A generator, a range extender and a vehicle

Abstract

The application relates to a generator, a range extender and a vehicle, and belongs to the technical field of the generator of an electric vehicle. The generator can efficiently cool the whole generator through a pipeline in a rear housing assembly; the rotor and the stator are cooled in a spraying mode, the rotor does not need to be soaked in lubricating oil for cooling, stirring of the lubricating oil by the rotor during rotation is avoided, the peak power of the motor and the oil-electricity conversion efficiency are improved; and the lubricating oil is delivered to the rotor assembly, so that the lubricating effect is achieved.

Description

Technical Field

[0001] This invention relates to the technical field of electric vehicle engines, specifically to a generator, a range extender, and a vehicle. Background Technology

[0002] In practical applications, generators can output electrical energy to other equipment (such as vehicles). When the rotor of an electric motor rotates around the stator driven by the engine, it can generate a significant amount of heat. This heat can affect the generator's efficiency and reduce its lifespan. To cool the rotor and stator, they can be immersed in lubricating oil. The lubricating oil can carry away the heat generated by the rotor and stator. The heat-absorbing lubricating oil can then be pumped to cooling components for further cooling, and then circulated back to the rotor and stator for continued cooling.

[0003] While this method can reduce the temperature of the rotor and stator, when the rotor is immersed in lubricating oil, it may cause unnecessary dragging during rotation. Furthermore, the rotor and stator are not entirely in direct contact with the lubricating oil, which may lead to localized overheating. This will still affect the generator's operating efficiency and reduce its lifespan. Summary of the Invention

[0004] In view of the above problems, a generator, a range extender, and a vehicle are proposed to overcome or at least partially solve the above problems, comprising:

[0005] A generator includes: a front housing assembly, a rear housing assembly, an oil cooling assembly, and an oil pump assembly;

[0006] The rear housing assembly includes a rear housing, a cooling oil pipe, a pump inlet channel, a cooling inlet channel, a shaft inlet channel, and a pipe inlet channel;

[0007] The oil cooling assembly includes an oil cooler, an oil cooling water inlet pipe, an oil cooling water outlet pipe, an oil cooling oil inlet pipe, and an oil cooling oil outlet pipe;

[0008] The front housing assembly and the rear housing are joined together to form a first cavity; the rotor assembly and stator assembly of the generator are located in the first cavity, and the oil pump assembly is connected to the rotor assembly;

[0009] One end of the pump inlet channel is connected to the first cavity, and the other end of the pump inlet channel is connected to the oil inlet of the oil pump assembly; one end of the cooling inlet channel is connected to the oil outlet of the oil pump assembly, and the other end of the cooling inlet channel is connected to the oil cooling inlet pipe; one end of the shaft inlet channel is connected to the oil cooling outlet pipe, and the other end of the shaft inlet channel is connected to the rotor assembly; one end of the pipe inlet channel is connected to the oil cooling outlet pipe, and the other end of the pipe inlet channel is connected to the cooling oil pipe;

[0010] The cooling oil pipe includes a cooling oil pipe root and multiple cooling oil pipe stems connected to the cooling oil pipe root, and each cooling oil pipe stem is provided with multiple spray holes; the other end of the inlet pipe channel is connected to the cooling oil pipe root, and the multiple cooling oil pipe stems are located in the first cavity;

[0011] The oil-cooled water inlet pipe is connected to an outlet pipe, and the oil-cooled water outlet pipe is connected to an inlet pipe.

[0012] Optionally, the rotor assembly includes an input shaft, bearings, a rotor support, bolts, and a rotor;

[0013] One end of the input shaft passes through the front housing assembly and is connected to the engine to obtain power from the engine;

[0014] The rotor bracket is fixedly connected to the input shaft by the bolts, and the outer side of the rotor bracket is fixedly connected to the rotor;

[0015] The bearing is located on the input shaft.

[0016] Optionally, the front housing assembly includes a front housing and an oil seal;

[0017] The front housing is a barrel-shaped box. The flange on the side of the front housing without an opening is connected to the engine. The flange on the side of the front housing with an opening is spliced ​​with the rear housing to form a first cavity.

[0018] The oil seal is located at the center of the unopened side of the front housing, and the input shaft extends out of the front housing and is connected to the engine through the opening filled by the oil seal.

[0019] Optionally, the head of the bolt faces the oil seal.

[0020] Optionally, the rear housing and the input shaft form a second cavity, and the other end of the input shaft channel is connected to the second cavity.

[0021] Optionally, the oil pump assembly includes an oil pump and an oil pump rotor shaft, wherein the oil pump is fixedly connected to the rear housing;

[0022] The other end of the pump inlet channel is connected to the oil inlet of the oil pump, and one end of the cooling inlet channel is connected to the oil outlet of the oil pump.

[0023] The oil pump rotor shaft is connected to the other end of the input shaft.

[0024] Optionally, the input shaft has a hollow input shaft oil passage inside, and the rotor support has a rotor support oil passage inside;

[0025] One end of the input shaft oil passage is located at the connection between the oil pump rotor shaft and the input shaft, and the other end of the input shaft oil passage is connected to one end of the rotor support oil passage; the other end of the rotor support oil passage is open.

