channel design cancels the use of the connecting water pipe, shortens the length of the water channel, effectively reduces the cooling liquid flow resistance, helps the circulation of the cooling liquid, and timely removes the heat of the system.

[0028] 5) The motor controller and the generator are integrated in an axial arrangement, and since internal copper bars are needed for power connection between the generator and the motor controller, the controller box needs to be connected with the internal motor shell. The controller has a separate AC end cavity, which is sealed by an AC plastic copper bar, thereby blocking the influence of the harsh environment and dust at the motor and engine end on the internal controller, and realizing the IP67 protection of the controller cavity of the axial integration scheme. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 It is an explosion diagram of a generator system integrated structure for an extended range electric vehicle according to an embodiment of the application.

[0030] Figure 2It is a generator system integration structure schematic diagram for the range extended electric vehicle of the embodiment of the present application;

[0031] Figure 3 It is an explosion schematic diagram of the motor controller assembly structure of the embodiment of the present application;

[0032] Figure 4 It is a box upper surface structure schematic diagram of the embodiment of the present application;

[0033] Figure 5 It is a box bottom structure schematic diagram of the embodiment of the present application;

[0034] Figure 6 It is a friction stir welding heat dissipation cover plate structure schematic diagram of the embodiment of the present application;

[0035] Figure 7 It is a box cover structure schematic diagram of the embodiment of the present application;

[0036] Figure 8 It is an explosion schematic diagram of the range extended generator structure of the embodiment of the present application;

[0037] Figure 9 It is a generator shell structure schematic diagram of the embodiment of the present application;

[0038] Figure 10 It is a generator rotor assembly structure schematic diagram of the embodiment of the present application;

[0039] Figure 11 It is a generator rotor hub structure schematic diagram of the embodiment of the present application;

[0040] Figure 12 It is a generator system integration structure heat dissipation waterway schematic diagram of the embodiment of the present application;

[0041] Wherein: 1, motor controller, 2, shell assembly, 3, rotor assembly, 4, controller heat dissipation waterway, 5, motor heat dissipation waterway, 11, box, 12, box cover, 13, support capacitor, 14, power assembly, 15, filter assembly, 16, AC plastic package, 17, upper cover plate, 18, side cover plate; 111, first platform, 112, second platform, 113, AC end cavity, 114, side platform, 1111, heat dissipation cover plate, 1112, heat dissipation pool, 115, first water inlet, 116, first water outlet, 117, side water pumping channel, 118, rotary variable transformer boss, 1111, heat dissipation cover plate, 121, cover plate, 122, boss, 123, support leg, 21, shell, 22, stator assembly, 23, rotary variable transformer support, 24, rotary variable transformer, 25, rotary variable transformer pressing plate, 3, rotor assembly, 211, shell body, 212, front end face, 213, rear end face, 214, second water inlet, 215, second water outlet, 31, rotor hub, 32, rotor core, 311 straight connection hole, 312, shaft shoulder. Detailed Implementation

[0042] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0043] like Figure 1 and Figure 2 As shown, the present invention proposes an integrated structure for a generator system for a range-extended electric vehicle, including a motor controller 1, a housing assembly 2, and a rotor assembly 3. The motor controller 1 is mounted on the rear end face of the housing assembly, and the assembly structure formed by the motor controller 1 and the housing assembly 2 is fixed on the flange face of the engine. The rotor assembly 3 is fixed on the engine flywheel disc.

[0044] like Figure 3 As shown, the motor controller 1 includes a housing 11, a cover 12, a supporting capacitor 13, a power assembly 14, a filter assembly 15, an AC plastic-coated component 16, a top cover 17, and a side cover 18. The housing 11 and cover 12 cooperate with each other. The supporting capacitor 13, power assembly 14, filter assembly 15, and AC plastic-coated component 16 are placed inside the housing 11. The bottom of the power assembly 14 is coated with thermal grease and fixed to the first platform 111. The supporting capacitor 13 is fixed to the second platform 112. The AC plastic-coated component 16 is installed on the upper surface of the AC terminal cavity 113, achieving a seal between the AC interfaces of the motor end and the controller end. The filter assembly 15 is installed on a mounting foot 123 inside the boss 122 of the cover 12. The input terminal of the supporting capacitor 13 is electrically connected to the output terminal of the filter assembly 15, the output terminal of the supporting capacitor 13 is electrically connected to the input terminal of the power assembly 14, and the output terminal of the power assembly 14 is electrically connected to the copper busbar of the AC plastic-coated component 16.

[0045] like Figure 4 and Figure 5 As shown, the housing 11 is a disc-shaped cavity structure. Inside the housing 11, there is a rectangular first platform 111. The first platform 111 is equipped with a heat dissipation cover 1111 made of friction stir welding. Below the heat dissipation cover 1111, there is a rectangular cavity structure heat dissipation pool 1112. A flat second platform 112 is provided on one side of the first platform 111, and a cuboid AC terminal cavity 113 is provided on the other side of the first platform 111. A rectangular side platform 114 is provided on the outer side of the housing 11 near the AC terminal cavity 113, and a first water inlet 115 is provided on the outer side of the housing 11 near the second platform 112. A side water extraction channel 117 is provided on the back of the second platform, and the side water extraction channel 117 communicates with the first water inlet 115 and the heat dissipation pool 1112. A cylindrical first water outlet 116 is provided on the bottom of the housing 11 near the AC terminal cavity, and a ring-shaped rotating boss 118 is provided at the center of the bottom of the housing 11. Multiple first fixing screw holes are provided near the edge.

