Range extender assembly and vehicle

Abstract

The invention relates to the technical field of vehicles, and discloses a range extender assembly and a vehicle. The range extender assembly comprises an engine, a generator and a control assembly which are connected in sequence; the generator comprises a power generation assembly and a first shell, the power generation assembly is connected with the power output end of the engine, and the first shell is connected with the engine and at least partially covers the power generation assembly; the control assembly comprises a controller and a controller shell, one side of the controller shell is open, the controller is installed in the controller shell, the controller shell is in butt joint with the second side of the first shell and seals the controller, and the first side is opposite to the second side. According to the range extender assembly and the vehicle, the number of parts is reduced, the overall size of the range extender assembly in the axial direction is reduced, and space arrangement of the whole vehicle is more convenient.

Description

Technical Field

[0001] The present application relates to the field of vehicle technology, and in particular to a range extender assembly and a vehicle. Background Art

[0002] As the country attaches great importance to automobile energy conservation and emission reduction, electric vehicles have been vigorously promoted by the national environmental protection department for their zero emissions and low energy consumption. Electric vehicles are equipped with on-board batteries to power the drive motor to drive the car; the on-board battery has limited power and short cruising range, and needs to be charged by an external power source, which is extremely inconvenient to use. Therefore, generally, a range extender is set in the electric vehicle as an on-board power supply, which can reduce the number of times the on-board battery is charged and extend the cruising range of the electric vehicle.

[0003] The range extender assembly usually consists of an engine, a generator and a control system. The engine can be an internal combustion engine, such as a gasoline engine or a diesel engine, or other types of power devices, such as a fuel cell. The generator converts the mechanical energy output by the engine into electrical energy to charge the battery of the electric device or directly power the motor. The control system is responsible for monitoring and controlling the operating status of the range extender to ensure its safe and efficient operation.

[0004] However, the range extender assembly in current electric vehicles has problems such as large axial dimensions, which will greatly affect the overall space layout of the electric vehicle. Summary of the invention

[0005] In view of this, the present application provides a range extender assembly and a vehicle, which have a shorter axial dimension and are more convenient for the spatial layout of the entire vehicle.

[0006] Specifically, the range extender assembly and vehicle provided in this application include the following technical solutions:

[0007] In a first aspect, the present application provides a range extender assembly, the range extender assembly comprising an engine, a generator and a control assembly connected in sequence;

[0008] The generator comprises a power generation assembly and a first housing, wherein the power generation assembly is connected to the power output end of the engine, and the first housing is connected to the engine and at least partially covers the power generation assembly;

[0009] The control assembly includes a controller and a controller housing, one side of the controller housing is open, the controller is installed inside the controller housing, the controller housing is docked with the second side of the first housing and closes the controller, and the first side is opposite to the second side.

[0010] Optionally, the power generation assembly includes a rotor shaft, a rotor part and a stator part; the rotor shaft is connected to the engine;

[0011] The rotor part is sleeved on the rotor shaft and fixedly connected to the rotor shaft;

[0012] The stator part is located on any one of two opposite sides of the rotor part along the axial direction of the rotor shaft, and is fixedly connected to the engine;

[0013] The magnetic field direction of the magnetic field generated by the stator part is parallel to the axial direction of the rotor shaft.

[0014] Optionally, the rotor portion includes a first rotor and a second rotor, the first rotor and the second rotor are arranged at an interval and are respectively fixedly connected to the rotor shaft.

[0015] Optionally, the outer diameter of the first rotor is larger than the stroke of the crankshaft; and / or,

[0016] The outer edge diameter of the second rotor is larger than the stroke of the crankshaft, and the stroke is the interval distance between the top dead center and the bottom dead center of the crankshaft during reciprocating motion.

[0017] Optionally, the generator further includes a second shell, which is located on a side of the stator part away from the first shell and connected to the stator part, the stator part is fixedly connected to the engine, and the side of the second shell away from the stator part at least partially covers the rotor part.

[0018] Optionally, the stator part is a disc-shaped component.

[0019] Optionally, the engine includes a housing and a crankshaft, wherein the crankshaft is installed inside the housing and partially exposed from the housing, and the exposed end of the crankshaft is directly connected to the rotor shaft.

