Range extending module and vehicle

Abstract

The invention relates to a range-extending module for connection to a vehicle engine, comprising a motor control device (1), a motor device (2), a motor housing (7), an adapter housing (3), an adapter mount (4) and a cooling device (5), the motor control device (1) being fixed in the radial direction of the motor housing (7), the adapter housing (3) being fixed in the radial direction of the motor housing (7), the adapter mount (4) being fixed in the radial direction of the motor housing (7), and the cooling device (5) being fixed in the radial direction of the motor housing (7). The adaptive shell (3) is used for being connected with the engine and can be matched with different engines, the adaptive suspension support (4) is used for supporting the range extending module and can be matched with frames of different vehicles, and the cooling device (5) is used for conducting oil cooling on the motor device (2). The motor controller device (1), the motor device (2), the motor housing (7) and the cooling device (5) are modular assemblies. The invention further relates to a vehicle having such an extended range module.

Description

Technical Field

[0001] The present invention relates to a range extender module for connecting to a vehicle engine, the range extender module comprising a motor device and a motor controller device fixed directly above the motor device. An adaptable housing for connecting to the engine is provided at the output end of the motor device, the adaptable housing having a flywheel cavity for accommodating an engine mass flywheel, and an output shaft of the motor device is connected to a flywheel shaft of the engine through a spline. Background Art

[0002] Although pure electric vehicles cannot completely replace traditional fuel vehicles due to the limitation of battery range, energy conservation and emission reduction have become an inevitable development direction. In this case, extended-range electric vehicles came into being. Extended-range electric vehicles generate electricity by installing a small engine and a range extender in the engine compartment of the vehicle to store energy for the power battery, thereby alleviating the contradiction between the power battery capacity and the range, ensuring that the hybrid vehicle has a long range and saves fuel to the greatest extent.

[0003] CN 213413503 U discloses a motor device system directly connected to an engine. Compared with the original technology, the motor controller device is fixed above the motor device. The front flange of the motor device can be directly connected to the engine. A flywheel cavity is provided in the front flange for accommodating a dual-mass flywheel of the engine. The spline of the output shaft of the motor device is connected to the flywheel shaft, so that the engine drives the dual-mass flywheel, and the dual-mass flywheel drags the motor device to generate electricity to charge the battery.

[0004] A coaxially arranged transmission mechanism for a range-extended hybrid system is known from CN 112240381 A, which is specifically an integrated mechanism of a coaxially arranged motor device, a drive motor, and a parking mechanism. The disadvantage is that the overall layout of the integrated mechanism is too long, the internal structure is complex, and the assembly space requirement of the whole vehicle is large, which is not convenient for assembly.

[0005] With the popularity of hybrid power system configuration models in the market and the national emission and fuel consumption requirements, when the extended-range power system is configured in different vehicle architectures, the system structure is very different, and different vehicle architectures need to be equipped with different styles of extended-range power systems. The range extender module in the prior art cannot match motors of different powers according to customer needs, and the motor of the range extender in the prior art does not match the high-efficiency zone of the engine well. At the same time, the motor device of this range extender usually adopts a water cooling system, which will increase the axial length and affect the layout of the whole vehicle when the same continuous power is met. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide an improved range-extended module, which can overcome the shortcomings of the above-mentioned prior art and can be platform-based, that is, it can be easily adapted to different vehicle architectures and engines according to needs, and has a compact layout to save structural space.

[0007] The technical problem is solved by a range extender module designed according to the present invention, which includes a motor controller device, a motor device, a motor housing, an adapter housing, an adapter suspension bracket and a cooling device, wherein the motor controller device is fixed in the radial direction of the motor housing, the motor housing accommodates the motor device, the adapter housing is used to connect to the vehicle engine and can match different engines, the adapter suspension bracket is used to support the range extender module on the vehicle frame and can match the frames of different vehicles, and the cooling device is used for oil cooling the motor device. The cooling device for motor cooling is an oil cooling system, which can save the size envelope space of the range extender structure through a compact arrangement. The adapter housing and the adapter suspension bracket can be designed separately to match different vehicle requirements. The adapter housing and the adapter suspension bracket are preferably fixed to the motor housing in a detachable manner so that it is easier to achieve flexible assembly on the production line, and of course, the use of a non-detachable connection method is not excluded. In addition, the motor controller device, the motor device, the motor housing and the cooling device constitute a modular component. Modular components refer to several components that can constitute a module to be used as a whole, and the motor device can be platformized to achieve different requirements. In the design of the present invention, the motor controller device, the motor device, the motor housing and the cooling device are used as a module, which can be adaptively designed according to different vehicle models, so that it can be easily adapted to different vehicles and reduce development costs.

