A range extender and a method of assembling the same

Abstract

The application provides a range extender and an assembling method thereof. The range extender comprises an engine and a generator. The engine comprises an engine shell and a crankshaft. The generator comprises a stator assembly, a rotor assembly and an adapter. The stator assembly and the rotor assembly are pre-assembled as a whole through the adapter. The rotor assembly comprises a front rotor and a rear rotor, which are connected to opposite ends of the adapter respectively. The stator assembly comprises a stator and a first baffle. The stator is arranged around the adapter and is between the front rotor and the rear rotor. The first baffle is arranged on a side of the stator facing the engine shell. The first baffle is connected to an end surface of the engine shell. One end of the crankshaft extends into the generator and is connected to the adapter. In the actual assembling process, the stator assembly and the rotor assembly can be installed on the engine shell as a whole, without the need to install the motor shaft, the stator, the rotor and other parts one by one on one side of the engine shell. Therefore, the assembling efficiency is greatly improved, and the assembling mistake is avoided.

Description

Technical Field

[0001] This invention relates to the field of automotive motor and electrical technology, and in particular to a range extender and its assembly method. Background Technology

[0002] Electric vehicles, as an emerging green mode of transportation, are highly praised for their low noise and high energy efficiency. However, due to current limitations in power battery technology, such as insufficient battery capacity, long charging time, and the negative impact of fast charging on battery life, the driving range of pure electric vehicles is limited, making them mainly suitable for use in areas equipped with charging facilities. These factors have, to some extent, constrained the popularization and development of electric vehicles.

[0003] To address these shortcomings, range extender technology was developed. Utilizing mature internal combustion engine technology, the range extender automatically intervenes when the vehicle's battery is low, providing additional power. In high-energy-consumption scenarios such as climbing hills or carrying heavy loads, the range extender can also automatically activate to replenish battery energy, preventing over-discharge and thus extending battery life and reducing the risk of traffic accidents caused by battery problems.

[0004] Taking patent publication number CN206211731U as an example, the range extender generator structure described therein connects the generator's motor shaft to the engine's crankshaft via a flywheel. In contrast, the range extender internal combustion engine in patent publication number CN111749785A uses a torsional damper to connect the motor shaft and crankshaft. Both designs involve transmission between the motor shaft and crankshaft, but this transmission method increases the overall axial dimension and reduces assembly efficiency. Summary of the Invention

[0005] Based on this, the purpose of the present invention is to provide a range extender and its assembly method to solve the technical problems mentioned in the background art.

[0006] This invention provides a range extender, comprising:

[0007] An engine, the engine comprising an engine housing and a crankshaft;

[0008] A generator, comprising a stator assembly, a rotor assembly, and a transfer frame, wherein the stator assembly and the rotor assembly are pre-assembled together via the transfer frame, the rotor assembly comprising a front rotor and a rear rotor, the front rotor and the rear rotor being respectively connected to opposite ends of the transfer frame; the stator assembly comprising a stator and a first enclosure plate, the stator being disposed around the transfer frame and between the front rotor and the rear rotor, the first enclosure plate being disposed on the side of the stator facing the engine housing, and the front rotor being located within the space enclosed by the first enclosure plate;

[0009] The first enclosure is connected to the end face of the engine housing so that the stator assembly is fixed to one side of the engine housing; one end of the crankshaft extends into the generator and is connected to the adapter frame so that the rotor assembly is fixed to the crankshaft.

[0010] Furthermore, in the range extender, the generator further includes a rear end cover and a second enclosure. The rear end cover is disposed on the side of the stator facing away from the engine housing via the second enclosure, and the rear rotor is located within the space enclosed by the second enclosure.

[0011] Furthermore, in the range extender, the adapter includes a main body and an edge portion disposed around the periphery of the main body, the axial length of the edge portion being greater than the thickness of the stator, the front rotor and the rear rotor being respectively connected to opposite ends of the edge portion, and the stator being disposed around the edge portion and between the front rotor and the rear rotor.