[0020] Optionally, the crankshaft comprises a crankshaft body, a first connecting section and a second connecting section which are connected in sequence, and the diameter of the second connecting section is greater than the diameter of the first connecting section;

[0021] The rotor shaft comprises a first shaft segment and a second shaft segment which are connected to each other. The first shaft segment is connected to the second connecting segment. The diameter of the first shaft segment is greater than the diameter of the second shaft segment.

[0022] Optionally, the diameter of the first shaft segment is equal to the diameter of the second connecting segment.

[0023] Optionally, the second shaft segment includes a first portion and a second portion connected to each other, the first portion is connected to the first shaft segment, and a diameter of the first portion is greater than a diameter of the second portion;

[0024] The first rotor is sleeved on the first part, and the first rotor is connected to or abuts against a surface of the first shaft segment close to the first part, and the second rotor is connected to or abuts against a surface of the first part facing the second part.

[0025] A second aspect of the present application provides a vehicle, the vehicle comprising the range extender assembly as described in the above claims.

[0026] The beneficial effects of the technical solution provided by the embodiments of the present application include at least:

[0027] In the range extender assembly provided in the embodiment of the present application, the first shell in the generator is not only connected to the power generation component and serves as the rear shell of the generator, but also docks with the controller shell in the control component to form a closed space to enclose the controller inside the controller shell, that is, the first shell also serves as the front shell of the controller; that is, in the range extender assembly provided in the present application, the rear shell of the generator and the front shell of the controller are integrated into the same component, and two functions are realized simultaneously by one component. Compared with the range extender assembly in the related art, the number of parts is reduced, and the axial dimension that would originally be occupied by the front shell of the controller is saved, that is, the overall axial dimension of the range extender assembly is reduced, so that the overall structure is more compact, which can improve installation flexibility and facilitate the space layout of the whole vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0029] Figure 1 A schematic diagram of the structure of a range extender assembly provided in an embodiment of the present application is shown;

[0030] Figure 2 An exploded view of a range extender assembly provided in an embodiment of the present application is shown;

[0031] Figure 3 An exploded view of a stator portion, a first housing, a controller, and a controller housing provided in an embodiment of the present application is shown;

[0032] Figure 4 A schematic diagram showing the connection relationship between the crankshaft, the rotor shaft and the rotor provided in an embodiment of the present application is shown;

[0033] Figure 5 A schematic diagram showing the connection relationship between the crankshaft and the rotor shaft provided in an embodiment of the present application is shown.

[0034] Reference numerals:

[0035] 1. engine; 11. housing; 12. crankshaft; 121. crankshaft body; 122. first connecting section; 123. second connecting section;

[0036] 2. Generator; 21. Generator assembly; 211. Rotor shaft; 2111. First shaft section; 2112. Second shaft section; 21121. First part; 21122. Second part; 212. Rotor section; 2121. First rotor; 2122. Second rotor; 213. Stator section; 22. First housing; 23. Second housing;

[0037] 3. Control assembly; 31. Controller; 32. Controller housing.

[0038] The above drawings have shown clear embodiments of the present application, which will be described in more detail later. These drawings and text descriptions are not intended to limit the scope of the present application in any way, but to illustrate the concept of the present application to those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0039] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application. In order to make the technical solutions and advantages of the present application clearer, the range extender assembly and the vehicle will be described in detail in conjunction with the drawings.

[0040] The range extender assembly usually consists of an engine, a generator and a control system. The engine can be an internal combustion engine, such as a gasoline engine or a diesel engine, or other types of power devices, such as a fuel cell. The generator converts the mechanical energy output by the engine into electrical energy to charge the battery of the electric device or directly power the motor. The control system is responsible for monitoring and controlling the operating status of the range extender to ensure its safe and efficient operation. However, the range extender assembly in electric vehicles currently has problems such as large axial dimensions, which will greatly affect the overall space layout of the electric vehicle.

[0041] In this regard, the present application provides a range extender assembly, such as Figure 1 , Figure 2 and Figure 3As shown, the range extender assembly includes an engine 1, a generator 2 and a control component 3 connected in sequence; the generator 2 includes a power generation component 21 and a first shell 22, the power generation component 21 is connected to the power output end of the engine 1, the first shell 22 is connected to the engine 1 and at least partially covers the power generation component 21; the control component 3 includes a controller 31 and a controller shell 32, one side of the controller shell 32 is open, the controller 31 is installed inside the controller shell 32, the controller shell 32 is docked with the second side of the first shell 22, and the controller 31 is closed, and the first side is opposite to the second side.