[0008] According to a preferred embodiment of the present invention, the motor housing includes a main housing and a shell cover, the motor device includes a motor stator and a motor rotor, the motor stator and the motor rotor are contained in the main housing, the main housing is connected to the shell cover by bolts, and a motor cavity is formed between them, wherein the adapter housing is mounted on the main housing, and the adapter suspension bracket is mounted on the shell cover. The adapter housing and the adapter suspension bracket are preferably fixed and positioned by bolts and locating pins. Through this layout, the range extender module is stably supported, the overall structure is compact, and the reliability and adaptability of the module are better. It is further preferred that the motor controller device is fixed to the main housing and the shell cover at the same time. This fixed design enables the motor controller device to be tightly connected to the main housing and the shell cover, providing a stable support for the motor controller device. For example, when disassembling the motor controller device, it is necessary to unscrew all the bolts on the shell cover and the main housing, open the shell cover, and then remove the low-voltage plug-in head and the connecting bolts between the motor controller device and the busbar before the motor controller device can be removed, which helps the structural design of the motor controller. It is further preferred that the motor device has a resolver sensor, wherein the resolver sensor is placed in the motor cavity, and the resolver sensor is electrically connected to the motor controller device. The low-voltage plug-in head of the motor controller device can be fixed on the main housing, and the wiring harness of the temperature sensor and the resolver sensor is directly connected to the low-voltage plug-in head, which is firmly fixed and has a short wiring harness path, and also saves envelope space. It is also preferred that the adapter housing has a cavity for accommodating the engine damper, and the rotor shaft assembly of the rotor is connected to the damper through a spline, thereby saving axial length.

[0009] According to a preferred embodiment of the present invention, the motor stator of the motor device has a concentrated round wire winding. The motor stator winding is generally divided into distributed winding and concentrated winding. The concentrated winding occupies a smaller structural space while providing the same power. It is also preferred that the rotor shaft assembly of the motor device is supported on the main housing on one side by a bearing. Single-sided support means that usually only one bearing is used for support, which can shorten the axial length of the rotor shaft assembly as much as possible. This bearing support method simplifies the structure, while ensuring the stable rotation of the rotor shaft assembly, shortens the axial length of the rotor shaft and reduces the occupation of the internal space of the rotor bracket, so that there is enough space for accommodating other components.

[0010] According to a preferred embodiment of the present invention, the cooling device has an oil pump, a heat exchanger, a water pipe, a main housing oil passage and a shell cover oil passage, and the oil pump is fixed on the shell cover and is accommodated in the motor cavity. Since the oil pump is fixed on the shell cover, the redundant space in the rotor assembly is utilized, and the axial length of the system is shortened. In addition, according to the design scheme of the present invention, the motor housing is fully utilized, and oil passages are provided in the main housing and the shell cover, which reduces the cost of components and further reduces the space occupation. Preferably, an oil seal is arranged between the motor rotor and the main housing, facing the side of the adapter housing, and the oil seal can prevent the lubricating oil of the bearing and the rotor shaft from leaking to the outside. It is further preferred that the oil pump is interference-connected with the rotor shaft assembly of the motor rotor through a transition sleeve, and this connection mode ensures that the movement of the rotor shaft can drive the oil pump to rotate, thereby increasing the efficiency of the oil pump. The use of the transition sleeve can more accurately realize the connection between the two, ensure the stability and reliability of the anti-torsion transmission, and in order to make the oil pump and the rotor shaft more compatible, it is only necessary to replace the transition sleeve. It is further preferred that the transition sleeve is connected to the oil pump by a key, such as a rectangular spline, an involute spline and a flat key, and the involute spline is particularly preferred, so that the torque can be transmitted more stably. In addition, it can be considered that the heat exchanger of the cooling device for motor cooling is fixed in front of the main housing, that is, in the direction of the front of the vehicle. This arrangement of the heat exchanger can not occupy the axial space of the vehicle, and the whole vehicle pipeline is shorter. The cooling water of the whole vehicle enters the motor controller through the pipeline, and then enters the heat exchanger through the water pipe to cool the lubricating oil of the range extender, making the space of the range extender module more compact. It is further preferred that the water outlet of the heat exchanger is located on the same side as the water inlet of the motor controller device, and the water outlet and the water inlet are connected by a water pipe, thereby shortening the length of the water pipe, so that the overall size envelope space of the range extender is further reduced. It can be further considered that the cooling device for motor cooling has a filter, which is fixed on the main housing and the shell cover, and is connected to the oil pump through the shell cover oil channel. The setting of the filter helps to prevent lubricating oil with impurities from entering the cooling device, ensuring the normal operation of the system. The filter is connected to the oil pump through a pipeline arranged in the shell cover, which can further save structural space.