[0026] Optionally, it also includes: a stator assembly, the stator assembly comprising silicon steel sheets and windings;

[0027] The silicon steel sheet is fixedly connected to the front housing assembly, and the winding is inserted into the silicon steel sheet.

[0028] Optionally, it also includes: an electronic control component, the electronic control component including a motor controller, an electronically controlled water inlet pipe and an electronically controlled water outlet pipe;

[0029] The motor controller is connected to the stator assembly to obtain the electrical energy generated by the stator assembly;

[0030] The electronically controlled water inlet pipe and the electronically controlled water outlet pipe are connected to the vehicle's water circulation system to cool the motor controller.

[0031] Optionally, the electronically controlled water outlet pipe is also connected to the oil-cooled water inlet pipe, and the oil-cooled water outlet pipe is connected to the vehicle's water circulation system.

[0032] Optionally, the oil-cooled water inlet pipe and the oil-cooled water outlet pipe are connected to the vehicle's water circulation system.

[0033] Embodiments of the present invention also provide a range extender, including an engine and a generator as described above.

[0034] Embodiments of the present invention also provide a vehicle including the range extender described above.

[0035] The beneficial effects of this invention are:

[0036] This invention provides a generator that can efficiently cool the entire generator through pipes in the rear housing assembly; and cools the rotor and stator by spraying, eliminating the need to immerse the rotor in lubricating oil for cooling, avoiding the stirring of the lubricating oil during rotor rotation, thus improving the peak power and oil-to-electricity conversion efficiency of the motor; and by delivering lubricating oil to the rotor assembly, it can also play a lubricating role. Attached Figure Description

[0037] Figure 1 This is a first-view structural schematic diagram of a generator according to an embodiment of the present invention;

[0038] Figure 2 This is a second-view structural schematic diagram of a generator according to an embodiment of the present invention;

[0039] Figure 3This is a schematic diagram of the cross-section of a generator according to an embodiment of the present invention;

[0040] Figure 4 This is a schematic diagram of the rear housing of a generator according to an embodiment of the present invention;

[0041] Figure 5 This is a schematic diagram of the cooling oil pipe structure of a generator according to an embodiment of the present invention;

[0042] Figure 6 This is a schematic diagram of the structure of an oil cooler for a generator according to an embodiment of the present invention.

[0043] Explanation of reference numerals in the attached figures:

[0044] Generator-100, Front Housing Assembly-1, Front Housing-11, Oil Seal-12, First Cavity-111, Rear Housing Assembly-2, Rear Housing-21, Pump Inlet Channel-211, Cooling Inlet Channel-212, Shaft Inlet Channel-213, Pipe Inlet Channel-214, Second Cavity-215, Cooling Oil Pipe-22, Cooling Oil Pipe Root-221, Cooling Oil Pipe Stem-222, Nozzle-223, Rotor Assembly-3, Input Shaft-31, Input Shaft Oil Passage-311, Bearing -32, Rotor support -33, Rotor support oil passage -331, Bolt -34, Rotor -35, Electrical control assembly -4, Motor controller -41, Electrical control water inlet pipe -42, Electrical control water outlet pipe -43, Oil cooling assembly -5, Oil cooler -51, Oil cooling water inlet pipe -52, Oil cooling water outlet pipe -53, Oil cooling oil inlet pipe -54, Oil cooling oil outlet pipe -55, Oil pump assembly -6, Oil pump -61, Oil pump rotor shaft -62, Stator assembly -7, Silicon steel sheet -71, Winding -72. Detailed Implementation

[0045] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0046] To avoid excessive drag loss caused by the stirring of lubricating oil during rotor rotation, and to achieve more efficient cooling of the rotor and stator, this invention provides a generator that can efficiently cool the entire generator through pipes in the rear housing assembly; and to cool the rotor and stator by spraying, eliminating the need to immerse the rotor in lubricating oil for cooling, thus avoiding the stirring of lubricating oil during rotor rotation.

[0047] Reference Figure 1The diagram shows a first-view structural schematic of a generator according to an embodiment of the present invention; refer to Figure 2 The diagram shows a second-view structural schematic of a generator according to an embodiment of the present invention; refer to Figure 3 The diagram shows a cross-sectional structural schematic of a generator according to an embodiment of the present invention; refer to Figure 4 A schematic diagram of the rear housing of a generator according to an embodiment of the present invention is shown; refer to Figure 5 A schematic diagram of the cooling oil pipe structure of a generator according to an embodiment of the present invention is shown; refer to Figure 6 The diagram shows a schematic of the structure of an oil cooler for a generator according to an embodiment of the present invention.

[0048] In this embodiment of the invention, the generator 100 may include: a front housing assembly 1, a rear housing assembly 2, an oil cooling assembly 5, and an oil pump assembly 6;

[0049] The rear housing assembly 2 may include a rear housing 21, a cooling oil pipe 22, a pump inlet channel 211, a cooling inlet channel 212, a shaft inlet channel 213, and a pipe inlet channel 214;

[0050] The oil cooling assembly 5 includes an oil cooler 51, an oil cooling water inlet pipe 52, an oil cooling water outlet pipe 53, an oil cooling oil inlet pipe 54, and an oil cooling oil outlet pipe 55;

[0051] The front housing assembly 1 and the rear housing 21 are spliced ​​together to form the first cavity 111; the rotor assembly 3 and the stator assembly 7 of the generator 100 are located in the first cavity 111, and the oil pump assembly 6 is connected to the rotor assembly 3.