[0012] Furthermore, in the range extender, the main body and the edge portion enclose a clearance space, and the rear end cover is provided with a bearing chamber accommodated within the clearance space, and a bearing is provided in the bearing chamber.

[0013] Furthermore, in the range extender, the outer wall of the crankshaft is provided with a crankshaft flange, one side of the main body is provided with a positioning groove adapted to the crankshaft, and the other side is provided with a motor shaft collinear with the central axis of the crankshaft. One end of the crankshaft is inserted into the positioning groove and is fixedly connected to the main body through the crankshaft flange, and the motor shaft is connected to the bearing.

[0014] Furthermore, in the range extender, the outer wall of the crankshaft is provided with a crankshaft flange, a central hole is opened on the main body, one end of the crankshaft passes through the central hole and is connected to the bearing, and the crankshaft flange is fixedly connected to the main body.

[0015] Furthermore, in the range extender, the generator further includes a positioning fixture, which includes an annular frame and at least two connecting arms disposed around the annular frame. The connecting arms are detachably connected to the first enclosure plate, and the annular frame is detachably connected to the rear rotor, so that the stator maintains the air gap with the front rotor and the rear rotor and is collinear with the central axis.

[0016] In another aspect, the present invention also proposes a method for assembling a range extender, the method comprising:

[0017] Step a: Pre-assemble the stator assembly and rotor assembly into one unit using an adapter frame;

[0018] Step b: Assemble the stator assembly onto the end face of the engine housing;

[0019] Step c: Assemble the adapter onto the crankshaft.

[0020] Furthermore, in the range extender assembly method, the adapter frame includes a main body and an edge portion disposed around the periphery of the main body, the stator assembly includes a stator, and the rotor assembly includes a front rotor and a rear rotor. Therefore, step a includes:

[0021] First, fix the front rotor to one axial end of the edge portion;

[0022] Then the stator is fitted around the periphery of the main body;

[0023] Finally, the rear rotor is fixed to the other axial end of the edge portion so that the stator is positioned between the front rotor and the rear rotor.

[0024] Furthermore, in the range extender assembly method, a positioning groove is provided on one side of the main body and a motor shaft is provided on the other side, and step c includes:

[0025] Insert one end of the crankshaft into the positioning groove until the crankshaft flange on the crankshaft abuts against the main body.

[0026] The crankshaft flange and the main body are fixed together so that the central axes of the crankshaft and the motor shaft are collinear.

[0027] Furthermore, in the range extender assembly method, the main body is provided with a central hole, and step c further includes:

[0028] Pass one end of the crankshaft through the central hole until the crankshaft flange on the crankshaft abuts against the main body;

[0029] The crankshaft flange and the main body are fixedly connected.

[0030] Furthermore, in the range extender assembly method, after the step of finally fixing the rear rotor to the other axial end of the edge portion so that the stator is positioned between the front rotor and the rear rotor, the method further includes:

[0031] A positioning fixture is added on the same side of the rear rotor and the stator to keep the air gap between the stator and the front rotor and the rear rotor collinear with the central axis.

[0032] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0033] 1. The stator assembly and rotor assembly are pre-assembled as a whole through the adapter frame, so that during the actual assembly process, the two can be installed as a whole on the engine housing, without having to install the motor shaft, stator, rotor and other parts one by one on one side of the engine housing. This greatly improves the assembly efficiency and makes it less likely to be installed incorrectly.

[0034] 2. The crankshaft is directly connected to the adapter, eliminating the need for a flywheel and torsional damper. Instead, the front and rear rotors on the adapter replace the flywheel and other structures, ensuring smooth and reliable operation while reducing the mass of the range extender and helping to reduce its axial dimensions.