[0011] In addition, the technical problem to be solved by the present invention is solved by a vehicle, which includes a range-extending module having the above technical features. This range-extending module realizes platformization through reasonable structural design and modular component layout, can adapt to various vehicle architectures through simple structural changes, and occupies less structural space as a whole, especially axial space, which can give full play to the performance of the motor and improve system reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Preferred embodiments of the present invention will be described with reference to the accompanying drawings. In all drawings, the same reference numerals indicate the same components or components with similar functions.

[0013] Figure 1a The first working mode of the range extender module designed according to the present invention is shown;

[0014] Figure 1b The second working mode of the range extender module designed according to the present invention is shown;

[0015] Figure 2 A cross-sectional view showing a range-extending module designed according to the present invention;

[0016] Figure 3 A front perspective view of a range extender module designed according to the present invention is shown;

[0017] Figure 4 A rear perspective view of a range extender module designed according to the present invention is shown. DETAILED DESCRIPTION

[0018] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The "axial" and "radial" referred to in the present invention are generally relative to the rotor shaft of the motor device. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be understood as limiting the present invention.

[0019] FIG1 shows the working mode of the range extender module designed according to the present invention. The range extender module has a motor controller 1, a motor device 2, a motor housing 7 and a cooling device 5 for oil cooling. These four components constitute a modular component, that is, they constitute an integral component and can be replaced as a whole. The range extender module is torsionally connected to the shock absorber 6 of the engine ICE through an adapter housing 3. The range extender module mainly has two working modes, a first working mode: an engine start mode; and a second working mode: a power generation mode. When the vehicle wants to restart the engine, the range extender module is in the first working mode, and the motor controller device 1 of the range extender module sends a control command to the motor 2, and the power from the motor drives the engine ICE through the shock absorber 6, thereby realizing the function of starting the engine. When the vehicle needs to generate electricity, the range extender module is in the second working mode, and the power of the engine drives the motor to generate electricity through the shock absorber. The direction of the arrow in FIG1 indicates the flow direction of the torque.