[0052] One end of the pump inlet channel 211 is connected to the first cavity 111, and the other end of the pump inlet channel 211 is connected to the oil inlet of the oil pump assembly 6; one end of the cooling inlet channel 212 is connected to the oil outlet of the oil pump assembly 6, and the other end of the cooling inlet channel 212 is connected to the oil cooling inlet pipe 54; one end of the shaft inlet channel 213 is connected to the oil cooling outlet pipe 55, and the other end of the shaft inlet channel 213 is connected to the rotor assembly 3; one end of the inlet pipe channel 214 is connected to the oil cooling outlet pipe 55, and the other end of the inlet pipe channel 214 is connected to the cooling oil pipe 22.

[0053] The cooling oil pipe 22 includes a cooling oil pipe root 221 and a plurality of cooling oil pipe stems 222 connected to the cooling oil pipe root 221. Each cooling oil pipe stem 222 is provided with a plurality of spray holes 223. The other end of the inlet pipe channel 214 is connected to the cooling oil pipe root 221, and the plurality of cooling oil pipe stems 222 are located in the first cavity 111.

[0054] The oil-cooled water inlet pipe 52 is connected to an outlet pipe, and the oil-cooled water outlet pipe 53 is connected to an inlet pipe.

[0055] In this embodiment of the invention, the generator 100 may be composed of a front housing assembly 1, a rear housing assembly 2, an oil cooling assembly 5, and an oil pump assembly 6. The front housing assembly 1 and the rear housing assembly 2 may form the overall frame of the generator 100. The pipes in the rear housing 21 may cooperate with the oil cooling assembly 5 and the oil pump assembly 6 to achieve cooling and lubrication of the generator 100. The generator 100 may be a range-extended generator or other types of generators, and this embodiment of the invention does not limit this.

[0056] As an example, the rear housing assembly 2 may consist of a rear housing 21, a cooling oil pipe 22, a pump inlet channel 211, a cooling inlet channel 212, a shaft inlet channel 213, and a pipe inlet channel 214; wherein, the rear housing 21 may be a flat plate structure or a cube with one open side; the rear housing 21 may be spliced ​​with the front housing assembly 1 to form a first cavity 111, in which the stator assembly 7 and the rotor assembly 3 of the generator 100 may be placed.

[0057] The pump inlet channel 211 can be a hollow pipe with openings at both ends. The pump inlet channel 211 can be fixed on the rear housing 21, and the pump inlet channel 211 can communicate with the first cavity 111 and the oil pump assembly 6 respectively, so that the oil pump assembly 6 can extract the lubricating oil in the first cavity 111 through the pump inlet channel 211, thereby avoiding the lubricating oil from generating a dragging force on the rotating rotor 35.

[0058] The cooling channel 212 can be a hollow pipe with openings at both ends; the cooling channel 212 can also be fixed on the rear housing 21, and the cooling channel 212 can be connected to the oil pump assembly 6 and the oil cooling assembly 5 respectively, so that the oil pump assembly 6 can pump the lubricating oil that has absorbed heat from the first cavity 111 to the oil cooling assembly 5 for cooling through the cooling channel 212.

[0059] The shaft inlet channel 213 can be a hollow pipe with openings at both ends; the shaft inlet channel 213 can also be fixed on the rear housing 21, and the shaft inlet channel 213 can be connected to the oil cooling assembly 5 and the rotor assembly 3 respectively, so that the lubricating oil cooled by the oil cooling assembly 5 can flow through the shaft inlet channel 213 to the rotor assembly 3 to cool and lubricate the rotor assembly 3.

[0060] The inlet pipe channel 214 can be a hollow pipe with openings at both ends; the inlet pipe channel 214 can also be fixed on the rear housing 21, and the inlet pipe channel 214 can be connected to the oil cooling assembly 5 and the cooling oil pipe 22 respectively, so that the lubricating oil cooled by the oil cooling assembly 5 can flow through the inlet pipe channel 214 to the cooling oil pipe 22.

[0061] The cooling oil pipe 22 may include a cooling oil pipe root 221 and a plurality of cooling oil pipe stems 222 connected to the cooling oil pipe root 221; the cooling oil pipe root 221 may be a hollow pipe with a plurality of holes on its side; the cooling oil pipe stem 222 may be a hollow pipe with one end open and the other end closed, and a plurality of spray holes 223 provided on its side; the opening of the cooling oil pipe stem 222 may be connected to the opening on the side of the cooling oil pipe root 221, and at least one of the plurality of holes on the side of the cooling oil pipe root 221 may be connected to the inlet pipe channel 214 so as to input lubricating oil into the cooling oil pipe 22.