[0035] 3. The front rotor, rear rotor and stator are parallel, that is, the generator is an axial flux motor. The axial flux motor has the advantages of small axial size, compact structure, small size, light weight and high torque density, thus further reducing the overall axial size. Attached Figure Description

[0036] Figure 1 This is an assembly diagram of the range extender from a first-view perspective in the first embodiment of the present invention;

[0037] Figure 2 This is an assembly diagram of the range extender from a second perspective in the first embodiment of the present invention;

[0038] Figure 3 This is a cross-sectional view of the range extender in the first embodiment of the present invention;

[0039] Figure 4 This is a cross-sectional view of the adapter frame in the first embodiment of the present invention;

[0040] Figure 5 This is a perspective view of the adapter frame in the first embodiment of the present invention;

[0041] Figure 6 This is a perspective view of the crankshaft in the first embodiment of the present invention;

[0042] Figure 7 This is a cross-sectional view of the range extender in the second embodiment of the present invention;

[0043] Figure 8 This is a cross-sectional view of the adapter frame in the second embodiment of the present invention;

[0044] Figure 9 This is a perspective view of the adapter frame in the second embodiment of the present invention;

[0045] Figure 10 This is a perspective view of the crankshaft in the second embodiment of the present invention;

[0046] Figure 11 This is an assembly diagram of the positioning tooling on the generator in the third embodiment of the present invention;

[0047] Explanation of key component symbols:

[0048] 100. Engine; 200. Generator; 11. Engine housing; 12. Crankshaft; 21. Stator; 22. First enclosure; 23. Front rotor; 24. Rear rotor; 25. Adapter frame; 31. Rear end cover; 32. Second enclosure; 33. Bearing chamber; 34. Bearing; 41. First connecting lug; 42. Second connecting lug; 111. Engine rear housing; 112. Adapter housing; 113. Second perforation; 50. Reinforcing rib; 51. Straight rib segment; 52. Annular rib segment; 251. Main body; 252. Edge; 253. Clearance space; 121. Crankshaft flange; 254. Positioning groove; 255. Motor shaft; 60. Through hole; 61. Center hole; 71. Annular frame; 72. Connecting arm; 73. Positioning pin.

[0049] The following detailed description, in conjunction with the accompanying drawings, will further illustrate the present invention. Detailed Implementation

[0050] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Several embodiments of the invention are illustrated in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.

[0051] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0052] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0053] First Embodiment

[0054] Please see Figures 1 to 3 The range extender in the first embodiment of the present invention includes an engine 100 and a generator 200.

[0055] The engine 100 includes an engine housing 11 and a crankshaft 12;

[0056] The generator 200 includes a stator assembly, a rotor assembly, and a transition frame 25. The stator assembly and the rotor assembly are pre-assembled together via the transition frame 25. The rotor assembly includes a front rotor 23 and a rear rotor 24, which are respectively connected to opposite ends of the transition frame 25. The stator assembly includes a stator 21 and a first enclosure plate 22. The stator 21 is arranged around the transition frame 25 and is located between the front rotor 23 and the rear rotor 24. The first enclosure plate 22 is located on the side of the stator 21 facing the engine housing 11, and the front rotor 23 is located within the space enclosed by the first enclosure plate 22.

[0057] The first enclosure 22 is connected to the end face of the engine housing 11 so that the stator assembly is fixed to one side of the engine housing 11; one end of the crankshaft 12 extends into the generator 200 and is connected to the adapter frame 25 so that the rotor assembly is fixed to the crankshaft 12.

[0058] Understandably, the stator assembly and rotor assembly are pre-assembled as a single unit via the adapter 25, allowing them to be mounted as a whole on the engine housing 11 during actual assembly. This eliminates the need to install the motor shaft, stator, rotor, and other parts individually on one side of the engine housing 11, greatly improving assembly efficiency and reducing the risk of incorrect assembly. Furthermore, the crankshaft 12 is directly connected to the adapter 25, eliminating the need for a flywheel and torsional damper. The front rotor 23 and rear rotor 24 on the adapter 25 replace the flywheel and other structures, ensuring smooth and reliable operation while reducing the range extender's mass and axial dimensions.

[0059] It should be noted that the pre-assembled unit described in this embodiment is not entirely equivalent to a fixed connection. Instead, the stator assembly and the rotor assembly are formed as a whole through the adapter frame 25. Although there is no fixed connection between the stator 21 and the adapter frame 25, the front rotor 23 and the rear rotor 24 are fixed at both ends of the adapter frame 25 and located on the left and right sides of the stator 21, making it impossible for the stator 21 to be separated from the adapter frame 25. Thus, the stator assembly and the rotor assembly can be assembled as a whole.