[0020] like Figure 2 and 3As shown, the range extender module includes a motor controller device 1, a motor device 2, a motor housing 7, an adapter housing 3, an adapter suspension bracket 4 and a cooling device 5. The motor controller device 1 is fixed above the motor housing 7. The motor device 2 has a motor stator 22 and a motor rotor 23. The motor rotor 23 has a rotor shaft assembly 231. The rotor shaft assembly 231 generally refers to a combined structure of a rotor bracket and a rotor shaft. The motor housing 7 includes a main housing 71 and a housing cover 72. The motor stator 22, the motor rotor 23 and other components of the motor device 2 are placed in the main housing 71, and the open end of the main housing 71 is closed by the housing cover 72 to form a motor cavity 73. The motor controller device 1 is preferably fixed to the main housing 71 and the housing cover 72 by bolts at the same time. The connecting bolts in the main housing 71 can only be removed after the housing cover 72 is removed, so that the motor controller 1 is fixed more securely. The motor stator 22 is fixed to the main housing 71 through the motor stator bracket. In the embodiment of the present invention, in order to reduce the occupied space, the motor stator 22 uses a centralized round wire winding. According to the design scheme of the present invention, the rotor shaft assembly 231 is supported on the main housing 71 on one side through the bearing 27. Figure 2 As shown, for example, the rotor shaft assembly 231 is supported only on one side by a double-row ball bearing, thereby shortening the length of the rotor shaft, thereby shortening the axial length of the range extender module, and saving the space on the other side for arranging other components. In this embodiment, the space on the other side is used to arrange the oil pump 51, for example. An oil seal 29 is arranged between the rotor shaft and the main housing 71 to prevent leakage of lubricating oil in the motor cavity 73. In addition, a resolver sensor 28 is also provided in the main housing 71 to measure the rotational speed of the motor rotor assembly. Preferably, the low-voltage plug-in head of the motor controller device 1 is fixed in the main housing 71, especially on the side close to the resolver sensor 28, and the wiring harness of the resolver sensor 28 is connected to the low-voltage plug-in head, thereby shortening the wiring harness path.

[0021] The adapter housing 3 is mainly used to connect with the engine. The adapter housing has a cavity 31 for accommodating the shock absorber 6 of the engine. The rotor shaft assembly 231 of the motor device 2 is torsionally connected to the shock absorber 6, so that when the engine is running, the shock absorber is driven to rotate, thereby driving the motor device 2 to generate electricity. According to the design scheme of the present invention, the adapter housing 3 can be designed separately to match different engines, for example, it can be designed separately according to the style of the shock absorber 6. For example, Figure 3 As shown, the adapter housing 3 is connected to the main housing 71 by bolts. The adapter housing can be individually designed according to different engines, and because it is detachably fixed to the main housing 71, it is also convenient for adaptability design.

[0022] The adaptable suspension bracket 4 is mainly used to support the range extender module on the vehicle frame. The adaptable suspension bracket 4 can also be designed separately and adapted according to customer needs or different vehicle frames. Figure 4 As shown, the adapter suspension bracket 4 is fixed to the housing cover 72 by bolts.

[0023] The cooling device 5 for oil cooling includes an oil pump 51, a heat exchanger 52, a water pipe 57, a shell cover oil passage 53 and a main shell oil passage 56. The oil pump 51 is placed in the motor cavity 73, and is preferably connected to the rotor shaft assembly 231 through a transition sleeve 54, so that the rotor shaft can drive the oil pump 51. In addition, since the rotor shaft assembly 231 is supported on one side by a double-row bearing, there is space in the axial direction of the rotor shaft to place the oil pump 51, thereby minimizing the axial space. The oil pump 51 is fixed on the shell cover 72. The heat exchanger 52 is as shown in FIG. Figure 3 As shown, it is arranged in front of the main housing 71, that is, pointing in the direction of the front of the vehicle, thereby saving the envelope space of the range extender, especially shortening the axial space size. A filter 55 is also provided on the main housing 71 and the housing cover 72, and the filter 55 extends into the housing cover 72. A housing cover oil passage 53 is provided in the housing cover 72, and the inlet of the oil pump 51 is connected to the housing cover oil passage 53, so that the oil entering the oil pump 51 is filtered, and the space occupied by the oil circuit and the material cost are saved.

[0024] Although possible embodiments are described by way of example in the above description, it should be understood that there are still a large number of variations of embodiments through the combination of all known and easily conceivable technical features and embodiments by the skilled person. It should also be understood that the exemplary embodiment is only an example and that such embodiment in no way limits the scope of protection, application and configuration of the present invention. The foregoing description is more to provide a technical guide for converting at least one exemplary embodiment to the skilled person, wherein various changes can be made, especially changes in the functions and structures of the components, as long as they do not depart from the scope of protection of the claims.