[0062] Of course, the root of the cooling oil pipe 221 can be a hollow pipe with an opening at one end and multiple holes on the side; the inlet pipe channel 214 can be connected to the opening at one end of the root of the cooling oil pipe 221 so as to input lubricating oil into the cooling oil pipe 22.

[0063] In practical applications, multiple cooling oil pipe stems 222 can be distributed at different positions in the first cavity 111; preferably, the cooling oil pipe stems 222 can be located at the top of the first cavity 111; thus, when the lubricating oil cooled in the inlet channel 214 enters the cooling oil pipe stem 222 through the root of the cooling oil pipe 221, the cooled lubricating oil can be sprayed into the first cavity 111 through the nozzle of the cooling oil pipe stem 222, for example, it can be sprayed onto the stator assembly 7 and the rotor assembly 3; since the lubricating oil is cooled, it can absorb the heat generated by the stator assembly 7 and the rotor assembly 3, thereby reducing the temperature of the stator assembly 7 and the rotor assembly 3, and thus avoiding the effects of high temperature of the stator assembly 7 and the rotor assembly 3, such as magnet demagnetization, which would affect the service life and working efficiency of the generator 100.

[0064] The lubricating oil sprayed onto the rotor assembly 3 and stator assembly 7 will flow back to the bottom of the first cavity 111 due to the rotation of the rotor assembly 3 and the effect of gravity. It will then be drawn out again by the pump inlet channel 211, cooled again by the oil pump assembly 6 and the oil cooling assembly 5, and cooled again by the inlet pipe channel 214 and the shaft inlet channel 213.

[0065] In practical applications, the oil pump assembly 6 can be connected to the rotor assembly 3; thus, when the rotor assembly 3 rotates, it can provide power to the oil pump assembly 6, thereby driving the oil pump assembly 6 to draw lubricating oil from the first cavity 111, and driving the oil pump assembly 6 to pump the drawn lubricating oil through the cooling inlet channel 212 to the oil cooling assembly 5, and through the oil cooling assembly 5 to continue pumping to the inlet pipe channel 214, the shaft inlet channel 213, the cooling oil pipe 22, etc.

[0066] As an example, the oil cooling assembly 5 may include an oil cooler 51, an oil cooling water inlet pipe 52, an oil cooling water outlet pipe 53, an oil cooling oil inlet pipe 54, and an oil cooling oil outlet pipe 55; wherein, the oil cooling water inlet pipe 52 and the oil cooling water outlet pipe 53 may be hollow pipes with open ends, and the oil cooling water inlet pipe 52 and the oil cooling water outlet pipe 53 may be connected to the water pipe in the oil cooler 51 respectively; the oil cooling oil inlet pipe 54 and the oil cooling oil outlet pipe 55 may also be hollow pipes with open ends, and the oil cooling oil inlet pipe 54 and the oil cooling oil outlet pipe 55 may be connected to the oil pipe in the oil cooler 51 respectively.

[0067] The water pipes and oil pipes in the oil cooler 51 can be arranged adjacently so that the water in the water pipes can absorb the heat of the lubricating oil in the oil pipes, thereby cooling the lubricating oil. The oil cooling water inlet pipe 52 is connected to an outlet pipe, and the oil cooling water outlet pipe 53 can be connected to an inlet pipe so that cold water is continuously supplied to the oil cooler 51 through the outlet pipes, thereby continuously carrying away the heat of the lubricating oil in the oil cooler 51 and continuously cooling the lubricating oil.

[0068] As another example, the lubricating oil and water in the oil cooler 51 can also exchange heat through other structures, such as multiple cubes arranged in an alternating pattern. This embodiment of the invention does not limit this.

[0069] In this embodiment of the invention, one end of the pump inlet channel 211 can be connected to the first cavity 111, and the other end of the pump inlet channel 211 can be connected to the oil inlet of the oil pump assembly 6; thus, the lubricating oil that has absorbed heat in the first cavity 111 can be drawn out by the oil pump assembly 6 through the pump inlet channel 211.

[0070] Then, the lubricating oil in the oil pump assembly 6 can be pumped from the oil outlet to one end of the cooling inlet channel 212 and from one end of the cooling inlet channel 212 to the other end; the other end of the cooling inlet channel 212 can be connected to the oil cooling inlet pipe 54; thus, the lubricating oil can enter the oil cooling inlet pipe 54 from the other end of the cooling inlet channel 212 and enter the oil cooler 51 through the oil cooling inlet pipe 54 to be cooled; then, it enters the inlet pipe channel 214 and the shaft inlet channel 213 from the oil cooler 51 to cool and lubricate the generator.

[0071] The lubricating oil cooled by the oil cooler 51 can enter the inlet pipe channel 214 and the shaft inlet channel 213 through the oil cooling outlet pipe 55. Specifically, one end of the inlet pipe channel 214 can be connected to the oil cooling outlet pipe 55, and the other end of the inlet pipe channel 214 can be connected to the cooling oil pipe 22; thus, the lubricating oil can enter one end of the inlet pipe channel 214 through the oil cooling outlet pipe 55, and then enter the cooling oil pipe 22 through the other end of the inlet pipe channel 214.