[0060] See Figure 3 The generator 200 also includes a rear end cover 31 and a second enclosure 32. The rear end cover 31 is disposed on the side of the stator 21 facing away from the engine housing 11 through the second enclosure 32, and the rear rotor 24 is located within the space enclosed by the second enclosure 32.

[0061] Understandably, the rear cover 31 is the last step in the assembly process of the generator 200. It is designed to close the exposed rear rotor 24 after the assembly between the first enclosure 22 and the engine housing 11, and between the adapter 25 and the crankshaft 12, and to provide the necessary rotational support points for the crankshaft 12.

[0062] For details, please refer to Figure 1 and Figure 2 The periphery of the first enclosure 22 has a plurality of first connecting ears 41 protruding out, and the periphery of the second enclosure 32 has a plurality of second connecting ears 42 protruding out. The first connecting ears 41 and the second connecting ears 42 are correspondingly arranged. When the first connecting ears 41 and the second connecting ears 42 are aligned, they can be fixed by bolts, thereby realizing the assembly between the first enclosure 22 and the second enclosure 32, that is, the assembly of the rear end cover 31.

[0063] Furthermore, regarding the assembly of the first enclosure 22 onto the engine housing 11, it should be noted that in this embodiment, the engine housing 11 includes an engine rear housing 111 and an adapter housing 112. The adapter housing 112 has multiple first through holes and second through holes 113 on its end face near the edge. The first through holes correspond to the first connecting lugs 41, and the second through holes 113 correspond to the mounting holes on the engine rear housing 111. During assembly, firstly, the first connecting lugs 41 are aligned with the first through holes on the adapter housing 112 and secured with bolts. Then, the second through holes 113 on the adapter housing 112 are aligned with the mounting holes on the engine rear housing 111 and secured with bolts, thus achieving the assembly of the first enclosure 22 onto the engine rear housing 111. Of course, the engine housing 11 also includes an engine front housing (not shown in the figure), which is connected to the engine rear housing 111.

[0064] For further details, please refer to [link / reference]. Figure 1 The outer surface of the rear end cover 31 is provided with a plurality of reinforcing ribs 50 to improve the structural strength. In this embodiment, the outer surface of the rear end cover 31 has a plurality of spaced straight rib segments 51 radiating outward from the center point, and annular rib segments 52 connected to the straight rib segments 51. Of course, the arrangement of the reinforcing ribs 50 in this embodiment is only an example and not a limitation, and can be changed according to the actual situation.

[0065] See Figures 3-6 The adapter frame 25 includes a main body 251 and an edge portion 252 disposed around the periphery of the main body 251. The axial length of the edge portion 252 is greater than the thickness of the stator 21. The front rotor 23 and the rear rotor 24 are respectively connected to the opposite ends of the edge portion 252. The stator 21 is disposed around the edge portion 252 and is located between the front rotor 23 and the rear rotor 24.

[0066] It is understandable that the axial length of the edge portion 252 is greater than the thickness of the stator 21, so that after the front rotor 23 and the rear rotor 24 are installed at opposite ends of the edge portion 252, the gap formed between the front rotor 23 and the rear rotor 24 can meet the assembly of the stator 21.

[0067] Furthermore, in combination Figure 3 and Figure 4 As shown, the main body 251 and the edge part 252 enclose a clearance space 253. The rear end cover 31 is provided with a bearing chamber 33 that is accommodated in the clearance space 253. The bearing chamber 33 is provided with a bearing 34.

[0068] Understandably, the clearance space 253 formed on the inner side of the edge portion 252 allows the bearing housing 33 to extend in, making the mechanical layout of the generator 200 more compact and further reducing the axial dimension of the generator 200. In this embodiment, the axial dimension of the generator 200 can be reduced to 100mm, which is highly adaptable to the overall vehicle layout and has low cost.