[0042] In the range extender assembly provided in the embodiment of the present application, the first shell 22 in the generator 2 is not only connected to the power generation component 21, serving as the rear shell of the generator 2, but also docked with the controller shell 32 in the control component 3 to form a closed space to enclose the controller 31 inside the controller shell 32, that is, the first shell 22 also serves as the front shell of the controller 31; that is, in the range extender assembly provided in the present application, the rear shell of the generator 2 and the front shell of the controller 31 are integrated into the same component, and two functions are realized simultaneously by one component. Compared with the range extender assembly in the related art, the number of parts is reduced, and the axial dimension that would originally be occupied by the front shell of the controller 31 is saved, that is, the overall axial dimension of the range extender assembly is reduced, so that the overall structure is more compact, which can improve the installation flexibility and facilitate the space layout of the whole vehicle.

[0043] In addition, the present application integrates the rear housing of the engine 1 and the front housing of the controller 31 into one component, which can reduce the amount of materials required. This can reduce the procurement cost of raw materials and also reduce material waste in the production process; and integrating the two into one component also reduces the number of parts, providing support for weight reduction of the range extender assembly.

[0044] In some embodiments of the present application, Figure 1 and Figure 2 As shown, the power generation component 21 may include a rotor shaft 211, a rotor part 212 and a stator part 213; the rotor shaft 211 is connected to the engine 1; the rotor part 212 is sleeved on the rotor shaft 211 and fixedly connected to the rotor shaft 211; the stator part 213 is located on any one of the two opposite sides of the rotor part 212 along the axial direction of the rotor shaft 211, and is fixedly connected to the engine 1; wherein the magnetic field direction of the magnetic field generated by the stator part 213 is parallel to the axial direction of the rotor shaft 211.

[0045] In the range extender assembly provided in the embodiment of the present application, the rotor shaft 211 in the power generation component 21 is connected to the engine 1, and the engine 1 transmits power to the rotor shaft 211 and drives the rotor shaft 211 to rotate. At the same time, the rotor part 212 is fixedly connected to the rotor shaft 211 and is driven by the rotor shaft 211 to rotate synchronously. At this time, since the stator part 213 generates a magnetic field, the rotor part 212 cuts the magnetic field to generate electromagnetic induction and generate current. That is, the engine 1 generates kinetic energy by consuming other energy sources (such as fuel) and converts this part of the kinetic energy into electrical energy for use by the vehicle, thereby increasing the vehicle's cruising range.

[0046] It should be noted that in the range extender assembly provided in the embodiment of the present application, the magnetic field direction of the magnetic field generated by the stator part 213 in the power generation component 21 is parallel to the axial direction of the rotor shaft 211, which means that the magnetic lines of force are perpendicular to the air gap surface and parallel to the direction of the rotating shaft, forming a relatively short and direct magnetic flux path. This method not only reduces the length of the magnetic flux path, thereby reducing the axial size of the generator 2, and then reduces the overall axial size of the range extender assembly, improves installation flexibility, and facilitates the layout of the entire vehicle.

[0047] In some embodiments of the present application, Figure 2 and Figure 4 As shown, the rotor portion 212 may include a first rotor 2121 and a second rotor 2122 . The first rotor 2121 and the second rotor 2122 are arranged at an interval and are fixedly connected to the rotor shaft 211 respectively.

[0048] In the related art, a conventional generator 2 is generally provided with a rotor and a stator, but its axial dimension is relatively long, and its power density and torque density cannot meet the requirements.

[0049] In the range extender assembly provided in the embodiment of the present application, a single-stator dual-rotor design is adopted, and a first rotor 2121 and a second rotor 2122 are respectively arranged on both sides of the stator part 213, and the air gap between the rotor and the stator is a plane perpendicular to the rotor shaft 211. This design allows the magnetic flux to flow more directly from the rotor to the stator and then return to the rotor, reducing the length of the magnetic flux path, thereby reducing the axial size of the motor. Furthermore, the overall size of the range extender assembly in the axial direction will also be shorter; and the single-stator dual-rotor design makes the engine 1 smaller and lighter in volume and weight than the traditional single-stator single-rotor generator 2.

[0050] In addition, the single-stator dual-rotor generator 2 has a shorter magnetic flux path and a higher magnetic flux density, which can generate a larger torque and has a higher power density and torque density, thereby improving the performance of the vehicle and providing a better driving experience for the user.