[0072] The lubricating oil that enters the cooling oil pipe 22 can be sprayed into the first cavity 111 through the nozzle of the cooling oil pipe stem 222, thereby cooling and lubricating the rotor assembly 3, stator assembly 7 and other components in the first cavity 111.

[0073] The lubricating oil sprayed onto the rotor assembly 3 will be thrown off the rotor assembly 3 during the rotation of the rotor assembly 3 and flow to the bottom of the first cavity 111; the lubricating oil on the stator assembly 7 will leave the stator assembly 7 under the action of gravity and flow to the bottom of the first cavity 111.

[0074] In addition, one end of the inlet channel 213 can be connected to the oil cooling outlet pipe 55, and the other end of the inlet channel 213 can be connected to the rotor assembly 3; thus, lubricating oil can enter one end of the inlet channel 213 through the oil cooling outlet pipe 55, and be delivered to the rotor assembly 3 through the other end of the inlet channel 213.

[0075] The lubricating oil supplied to the rotor assembly 3 through the shaft inlet channel 213 will partly lubricate the rotor assembly 3 and partly cool the rotor assembly 3. During the rotation of the rotor assembly 3, the lubricating oil will be thrown away from the rotor assembly 3 and flow to the bottom of the first cavity 111.

[0076] The lubricating oil flowing to the bottom of the first cavity 111 will be drawn away by the pump inlet channel 211 to avoid dragging the rotor assembly 3.

[0077] In one embodiment of the present invention, the rotor assembly 3 of the generator 100 may include an input shaft 31, a bearing 32, a rotor bracket 33, bolts 34 and a rotor 35; one end of the input shaft 31 passes through the front housing assembly 1 and is connected to the engine to obtain the engine's power; the rotor bracket 33 is fixedly connected to the input shaft 31 by bolts 34, and the outer side of the rotor bracket 33 is fixedly connected to the rotor 35; the bearing 32 is located on the input shaft 31.

[0078] In practical applications, the rotor assembly 3 of the generator 100 may include an input shaft 31, a bearing 32, a rotor bracket 33, bolts 34, and a rotor 35. The input shaft 31 may be a multi-section cylinder. The input shaft 31 may pass through the front housing assembly 1 and be connected to the engine's torque limiter through a head spline at one end, so that the input shaft 31 rotates under the rotation of the engine, thereby driving the entire rotor assembly 3 to rotate, and thus enabling the generator 100 to obtain the engine's power. Then, the rotor assembly 3 and the stator assembly 7 cooperate to generate a back electromotive force, thereby converting the engine's mechanical energy into electrical energy.

[0079] The rotor support 33 can be composed of multiple spokes, which can be fixedly connected to the input shaft 31 by bolts 34; the rotor 35 can be fixed on the outside of the rotor support 33, specifically, on the outside of each spoke; the bearing 32 can be located on the input shaft 31, and the bearing 32 can be used to support the input shaft 31, reduce the coefficient of friction of the rotating shaft during rotation, and ensure the rotational accuracy of the input shaft 31.

[0080] In one embodiment of the present invention, the front housing assembly 1 includes a front housing 11 and an oil seal 12; the front housing 11 is a barrel-shaped box, the flange on the side of the front housing 11 without an opening is connected to the engine, and the flange on the side of the front housing 11 with an opening is spliced ​​with the rear housing 21 to form a first cavity 111; the oil seal 12 is located at the center of the side of the front housing 11 without an opening, and the input shaft 31 extends out of the front housing 11 through the opening filled by the oil seal 12 and is connected to the engine.

[0081] In practical applications, the front housing assembly 1 can be composed of a front housing 11 and an oil seal 12. The front housing 11 can be a barrel-shaped box, and one side of the front housing 11 can be open. The flange (also called a flange plate or flange) on the unopened side of the front housing 11 can be connected to the engine. The flange on the open side of the front housing 11 can be spliced ​​with the rear housing 21 to form the first cavity 111.

[0082] The oil seal 12 can be a ring-shaped seal, which can be located at the center of the side of the front housing 11 without an opening, and the input shaft 31 of the rotor assembly 3 can extend out of the front housing 11 through the opening filled by the oil seal 12 and be connected to the engine; the oil seal 12 can be used to fill the gap between the input shaft 31 and the opening, thereby preventing lubricating oil from leaking out of the first cavity 111 from the opening from which the input shaft 31 extends.

[0083] As an example, to prevent the input shaft 31 from colliding with the opening and causing damage to the input shaft 31 or the front housing 11, the oil seal 12 can be made of a high-temperature resistant elastic material.

[0084] The head of bolt 34 faces the oil seal 12. The head of bolt 34 can face the oil seal 12 of the front housing 11, and the tightening direction of bolt 34 can be consistent with the rotation direction of rotor assembly 3, thereby preventing bolt 34 from easily loosening.

[0085] In one embodiment of the present invention, the rear housing 21 and the input shaft 31 form a second cavity 215, and the other end of the input shaft channel 213 is connected to the second cavity 215.