[0069] It is worth mentioning that, in some embodiments of this example, one of the front rotor 23 or the rear rotor 24 may be integrally formed with the edge portion 252, while the other is fixed to the edge portion 252 by bolts. Of course, the front rotor 23 and the rear rotor 24 may also be fixed to the edge portion 252 by bolts respectively.

[0070] See Figures 3-6 The crankshaft 12 has a crankshaft flange 121 on its outer wall. The main body 251 has a positioning groove 254 adapted to the crankshaft 12 on one side and a motor shaft 255 colinear with the central axis of the crankshaft 12 on the other side. One end of the crankshaft 12 is inserted into the positioning groove 254 and is fixedly connected to the main body 251 through the crankshaft flange 121. The motor shaft 12 is connected to the bearing 34.

[0071] Specifically, the main body 251 has multiple through holes 60 surrounding the motor shaft 255. These through holes 60 are used to insert bolt holes on the crankshaft flange 121 for bolting, so that the main body 251 is fixed to the crankshaft flange 121. After the assembly between the adapter 25 and the crankshaft 12 is completed, the bearing 34 is press-fitted onto the motor shaft 255, and then the rear end cover 31 is sealed.

[0072] It should be noted that in this embodiment, the engine 100 has a conventional structure. By redesigning the generator 200, it is made suitable for installing different types of engines 100. The generator 200 is independently assembled and has no shared parts with the engine 100, thus requiring no modification to the existing structure of the engine 100, thereby increasing the applicability of the generator 200. The engine 100 can also be an axial flux motor.

[0073] In summary, in the above embodiments of the present invention, the stator assembly and rotor assembly of the range extender are pre-assembled as a whole through the adapter 25, so that in the actual assembly process, the two can be installed as a whole on the engine housing 11 without having to install the motor shaft, stator, rotor and other parts one by one on one side of the engine housing 11, which greatly improves the assembly efficiency and makes it less likely to be installed incorrectly.

[0074] Second Embodiment

[0075] Please refer to Figures 7-10 The range extender in the second embodiment of the present invention differs from the range extender in the first embodiment in that:

[0076] The outer wall of the crankshaft 12 is provided with a crankshaft flange 121, and a central hole 61 is opened on the main body 251. One end of the crankshaft 12 passes through the central hole 61 and is connected to the bearing 34. The crankshaft flange 121 is fixedly connected to the main body 251.

[0077] Therefore, in this embodiment, the generator 200 and the engine 100 share a crankshaft 12, and one end of the crankshaft 12 located inside the generator 200 can be directly connected to the bearing 34 on the rear end cover 31. This eliminates the concentricity error that may occur when the motor shaft 255 is connected to the crankshaft 12, thus helping to improve the overall performance and stability of the motor.

[0078] In this embodiment, a plurality of through holes 60 are also provided on the main body 251 around the central hole 61. The through holes 60 are used to insert into the bolt holes on the crankshaft flange 121 so that the main body 251 is fixed on the crankshaft flange 121.

[0079] Third Embodiment

[0080] Please refer to Figure 11The range extender in the third embodiment of the present invention differs from the range extender in the first embodiment in that: the generator 200 further includes a positioning fixture, the positioning fixture includes an annular frame 71 and at least two connecting arms 72 disposed around the annular frame 71, the connecting arms 72 are detachably connected to the first enclosure plate 22, and the annular frame 71 is detachably connected to the rear rotor 24, so that the stator 21 maintains the air gap with the front rotor 23 and the rear rotor 24 and the central axis is collinear.

[0081] In this embodiment, the number of connecting arms 72 around the periphery of the ring frame 71 is two. Of course, it can also be three or four. This embodiment is only an example and not a limitation.

[0082] Specifically, in this embodiment, the connecting arm 72 can be fixed to the first connecting lug 41 of the first enclosure plate 22 by bolts, and the annular frame 71 and the rear rotor 24 can be locked together by the positioning pin 73 to ensure that the central axis of the stator 21 and the rotor remains collinear. At the same time, the distance between the positioning fixture and the contact surface of the stator 21 and the rotor ensures the axial position of the stator 21 and the rotor.