[0051] In the range extender assembly in the related technology, the power output end of the crankshaft 12 in the engine 1 needs to be connected to the flywheel. The flywheel is generally a large-mass disc-shaped component that can store energy. After the piston of the engine 1 stores energy in the compression stroke, this part of the energy will be released through the flywheel in the power stroke, helping the engine 1 to overcome the resistance in the compression stroke, thereby ensuring the normal operation of the engine 1.

[0052] In order to reduce the number of parts and components and reduce the axial direction and weight of the range extender assembly, in some embodiments of the present application, the outer edge diameter of the first rotor 2121 is larger than the stroke of the crankshaft 12; and / or, the outer edge diameter of the second rotor 2122 is larger than the stroke of the crankshaft 12, and the stroke is the spacing distance between the top dead center and the bottom dead center of the crankshaft 12 during reciprocating motion.

[0053] In the range extender assembly provided in the embodiment of the present application, if Figure 4 As shown, the radial dimension of the outer edge of the first rotor 2121 and / or the second rotor 2122 is larger than the stroke of the crankshaft 12 during reciprocating motion. The first rotor 2121 and / or the second rotor 2122 are large-mass components. That is, when the engine 1 is in the power stroke, the energy stored in the piston of the engine 1 in the compression stroke can be released through the first rotor 2121 and / or the second rotor 2122, that is, the first rotor 2121 and / or the second rotor 2122 act as the flywheel in the related technology, which can match the required inertia of the crankshaft 12 to ensure the stable operation of the engine 1. The first rotor 2121 and / or the second rotor 2122 are both rotors and flywheels. One component has two functions, and there is no need to set up an additional flywheel. The axial dimension is reduced, the number of components is reduced, and the overall weight of the range extender assembly is reduced.

[0054] Optionally, the first rotor 2121 and / or the second rotor 2122 is an annular member, and the outer edge diameter of the first rotor 2121 and the outer edge diameter of the second rotor 2122 can be selected and adjusted according to actual needs.

[0055] In some embodiments of the present application, Figure 2 As shown, the stator portion 213 is a disc-shaped member.

[0056] It should be noted that the stator in the related art generally has a stator yoke, which is usually located on the outside of the stator core, is ring-shaped, and can constitute a part of the magnetic circuit, providing a low magnetic resistance path for the magnetic field.

[0057] In the range extender assembly provided in the embodiment of the present application, the stator portion 213 is a disc-shaped component and a yoke-free stator structure, which has the following advantages:

[0058] (1) Reduce motor weight and volume

[0059] The yokeless design allows the stator to occupy less axial space, thereby making the structure of the generator 2 more compact and easier to install and layout in places with limited space; in addition, after the yoke is removed from the stator, the core size is small and the weight is reduced, thereby reducing the overall weight of the range extender assembly.

[0060] Through research and experiments, it can be found that due to the use of the generator 2 provided in the embodiment of the present application, the range extender assembly provided in the present application is reduced in weight by 35%-40% compared with the range extender assembly in the related art; the overall axial length is ≤700mm.

[0061] (2) Improve the efficiency of the motor

[0062] In a motor with a yoke, the magnetic flux needs to be conducted through the stator yoke, and the presence of the yoke increases the length of the magnetic circuit and the magnetic resistance, resulting in the loss of magnetic energy. The yokeless design shortens the conduction path of the magnetic flux, making the magnetic circuit more direct, reducing the loss of magnetic energy during the conduction process, and thus improving the efficiency of the generator 2.

[0063] (3) Reduce the manufacturing cost of the motor

[0064] After removing the stator yoke, the structure of the motor becomes relatively simple, reducing the processing steps and assembly links in the manufacturing process, which not only reduces the difficulty and complexity of the manufacturing process, but also improves production efficiency and reduces manufacturing costs.

[0065] In addition, the removal of the stator yoke reduces material consumption. At the same time, since the yoke-free design can improve the efficiency and power density of the motor, the size of the motor can be reduced to a certain extent, thereby further reducing the amount of material used and reducing the overall cost of the generator 2.

[0066] In some embodiments of the present application, Figure 1 and Figure 2 As shown, the generator 2 may further include a second shell 23, which is located on a side of the stator portion 213 away from the first shell 22 and connected to the stator portion 213, the stator portion 213 is fixedly connected to the engine 1, and the side of the second shell 23 away from the stator portion 213 at least partially covers the rotor portion 212.