[0086] In practical applications, the rear housing 21 can form a second cavity 215 with the input shaft 31. The second cavity 215 can be connected to the other end of the input shaft channel 213. Thus, a portion of the lubricating oil output from the other end of the input shaft channel 213 can enter the second cavity 215 and flow through the second cavity 215 to the bearing 32 on the input shaft 31. On the one hand, the lubricating oil flowing to the bearing 32 can cool the bearing 32. On the other hand, the lubricating oil flowing to the bearing 32 can also lubricate the bearing 32.

[0087] In one embodiment of the present invention, the oil pump assembly 6 includes an oil pump 61 and an oil pump rotor shaft 62. The oil pump 61 is fixedly connected to the rear housing 21. The other end of the pump inlet channel 211 is connected to the oil inlet of the oil pump 61, and one end of the cooling channel 212 is connected to the oil outlet of the oil pump 61. The oil pump rotor shaft 62 is connected to the other end of the input shaft 31.

[0088] In practical applications, the oil pump assembly 6 can be composed of an oil pump 61 and an oil pump rotor shaft 62; wherein, the oil pump 61 can be a container with an oil outlet and an oil inlet; the oil pump 61 can be fixed on the rear housing 21; the oil pump 61 can be provided with an oil pump rotor shaft 62, and the oil pump rotor shaft 62 can be connected to the other end of the input shaft 31; specifically, the oil pump rotor shaft 62 can be connected to the other end of the input shaft 31 through a flat bar.

[0089] Therefore, when the input shaft 31 is driven to rotate by the engine, it can drive the rotation of the oil pump rotor shaft 62, thereby extracting the lubricating oil from the first cavity 111 and pumping it to the oil cooling assembly 5, and further pumping it to the inlet pipe channel 214, the inlet shaft channel 213, etc.

[0090] The other end of the pump inlet channel 211 can be connected to the oil inlet of the oil pump 61, so that the lubricating oil in the first cavity 111 is delivered to the oil pump 61 through the oil inlet. The lubricating oil entering the oil pump 61 is driven by the rotation of the oil pump rotor shaft 62 and enters the cooling channel 212 from the oil outlet of the oil pump 61, and is further pumped to the oil cooling assembly 5 for cooling. Then, the cooled lubricating oil can enter the first cavity 111 again through the inlet pipe channel 214 and the inlet shaft channel 213, etc., to cool and lubricate the components in the generator 100.

[0091] In one embodiment of the present invention, the input shaft 31 has a hollow input shaft oil passage 311 inside, and the rotor support 33 has a hollow rotor support oil passage 331 inside; one end of the input shaft oil passage 311 is located at the connection between the oil pump rotor shaft 62 and the input shaft 31, and the other end of the input shaft oil passage 311 is connected to one end of the rotor support oil passage 331; the other end of the rotor support oil passage 331 is open.

[0092] In practical applications, a hollow input shaft oil passage 311 can be provided inside the input shaft 31. One end of the input shaft oil passage 311 is open and adjacent to the connection between the oil pump rotor shaft 62 and the input shaft 31. Thus, lubricating oil can enter the input shaft oil passage 311 through the connection to cool the input shaft 31 from the inside.

[0093] In addition, a hollow rotor support oil passage 331 can also be provided inside the rotor support 33. The rotor support oil passage 331 can be deployed in each spoke, and each rotor support oil passage 331 has openings at both ends. One end of the rotor support oil passage 331 can be connected to the other end of the input shaft oil passage 311. Therefore, the lubricating oil entering the input shaft oil passage 311 can flow into the rotor support oil passage 331 to cool down the rotor support 33.

[0094] Furthermore, the lubricating oil entering the rotor support oil passage 331 can flow out from the other end opening of the rotor support oil passage 331 under the rotation of the rotor support 33 and return to the bottom of the first cavity 111; then, it enters the oil pump 61 again from the pump inlet channel 211, and enters the oil cooling assembly 5 for cooling through the rotation of the oil pump rotor shaft 62; then, the cooled lubricating oil will be pumped again to the inlet pipe channel 214 and the shaft inlet channel 213 to cool and lubricate the components in the generator 100.

[0095] In one embodiment of the present invention, the generator 100 may further include a stator assembly 7, which includes silicon steel sheets 71 and windings 72; the silicon steel sheets 71 are fixedly connected to the front housing assembly 1, and the windings 72 are inserted into the silicon steel sheets 71.

[0096] In practical applications, the stator of the generator 100 may gradually include silicon steel sheets 71 and windings 72; wherein, the silicon steel sheets 71 may be fixed to the front housing assembly 1, specifically, may be fixedly connected to the front housing 11; and the windings 72 may be inserted into the silicon steel sheets 71. The silicon steel sheets 71 may be made of multiple layers of sheet metal, and the windings 72 may be multiple U-shaped metal rods, the two ends of which may extend out of the silicon steel sheets 71 and be connected to each other.

[0097] In this embodiment of the invention, the lubricating oil in the cooling oil stem will be sprayed out from the nozzle 223 under the action of pumping pressure and adhere to the silicon steel sheet 71 and the winding 72; then, the lubricating oil can absorb the heat of the silicon steel sheet 71 and the winding 72, and flow back to the bottom of the first cavity 111 under the action of gravity, and be drawn back into the oil pump 61 by the pump inlet channel 211.