[0083] It should be noted that after the assembly between the first enclosure 22 and the engine housing 11 and the assembly between the adapter 25 and the crankshaft 12 are completed, the positioning fixture needs to be removed from the first enclosure 22 before the rear end cover 31 is assembled.

[0084] Fourth embodiment

[0085] The fourth embodiment of the present invention also provides a range extender assembly method, the method comprising:

[0086] Step a: Pre-assemble the stator assembly and rotor assembly into one unit using the adapter 25;

[0087] Step b: Assemble the stator assembly onto the end face of the engine housing 11;

[0088] Step c: Assemble the adapter 25 onto the crankshaft 12.

[0089] Understandably, the stator assembly and rotor assembly can be pre-assembled and prepared using the adapter frame 25, so that they can be directly used during the actual assembly process. Compared with the existing solution, which installs the motor shaft, stator, rotor and other parts one by one on one side of the engine housing 11, this greatly improves the assembly efficiency and makes it less likely to be assembled incorrectly.

[0090] For further details, please refer to [link / reference]. Figure 3 and Figure 4The adapter frame 25 includes a main body 251 and an edge portion 252 disposed around the periphery of the main body 251. The stator assembly includes a stator 21, and the rotor assembly includes a front rotor 23 and a rear rotor 24. Therefore, step a includes:

[0091] First, the front rotor 23 is fixed to one axial end of the edge portion 252;

[0092] Then the stator 21 is fitted around the periphery of the main body 251;

[0093] Finally, the rear rotor 24 is fixed to the other axial end of the edge portion 252 so that the stator 21 is positioned between the front rotor 23 and the rear rotor 24.

[0094] For further details, please refer to [link / reference]. Figure 3 The stator 21 has a first enclosure 22 on the side facing the engine housing 11, and therefore step b includes:

[0095] The first enclosure 22 is connected to the end face of the engine housing 11 so that the front rotor 23 is located within the space enclosed by the first enclosure 22.

[0096] See Figure 4 The main body 251 has a positioning groove 254 on one side and a motor shaft 255 on the other side, and therefore step c includes:

[0097] Insert one end of the crankshaft 12 into the positioning groove 254 until the crankshaft flange 121 on the crankshaft 12 abuts against the main body 251;

[0098] The crankshaft flange 121 and the main body 251 are fixed together so that the central axes of the crankshaft 12 and the motor shaft 255 are collinear.

[0099] See Figure 8 The main body 251 is provided with a central hole 61, and therefore step c includes:

[0100] Pass one end of the crankshaft 12 through the central hole 61 until the crankshaft flange 121 on the crankshaft 12 abuts against the main body 251;

[0101] The crankshaft flange 121 and the main body 251 are fixedly connected.

[0102] It should be noted that in this step, the generator 200 and the engine 100 share the crankshaft 12.

[0103] Furthermore, after the step of assembling the adapter bracket 25 onto the crankshaft 12, the method further includes:

[0104] A rear end cover 31 is installed on the side of the stator 21 facing away from the engine housing 11, so that the rear rotor 24 is located inside the second enclosure 32 provided on the rear end cover 31.

[0105] Fifth embodiment

[0106] The fifth embodiment of the present invention also provides a method for assembling a range extender, the method comprising:

[0107] Step a: Pre-assemble the stator assembly and rotor assembly into one unit using the adapter 25;

[0108] Step b: Assemble the stator assembly onto the end face of the engine housing 11;

[0109] Step c: Assemble the adapter 25 onto the crankshaft 12.

[0110] Furthermore, the adapter frame 25 includes a main body 251 and an edge portion 252 disposed around the periphery of the main body 251, the stator assembly includes a stator 21, and the rotor assembly includes a front rotor 23 and a rear rotor 24. Therefore, step a includes:

[0111] First, the front rotor 23 is fixed to one axial end of the edge portion 252;

[0112] Then the stator 21 is fitted around the periphery of the main body 251;

[0113] Finally, the rear rotor 24 is fixed to the other axial end of the edge portion 252 so that the stator 21 is positioned between the front rotor 23 and the rear rotor 24.