[0067] In the range extender assembly provided in the embodiment of the present application, in addition to the first shell 22, a second shell 23 is also provided which is spaced apart therefrom. The first shell 22 and the second shell 23 can form a solid protective shell 11 on the outside of key components such as the stator part 213, the rotor part 212 and the winding to prevent external dust, moisture, foreign matter, etc. from entering the interior of the generator 2, thereby avoiding these substances from damaging the normal operation of the motor and extending the service life of the motor.

[0068] Furthermore, the stator part 213 and the rotor part 212 may be fixed on the first shell 22 and / or the second shell 23 to ensure that the relative positions therebetween are accurate, so as to ensure the normal operation of the generator 2 and the range extender.

[0069] In some embodiments of the present application, Figure 2 As shown, the engine 1 includes a housing 11 and a crankshaft 12 . The crankshaft 12 is installed inside the housing 11 and partially exposed from the housing 11 . The exposed end of the crankshaft 12 is directly connected to the rotor shaft 211 .

[0070] In the range extender assembly provided in the embodiment of the present application, a portion of the crankshaft 12 is exposed from the housing 11 of the engine 1, which is convenient for connection with the rotor shaft 211 of the generator 2, and is convenient for workers to operate and assemble; and on the basis of the crankshaft 12 of the traditional engine 1, the range extender assembly provided in the present application directly connects the crankshaft 12 with the rotor shaft 211, without the need to set up transition components such as flywheel clutch and spline, reducing the number of parts, improving the problems of idle knocking and large complaints of starting jitter when spline connection, and improving NVH performance. When the engine 1 is working, the piston connecting rod drives the crankshaft 12 to rotate and transmit torque, and the crankshaft 12 transmits power to the motor shaft and generates electricity through the generator 2.

[0071] In some embodiments, the crankshaft 12 is fixedly connected to the rotor shaft 211 via a connecting member.

[0072] Optionally, the connecting member may be a positioning pin and a bolt. Those skilled in the art may adjust the type and quantity of the connecting member according to actual needs, as long as the fixed connection between the crankshaft 12 and the rotor shaft 211 can be achieved.

[0073] In some embodiments, the crankshaft 12 in the engine 1 is integrally connected with the rotor shaft 211 in the generator 2. The crankshaft 12 can directly transmit power to the rotor shaft 211 so that the generator 2 can convert the power into electrical energy. There is no need to connect the crankshaft 12 and the rotor shaft 211 through a switching component (such as a locating pin, a spline, a switching shaft, a bolt, etc.) as in the range extender assembly in the related art, thereby saving the axial dimension that the switching component would originally occupy, that is, reducing the axial dimension of the range extender assembly, making the overall structure more compact, and being able to improve installation flexibility and facilitate the spatial layout of the entire vehicle. In addition, there is no need to set up a switching component, which reduces the number of parts and components, and can also reduce the overall weight of the range extender assembly, thereby reducing the weight of the entire vehicle and meeting the lightweight requirements.

[0074] The crankshaft 12 is directly connected to the rotor shaft 211, and the engine 1 outputs power to the rotor shaft 211 through the crankshaft 12. Therefore, the connection between the crankshaft 12 and the rotor shaft 211 needs to have sufficient strength to maintain structural stability during operation and avoid bending or breaking of the connection.

[0075] Therefore, in some embodiments of the present application, Figure 5 As shown, the crankshaft 12 includes a crankshaft body 121, a first connecting section 122 and a second connecting section 123 connected in sequence, and the diameter of the second connecting section 123 is larger than the diameter of the first connecting section 122; the rotor shaft 211 includes a first shaft section 2111 and a second shaft section 2112 connected to each other, the first shaft section 2111 is connected to the second connecting section 123, and the diameter of the first shaft section 2111 is larger than the diameter of the second shaft section 2112.

[0076] In the range extender assembly provided in the embodiment of the present application, the diameter of the second connecting section 123 is greater than the diameter of the first connecting section 122, which is equivalent to increasing the diameter of the connecting portion between the crankshaft 12 and the rotor shaft 211; the diameter of the first shaft section 2111 is greater than the diameter of the second shaft section 2112, which is equivalent to the diameter of the connecting portion between the rotor shaft 211 and the crankshaft 12, that is, the diameter of the connection between the crankshaft 12 and the rotor shaft 211 is increased, the connection strength and torsional resistance of the connection are improved, stress concentration can be avoided, connection stability is ensured, and the service life of the range extender assembly is improved.