[0098] In one embodiment of the present invention, the generator 100 further includes an electronic control component 4, which includes a motor controller 41, an electronically controlled water inlet pipe 42, and an electronically controlled water outlet pipe 43. The motor controller 41 is connected to the stator assembly 7 to obtain the electrical energy generated by the stator assembly 7. The electronically controlled water inlet pipe 42 and the electronically controlled water outlet pipe 43 are connected to the vehicle water circulation system to cool the motor controller 41.

[0099] In this embodiment of the invention, the generator 100 may further include an electronic control component 4, which may include a motor controller 41, an electronically controlled water inlet pipe 42, and an electronically controlled water outlet pipe 43. The motor controller 41 may be connected to the stator assembly 7 via a three-phase wiring harness to receive the electrical energy generated by the stator assembly 7 and perform inverter conversion to obtain direct current. Then, the motor controller 41 may transmit the direct current to other motors and / or batteries for use.

[0100] The electronically controlled water inlet pipe 42 and electronically controlled water outlet pipe 43 of the electronic control component 4 can be connected to the vehicle's water circulation system to cool the motor controller 41.

[0101] As an example, the electronically controlled water outlet pipe 43 is also connected to the oil-cooled water inlet pipe 52, and the oil-cooled water outlet pipe 53 is connected to the vehicle's water circulation system.

[0102] In practical applications, the electronically controlled water outlet pipe 43 can be connected to the oil-cooled water inlet pipe 52, and the oil-cooled water outlet pipe 53 of the oil-cooling component 5 can be connected to the vehicle's water circulation system. Thus, the water flowing out of the electronically controlled water outlet pipe 43 can enter the oil cooler 51 through the oil-cooled water inlet pipe 52 to cool the lubricating oil in the oil cooler 51. Then, the water can flow out of the oil-cooled water outlet pipe 53 and return to the vehicle's water circulation system to be cooled again before entering the electronically controlled component 4 through the electronically controlled water inlet pipe 42.

[0103] As another example, the oil cooler inlet pipe 52 and the oil cooler outlet pipe 53 are connected to the vehicle's water circulation system.

[0104] In another embodiment, the oil-cooled inlet pipe 52 and the oil-cooled outlet pipe 53 can also be directly connected to the vehicle's water circulation system. Thus, the water cooled in the vehicle's water circulation system can enter the lubricating oil in the oil cooler 51 through the oil-cooled inlet pipe 52 for cooling. Then, the water can flow out through the oil-cooled outlet pipe 53 and return to the vehicle's water circulation system to be cooled again before entering the electronic control component 4 through the electronic control inlet pipe 42.

[0105] The following is a description of the cooling process of the electric motor provided in an embodiment of the present invention:

[0106] When the generator 100 is working, after the rotor assembly 3 obtains power from the engine, it drives the oil pump assembly 6 to pump the lubricating oil in the first cavity 111 into the cooling inlet channel 212 through the pump inlet channel 211. The lubricating oil passing through the oil cooling assembly 5 will be cooled by heat exchange, and then pumped into the shaft inlet channel 213 and the pipe inlet channel 214.

[0107] After the lubricating oil in the input shaft channel 213 is injected into the second cavity 215, part of the lubricating oil flows into the bearing 32 through the gap between the rear housing 21 and the input shaft 31 for lubrication, and the other part of the lubricating oil enters the input shaft oil passage 311 through the gap between the input shaft 31 and the flat surface of the oil pump rotor shaft 62, and then reaches the rotor support oil passage 331, where it cools the rotor 35 through heat conduction.

[0108] Finally, the lubricating oil is thrown towards the inside of the winding 72 by the centrifugal force of the rotor assembly 3, covering more of the surface of the winding 72, in order to further cool the winding 72.

[0109] The lubricating oil in the inlet pipe channel 214 passes through the root 221 of the cooling oil pipe 22 connected to it, enters the stem 222 of multiple cooling oil pipes, and is then sprayed out from multiple nozzles 223 located in the upper part of the generator 100. Under the action of pumping pressure and gravity, the lubricating oil flows to the outside of the silicon steel sheet 71 and the winding 72 to cool the silicon steel sheet 71 and the winding 72.

[0110] This invention provides a generator that can efficiently cool the entire generator through pipes in the rear housing assembly; and cools the rotor and stator by spraying, eliminating the need to immerse the rotor in lubricating oil for cooling, avoiding the stirring of the lubricating oil during rotor rotation, thus improving the peak power and oil-to-electricity conversion efficiency of the motor; and by delivering lubricating oil to the rotor assembly, it can also play a lubricating role.

[0111] This invention also provides a range extender, which refers to an electric vehicle component capable of providing additional electrical energy to increase the driving range of an electric vehicle. The range extender provided in this invention may include an engine and a generator as described in the above embodiments. The front housing of the generator may be fixedly connected to the engine, and the input shaft of the generator's rotor assembly may be connected to the engine's torque limiter so that the input shaft rotates under the rotation of the engine, thereby driving the entire rotor assembly to rotate, and thus enabling the generator to obtain power from the engine. Then, the rotor assembly and stator assembly cooperate to generate a back electromotive force, thereby converting the engine's mechanical energy into electrical energy.