[0114] The difference between this embodiment and the third embodiment is that:

[0115] After the step of finally fixing the rear rotor 24 to the other axial end of the edge portion 252 so that the stator 21 is positioned between the front rotor 23 and the rear rotor 24, the method further includes:

[0116] A positioning fixture is added to the same side of the rear rotor 24 and the stator 21 to keep the air gap between the stator 21 and the front rotor 23 and the rear rotor 24 and to make their central axes collinear.

[0117] Understandably, by adding positioning fixtures, when the stator assembly and rotor assembly are mounted as a whole on the engine housing 11, the errors that may occur during manual assembly can be reduced and the assembly quality can be improved.

[0118] It should be noted that in this embodiment, when step c is completed, the positioning fixture needs to be removed before the rear end cover 31 can be assembled.

[0119] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0120] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A range extender, characterized in that, include: An engine, the engine comprising an engine housing and a crankshaft; A generator, comprising a stator assembly, a rotor assembly, and a transfer frame, wherein the stator assembly and the rotor assembly are pre-assembled together via the transfer frame, the rotor assembly comprising a front rotor and a rear rotor, the front rotor and the rear rotor being respectively connected to opposite ends of the transfer frame; the stator assembly comprising a stator and a first enclosure plate, the stator being disposed around the transfer frame and between the front rotor and the rear rotor, the first enclosure plate being disposed on the side of the stator facing the engine housing, and the front rotor being located within the space enclosed by the first enclosure plate; The first enclosure is connected to the end face of the engine housing to fix the stator assembly to one side of the engine housing; one end of the crankshaft extends into the generator and is connected to the adapter frame to fix the rotor assembly to the crankshaft. The adapter includes a main body and an edge portion located around the periphery of the main body. The axial length of the edge portion is greater than the thickness of the stator. The front rotor and the rear rotor are respectively connected to opposite ends of the edge portion. The stator is arranged around the edge portion and is located between the front rotor and the rear rotor. The generator also includes a rear end cover and a second enclosure plate. The rear end cover is disposed on the side of the stator facing away from the engine housing via the second enclosure plate, and the rear rotor is located within the space enclosed by the second enclosure plate. The main body and the edge portion enclose a clearance space, and the rear end cover is provided with a bearing chamber that is accommodated in the clearance space, and a bearing is provided in the bearing chamber; The crankshaft has a crankshaft flange on its outer wall, and a central hole is opened on the main body. One end of the crankshaft passes through the central hole and is connected to the bearing. The crankshaft flange is fixedly connected to the main body.

2. The range extender according to claim 1, characterized in that, The generator further includes a positioning fixture, which includes an annular frame and at least two connecting arms located around the annular frame. The connecting arms are detachably connected to the first enclosure plate, and the annular frame is detachably connected to the rear rotor, so that the stator maintains the air gap with the front rotor and the rear rotor and is collinear with the central axis.

3. A method for assembling a range extender as described in any one of claims 1 or 2, characterized in that, The method includes: Step a: Pre-assemble the stator assembly and rotor assembly into one unit using an adapter frame; Step b: Assemble the stator assembly onto the end face of the engine housing; Step c: Assemble the adapter bracket onto the crankshaft; The adapter frame includes a main body and an edge portion disposed around the periphery of the main body; the stator assembly includes a stator; the rotor assembly includes a front rotor and a rear rotor; and step a includes: First, fix the front rotor to one axial end of the edge portion; Then the stator is fitted around the periphery of the main body; Finally, the rear rotor is fixed to the other axial end of the edge portion so that the stator is positioned between the front rotor and the rear rotor; The main body is provided with a central hole, and therefore step c includes: Pass one end of the crankshaft through the central hole until the crankshaft flange on the crankshaft abuts against the main body; The crankshaft flange and the main body are fixedly connected.

4. The range extender assembly method according to claim 3, characterized in that, After the step of finally fixing the rear rotor to the other axial end of the edge portion so that the stator is positioned between the front rotor and the rear rotor, the method further includes: A positioning fixture is added on the same side of the rear rotor and the stator to keep the air gap between the stator and the front rotor and the rear rotor collinear with the central axis.

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