[0046] As shown in Figure 6 , the heat dissipation cover plate 1111 is a rectangular flat structure, one side of the flat structure is provided with an oval heat dissipation fin needle, the long axis of the heat dissipation fin needle is 6mm, the short axis is 4mm, and the heat dissipation fin needles are uniformly and equidistantly distributed in order.

[0047] As shown in Figure 7 , the box cover 12 is a disc-shaped structure, the outer surface of the box cover 12 is provided with a square boss 122, the inside of the boss 122 is a cavity structure, and the cavity is provided with four strip-shaped mounting feet 123. The upper cover plate 17 is specifically arranged on the boss 122, and the side cover plate 18 is specifically arranged on the side platform 114.

[0048] As shown in Figure 8 , the generator is composed of a shell assembly 2 and a rotor assembly 3. The shell assembly 2 includes a shell 21, a stator assembly 22, a resolver support 23, a resolver 24 and a resolver pressing plate 25. The stator assembly 22 is in interference fit with the shell 21, the resolver support 23 is fixed on the resolver boss 118 at the back of the box body 11, the resolver 24 is fixed on the top of the resolver support 23 through the resolver pressing plate 25, the rear end surface 213 of the shell 21 is provided with a second fixing screw hole corresponding to the first fixing screw hole, the box body 11 and the rear end surface 213 of the shell 21 are fixedly connected through the bolts matched with the first fixing screw hole and the second fixing screw hole, and are sealed by glue between each other. The three-phase winding of the stator assembly 22 is electrically connected with the AC plastic package 16 of the motor controller 1.

[0049] As shown in Figure 9 , the shell 21 is a cylindrical shell body 211 in the middle, and the front end surface 212 and the rear end surface 213 are arranged on both sides of the shell 21 for installation and fixation. The rear end surface 213 is provided with a circular second water inlet 214, and the outer side of the shell body 211 is provided with a second water outlet 215. As shown in Figure 12 , the shell body 211 is integrated with upper and lower two layers of heat dissipation waterways inside. The cooling liquid enters the generator system assembly from the controller water inlet, passes through the heat dissipation waterway below the controller power assembly, then enters the motor heat dissipation waterway from the controller and the generator mounting surface, and finally flows out of the water outlet.

[0050] As shown in Figure 10 , the rotor assembly 3 is composed of a rotor hub 31 and a rotor core 32. As shown in Figure 11 , the rotor hub 31 is in the shape of a wheel, the inside of the rotor hub 31 is provided with a cone, a plurality of circular holes 311 are arranged on the cone, the circular holes 311 are mechanically connected with the engine flywheel, and the other side of the rotor hub 31 is provided with a shaft shoulder 312 for fixing the resolver rotor.

[0051] The assembly process of the integrated structure of the range-extending electric vehicle generator system is as follows:

[0052] First, assemble the motor controller.

[0053] First, apply thermal grease to the first platform 111 and the second platform 112 inside the box 11, then fix the power assembly 14 to the first platform 111 by bolts, then fix the support capacitor 13 to the second platform 112, and electrically connect the input terminals of the power assembly 14 with the output terminals of the support capacitor. Then, apply flat sealant to the upper end face of the AC end cavity 113, fix the AC plastic package 16 to the upper end face of the AC end cavity 113, and electrically connect the terminals of the AC plastic package 16 with the output terminals of the power assembly 14. Finally, fix the filter assembly 15 to the mounting leg 123 of the box cover 14, install the box cover 12 to the upper end face of the box 11, and electrically connect the terminals of the filter assembly 15 with the input terminals of the support capacitor 13.

[0054] Second, assemble the generator housing assembly.

[0055] After heating the generator housing 21, it is heat-fitted with the stator assembly 22, then the resolver bracket 23 is fixed to the resolver boss 118 on the bottom of the motor controller 1 box 11, and the resolver 24 is fixed to the top of the resolver bracket 23 through the resolver pressing plate 25. Finally, two O-rings are fitted at the first water outlet 116 on the bottom of the box 11, then the assembled generator housing assembly 2 is installed through the bottom of the motor controller 1, and the first water outlet 116 is matched with the second water inlet 214 of the generator housing 21, then the three-phase winding terminals of the stator assembly 22 are inserted into the AC end cavity 114 of the motor controller 1, and the three-phase winding terminals are electrically connected with the copper bars of the AC plastic package 16, and finally the side cover plate 18 is installed on the side platform 114 of the box 11.

[0056] Finally, assemble the engine and generator system assembly.

[0057] The rotor hub 31 of the rotor assembly 3 is mechanically connected with the engine flywheel disc through the direct connection hole 311, then the rotor assembly 3 is assembled with the generator housing assembly 2, and the front end face 212 of the generator housing 21 is mechanically connected with the engine flange mounting surface.