[0112] This invention also provides a vehicle that may include the range extender described above.

[0113] Finally, it should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or terminal device that includes said element.

[0114] The above provides a detailed description of a generator, a range extender, and a vehicle. Specific examples have been used to illustrate the principles and implementation methods of the invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the invention. At the same time, those skilled in the art will recognize that, based on the ideas of the invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the invention.

Claims

1. A generator characterized by, include: Front housing assembly, rear housing assembly, oil cooling assembly, and oil pump assembly; The rear housing assembly includes a rear housing, a cooling oil pipe, a pump inlet channel, a cooling inlet channel, a shaft inlet channel, and a pipe inlet channel; The oil cooling assembly includes an oil cooler, an oil cooling water inlet pipe, an oil cooling water outlet pipe, an oil cooling oil inlet pipe, and an oil cooling oil outlet pipe; The front housing assembly and the rear housing are joined together to form a first cavity; the rotor assembly and stator assembly of the generator are located in the first cavity, and the oil pump assembly is connected to the rotor assembly; One end of the pump inlet channel is connected to the first cavity, and the other end of the pump inlet channel is connected to the oil inlet of the oil pump assembly; one end of the cooling inlet channel is connected to the oil outlet of the oil pump assembly, and the other end of the cooling inlet channel is connected to the oil cooling inlet pipe; one end of the shaft inlet channel is connected to the oil cooling outlet pipe, and the other end of the shaft inlet channel is connected to the rotor assembly; one end of the pipe inlet channel is connected to the oil cooling outlet pipe, and the other end of the pipe inlet channel is connected to the cooling oil pipe; The cooling oil pipe includes a cooling oil pipe root and multiple cooling oil pipe stems connected to the cooling oil pipe root. Each cooling oil pipe stem is provided with multiple spray holes for spraying lubricating oil onto the rotor assembly and the stator assembly. The other end of the inlet pipe channel is connected to the cooling oil pipe root, and the multiple cooling oil pipe stems are located within the first cavity. The oil-cooled water inlet pipe is connected to an outlet pipe, and the oil-cooled water outlet pipe is connected to an inlet pipe; The rotor assembly includes an input shaft, bearings, a rotor support, bolts, and a rotor, with the head of the bolt facing the oil seal; The tightening direction of the bolts is consistent with the rotation direction of the rotor assembly; The oil pump assembly includes an oil pump and an oil pump rotor shaft, and the oil pump is fixedly connected to the rear housing. The other end of the pump inlet channel is connected to the oil inlet of the oil pump, and one end of the cooling inlet channel is connected to the oil outlet of the oil pump. The oil pump rotor shaft is connected to the other end of the input shaft via a flat plate.

2. The generator according to claim 1, characterized in that; One end of the input shaft passes through the front housing assembly and is connected to the engine to obtain power from the engine; The rotor bracket is fixedly connected to the input shaft by the bolts, and the outer side of the rotor bracket is fixedly connected to the rotor; The bearing is located on the input shaft.

3. The electric generator of claim 2, wherein, The front housing assembly includes a front housing and an oil seal; The front housing is a barrel-shaped box. The flange on the side of the front housing without an opening is connected to the engine. The flange on the side of the front housing with an opening is spliced ​​with the rear housing to form a first cavity. The oil seal is located at the center of the unopened side of the front housing, and the input shaft extends out of the front housing and is connected to the engine through the opening filled by the oil seal.

4. The electric generator of claim 3, wherein, The rear housing and the input shaft form a second cavity, and the other end of the input shaft channel is connected to the second cavity.

5. The electric generator of claim 1, wherein, The input shaft has a hollow input shaft oil passage inside, and the rotor support has a hollow rotor support oil passage inside. One end of the input shaft oil passage is located at the connection between the oil pump rotor shaft and the input shaft, and the other end of the input shaft oil passage is connected to one end of the rotor support oil passage; the other end of the rotor support oil passage is open.

6. The electric generator of claim 1, wherein, Also includes: A stator assembly, the stator assembly comprising silicon steel sheets and windings; The silicon steel sheet is fixedly connected to the front housing assembly, and the winding is inserted into the silicon steel sheet.

7. The generator according to claim 6, characterized in that, Also includes: An electronic control assembly, comprising a motor controller, an electronically controlled inlet pipe, and an electronically controlled outlet pipe; The motor controller is connected to the stator assembly to obtain the electrical energy generated by the stator assembly; The electronically controlled water inlet pipe and the electronically controlled water outlet pipe are connected to the vehicle's water circulation system to cool the motor controller.

8. The generator according to claim 7, characterized in that, The electronically controlled water outlet pipe is also connected to the oil-cooled water inlet pipe, and the oil-cooled water outlet pipe is connected to the vehicle's water circulation system.

9. The generator according to claim 1, characterized in that, The oil-cooled water inlet pipe and the oil-cooled water outlet pipe are connected to the vehicle's water circulation system.

10. A range extender, characterized in that, Includes an engine and a generator as described in any one of claims 1-9.

11. A vehicle, characterized in that, Includes the range extender as described in claim 10.

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