[0077] Optionally, the diameter of the first shaft segment 2111 is equal to the diameter of the second connecting segment 123, which can ensure that during the power transmission process, the power can be evenly transmitted from the crankshaft 12 to the rotor shaft 211, avoiding local stress concentration caused by inconsistent diameters.

[0078] In some embodiments of the present application, Figure 4 and Figure 5As shown, the second shaft segment 2112 includes a first part 21121 and a second part 21122 that are connected, the first part 21121 is connected to the first shaft segment 2111, and the diameter of the first part 21121 is greater than the diameter of the second part 21122; the first rotor 2121 is sleeved on the first part 21121, and the first rotor 2121 is connected to or abuts against the surface of the first shaft segment 2111 close to the first part 21121, and the second rotor 2122 is connected to or abuts against the surface of the first part 21121 toward the second part 21122.

[0079] Since the diameters of the first part 21121 and the second part 21122 are different, a step surface is formed at the connection between the first part 21121 and the second part 21122, and the second rotor 2122 is connected to or offset from the step surface (the surface of the first part 21121 facing the second part 21122), so that the first rotor 2121 and the second rotor 2122 are arranged at intervals, thereby avoiding mutual interference between the electromagnetic fields of the two rotors, improving the performance and stability of the generator 2, and the two rotors are arranged at intervals, which can improve the heat dissipation performance.

[0080] Optionally, the first rotor 2121 and / or the second rotor 2122 are fixedly connected to the rotor shaft 211 via connecting members such as bolts.

[0081] The following is a brief description of the assembly process of the range extender assembly provided in the embodiment of the present application:

[0082] (1) After the engine 1 is assembled, the axial movement amount is calculated, and the crankshaft 12 is pushed to the center position by the servo mechanism to limit the axial position of the crankshaft 12;

[0083] (2) Install the rotor shaft 211 and the first rotor 2121 onto the crankshaft 12 and tighten them with bolts, and press the fixed bearing onto the shaft bearing position;

[0084] (3) Align the positioning pin holes on the stator part 213 with the positioning pins on the end face of the engine 1, and fix the stator part 213 to the end face of the engine 1; fix the second rotor 2122 to the rotor shaft 211 with bolts, and then pre-fix the bearing pressure plate with bolts, and pre-fix the second housing 23 and the stator part 213 with bolts, then remove the crankshaft 12 limiter, and tighten the bearing pressure plate bolts and the second rotor 2122 bolts;

[0085] The controller 31 is installed on the first housing 22 , that is, the front housing of the controller 31 , and the controller housing 32 is fixed to the first housing 22 .

[0086] The present application also provides a vehicle, the vehicle comprising the range extender assembly of the above claims.

[0087] In the vehicle provided in the embodiment of the present application, the first shell 22 in the generator 2 is not only connected to the power generation component 21, serving as the rear shell of the generator 2, but also docked with the controller shell 32 in the control component 3 to form a closed space to enclose the controller 31 inside the controller shell 32, that is, the first shell 22 also serves as the front shell of the controller 31; that is, in the range extender assembly provided by the present application, the rear shell of the generator 2 and the front shell of the controller 31 are integrated into the same component, and two functions are realized simultaneously by using one component. Compared with the range extender assembly in the related art, the number of parts is reduced, and the axial dimension that would originally be occupied by the front shell of the controller 31 is saved, that is, the overall axial dimension of the range extender assembly is reduced, making the overall structure more compact.

[0088] Moreover, due to the use of the above-mentioned range extender assembly, the axial dimension is shorter and the weight is lighter, which is more conducive to the vehicle space layout of the vehicle provided in the embodiment of the present application, improves the layout flexibility of the range extender and other components, and greatly reduces the weight of the vehicle to meet the lightweight requirements; at the same time, the use of an axial flux motor and a dual rotor to replace the flywheel improves the problems of idle knocking and large startup jitter complaints, improves the NVH performance of the vehicle, and gives users a better user experience.

[0089] In the present application, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance. The term "plurality" refers to two or more than two, unless otherwise clearly defined.