[0058] Thus, the integrated structure assembly of the generator system for the range-extender electric vehicle is completed.

Claims

1. An integrated structure for a generator system in a range-extended electric vehicle, characterized in that, The motor controller (1), the casing assembly (2) and the rotor assembly (3), The motor controller (1) comprises a box body (11) and a box cover (12) matched with each other, a support capacitor (13), a power assembly (14), a filter assembly (15) and an AC plastic package (16) arranged in the box body (11), the box body (11) is a disc-shaped cavity structure, an annular rotary variable protrusion (118) is arranged at the center of the outer surface, a plurality of first fixing screw holes are arranged near the edge, The casing assembly (2) comprises a casing (21), a stator assembly (22), a rotary variable support (23), a rotary variable (24) and a rotary variable pressing plate (25), The stator assembly (22) is in interference fit after being shrink-fitted with the casing (21), the rotary variable support (23) is fixed on the rotary variable protrusion (118) of the box body (11), the rotary variable (24) is fixed on the top of the rotary variable support (23) through the rotary variable pressing plate (25), the rear end surface (213) of the casing (21) is provided with second fixing screw holes corresponding to the first fixing screw holes, and the box body (11) is fixedly connected with the rear end surface (213) of the casing (21) through bolts matched with the first fixing screw holes and the second fixing screw holes; The inner surface of the box body (11) is provided with a first platform (111), a second platform (112) and an AC end cavity (113), the second platform (112) and the AC end cavity (113) are respectively located on the two sides of the first platform (111), and a side platform (114) is arranged on the outer side of the box body (11) near the AC end cavity (113), The box cover (12) is in a disc-shaped structure, and the outer surface is provided with a protrusion (122), the inside of the protrusion (122) is a cavity, and the cavity is provided with a mounting leg (123); The power assembly (14) is fixed on the first platform (111), the support capacitor (13) is fixed on the second platform (112), and the AC plastic package (16) is mounted on the upper end surface of the AC end cavity (113).

2. The integrated structure of a generator system for a range-extended electric vehicle according to claim 1, wherein The bottom of the power assembly (14) is coated with heat-conducting silicone grease, the filter assembly (15) is mounted on the mounting leg (123) in the protrusion (122) of the box cover (12), the input terminal of the support capacitor (13) is electrically connected with the output terminal of the filter assembly (15), the output terminal of the support capacitor (13) is electrically connected with the input terminal of the power assembly (14), the output terminal of the power assembly (14) is electrically connected with the copper bar of the AC plastic package (16), and the three-phase winding of the stator assembly (22) is electrically connected with the AC plastic package (16) of the motor controller (1).

3. The integrated structure of a generator system for a range-extended electric vehicle according to claim 2, wherein The protrusion (122) is provided with an upper cover plate (17).

4. The integrated structure of a generator system for a range extended electric vehicle according to claim 2, wherein The side platform (114) is provided with a side cover plate (18).

5. The integrated structure of a generator system for a range-extended electric vehicle according to claim 2, wherein The first platform (111) is provided with a heat dissipation cover plate (1111), and a heat dissipation pool (1112) with a cavity structure is arranged below the heat dissipation cover plate (1111); a first water inlet (115) is arranged on the outer side of the box body (11) near the second platform (112); a first water outlet (116) is arranged on the bottom of the box body (11) near the alternating current end cavity (113); a side water outlet (117) is arranged on the back of the second platform (112), and the side water outlet (117) is in communication with the first water inlet (115) and the heat dissipation pool (1112).

6. The integrated structure of a generator system for a range extended electric vehicle according to claim 5, wherein The heat dissipation cover plate (1111) is a rectangular flat plate structure, one side of the flat plate structure is provided with an oval heat dissipation fin needle, the major axis of the heat dissipation fin needle is 6 mm, and the minor axis is 4 mm.

7. The integrated structure of a generator system for a range extended electric vehicle according to claim 5, wherein The second water inlet (214) and the second water outlet (215) are further arranged on the shell (21), the second water inlet (214) is arranged on the rear end face (213) of the shell (21) and is connected with the first water outlet (116).

8. The integrated structure of a generator system for a range-extended electric vehicle according to claim 5, wherein The rotor assembly (3) comprises a rotor hub (31) and a rotor core (32), the rotor hub (31) is in the shape of a wheel, and a conical frustum is arranged in the inside, a plurality of circular holes (311) are arranged on the conical frustum, the circular holes (311) are mechanically connected with an engine flywheel, and an axle shoulder (312) for fixing a resolver rotor is arranged on the other side of the rotor hub (31).

9. The integrated structure of a generator system for a range extended electric vehicle according to claim 2, wherein The first platform (111) is rectangular, and the alternating current end cavity (113) is in the shape of a cuboid.

10. The integrated structure of a generator system for a range-extended electric vehicle according to claim 1, wherein The rotor assembly (3) is fixed on an engine flywheel disc, and the motor controller (1) and the shell assembly (2) are assembled and fixed on a flange surface of the engine.

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