[0025] Reference numerals list

[0026] 1 Motor controller device

[0027] 2 Motor device

[0028] 22 Motor stator

[0029] 23 Motor rotor

[0030] 231 Rotor shaft assembly

[0031] 27 Bearings

[0032] 28 Resolver Sensor

[0033] 29 Oil seal

[0034] 3 Adapter housing

[0035] 31 Cavity

[0036] 4. Adapter bracket

[0037] 5 Cooling device

[0038] 51 Oil Pump

[0039] 52 Heat exchanger

[0040] 53 Shell cover oil passage

[0041] 54 Transition set

[0042] 55 Filters

[0043] 56 Main housing oil passage

[0044] 57 Water pipe

[0045] 6 Shock absorber

[0046] 7 Motor housing

[0047] 71 Main housing

[0048] 72 Shell cover

[0049] 73 Motor cavity

[0050] ICE Engine

Claims

1. A range extender module for connecting to a vehicle engine, comprising a motor controller device (1), a motor device (2), a motor housing (7), an adapter housing (3), an adapter suspension bracket (4) and a cooling device (5), wherein: The motor controller device (1) is fixed in the radial direction of the motor housing (7), the motor housing (7) accommodates the motor device (2), the adapter housing (3) is used to connect the engine and can match different engines, the adapter suspension bracket (4) is used to support the range extender module and can match different vehicle frames, and the cooling device (5) is used to oil cool the motor device (2), wherein the motor controller device (1), the motor device (2), the motor housing (7) and the cooling device (5) constitute a modular component.

2. The range-extending module according to claim 1, characterized in that: The motor housing (7) comprises a main housing (71) and a housing cover (72); the motor device (2) comprises a motor stator (22) and a motor rotor (23); the motor stator (22) and the motor rotor (23) are accommodated in the main housing (71); the main housing (71) and the housing cover (72) are connected by bolts to form a motor cavity (73); wherein the adapter housing (3) is mounted on the main housing (71); and the adapter suspension bracket (4) is mounted on the housing cover (72).

3. The range-extending module according to claim 2, characterized in that: The motor controller device (1) is mounted on both the main housing (71) and the housing cover (72).

4. The range-extending module according to claim 3, characterized in that: The motor device (2) has a resolver sensor (28), wherein the resolver sensor (28) is arranged in the motor cavity (73), a low-voltage plug-in head of the motor controller device (1) is fixed on the main housing (71), and the resolver sensor (28) is connected to the low-voltage plug-in head via a pin.

5. The range-extending module according to claim 2, characterized in that: The adapter housing (3) has a cavity (31) for accommodating a vibration damper (6) of the engine, and the rotor shaft assembly (231) of the motor rotor (23) is connected to the vibration damper (6) via a spline.

6. The range-extending module according to claim 2, characterized in that: The motor stator (22) adopts a concentrated round wire winding.

7. The range-extending module according to claim 5, characterized in that: The rotor shaft assembly (231) is supported on one side on the main housing (71) via a bearing (27).

8. The range extender module according to any one of claims 2 to 7, characterized in that: The cooling device (5) comprises an oil pump (51), a heat exchanger (52), a water pipe (57), a main casing oil passage (56) and a casing cover oil passage (53); the oil pump (51) is fixed on the casing cover (72) and is accommodated in the motor cavity (73).

9. The range-extending module according to claim 8, characterized in that: An oil seal (29) is arranged between the motor rotor (23) and the main housing (71) and on the side facing the adapter housing (3).

10. The range-extending module according to claim 8, characterized in that: The oil pump (51) is interference-connected with the rotor shaft assembly (231) of the motor rotor (23) via a transition sleeve (54).

11. The range-extending module according to claim 10, characterized in that: The oil pump (51) is connected to the transition sleeve (54) via a key.

12. The range-extending module according to claim 8, characterized in that: The heat exchanger (52) is fixed in front of the main casing (71).

13. The range-extending module according to claim 12, characterized in that: The water outlet of the heat exchanger (52) and the water inlet of the motor controller device (1) are located on the same side, and the water outlet and the water inlet are connected via the water pipe (57).

14. The range-extending module according to claim 8, characterized in that: The cooling device (5) has a filter (55) which is mounted on the main housing (71) and the housing cover (72). The filter is connected to the oil pump (51) via the housing cover oil passage (53).

15. A vehicle, characterized in that: The vehicle has a range extender module according to any one of claims 1 to 14.

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