[0090] Those skilled in the art will readily appreciate other embodiments of the present application after considering the specification and practicing the invention disclosed herein. The present application is intended to cover any modification, use or adaptation of the present application, which follows the general principles of the present application and includes common knowledge or customary techniques in the art that are not disclosed in the present application. The specification and examples are intended to be exemplary only.

[0091] It should be understood that the present application is not limited to the precise structures that have been described above and shown in the drawings, and that various modifications and changes may be made without departing from the scope thereof. The scope of the present application is limited only by the appended claims.

Claims

1. A range extender assembly, characterized in that: The range extender assembly comprises an engine (1), a generator (2) and a control component (3) which are connected in sequence; The generator (2) comprises a power generation component (21) and a first housing (22), wherein the power generation component (21) is connected to a power output end of the engine (1), and the first housing (22) is connected to the engine (1) and at least partially covers the power generation component (21); The control assembly (3) comprises a controller (31) and a controller housing (32), one side of the controller housing (32) is open, the controller (31) is installed inside the controller housing (32), the controller housing (32) is docked with the second side of the first housing (22) and encloses the controller (31), and the first side is opposite to the second side.

2. The range extender assembly according to claim 1, characterized in that: The power generation assembly (21) comprises a rotor shaft (211), a rotor part (212) and a stator part (213); the rotor shaft (211) is connected to the engine (1); The rotor part (212) is sleeved on the rotor shaft (211) and fixedly connected to the rotor shaft (211); The stator part (213) is located on any one of two opposite sides of the rotor part (212) along the axial direction of the rotor shaft (211), and is fixedly connected to the engine (1); The magnetic field direction of the magnetic field generated by the stator part (213) is parallel to the axial direction of the rotor shaft (211).

3. The range extender assembly according to claim 2, characterized in that: The rotor part (212) comprises a first rotor (2121) and a second rotor (2122); the first rotor (2121) and the second rotor (2122) are arranged at an interval and are respectively fixedly connected to the rotor shaft (211).

4. The range extender assembly according to claim 3, characterized in that: The engine includes a crankshaft (12); The outer diameter of the first rotor (2121) is greater than the stroke of the crankshaft (12); and / or, The outer edge diameter of the second rotor (2122) is greater than the stroke of the crankshaft (12), and the stroke is the interval distance between the top dead center and the bottom dead center of the crankshaft (12) during reciprocating motion.

5. The range extender assembly according to claim 2, characterized in that: The generator (2) further comprises a second shell (23), the second shell (23) being located on a side of the stator portion (213) away from the first shell (22) and connected to the stator portion (213), the stator portion (213) being fixedly connected to the engine (1), and the side of the second shell (23) away from the stator portion (213) at least partially covering the rotor portion (212).

6. The range extender assembly according to any one of claims 1 to 5, characterized in that: The stator part (213) is a disc-shaped component.

7. The range extender assembly according to claim 3, characterized in that: The engine (1) comprises a housing (11) and a crankshaft (12); the crankshaft (12) is installed inside the housing (11) and partially exposed from the housing (11); the exposed end of the crankshaft (12) is directly connected to the rotor shaft (211).

8. The range extender assembly according to claim 7, characterized in that: The crankshaft (12) comprises a crankshaft body (121), a first connecting section (122) and a second connecting section (123) which are connected in sequence, and the diameter of the second connecting section (123) is greater than the diameter of the first connecting section (122); The rotor shaft (211) comprises a first shaft section (2111) and a second shaft section (2112) which are connected to each other, the first shaft section (2111) is connected to the second connecting section (123), and the diameter of the first shaft section (2111) is greater than the diameter of the second shaft section (2112).

9. The range extender assembly according to claim 8, characterized in that: The diameter of the first shaft section (2111) is equal to the diameter of the second connecting section (123).

10. The range extender assembly according to claim 8, characterized in that: The second shaft segment (2112) comprises a first portion (21121) and a second portion (21122) connected to each other, the first portion (21121) is connected to the first shaft segment (2111), and the diameter of the first portion (21121) is greater than the diameter of the second portion (21122); The first rotor (2121) is sleeved on the first part (21121), and the first rotor (2121) is connected to or abuts against a surface of the first shaft segment (2111) close to the first part (21121), and the second rotor (2122) is connected to or abuts against a surface of the first part (21121) facing the second part (21122).

11. A vehicle, characterized in that: The vehicle comprises the range extender assembly according to any one of claims 1 to 10.

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