Range extender

Abstract

The invention relates to a range extender. The range extender comprises: a motor (20); a housing (110) comprising a first axial end and a second axial end; the first cover (120) is connected to the first axial end of the shell (110), and the first cover (120) and the shell (110) are constructed to jointly define a first cavity (S1) used for containing the motor (20) and a second cavity (S2) used for storing cooling liquid; a second cover (130) connected to a second axial end of the housing (110); the cooling liquid pump (30) is arranged in the first cavity (S1) and comprises a cooling liquid pump inlet (31) and a cooling liquid pump outlet (32); the cooling liquid supply channel is arranged in the shell (110) and / or the second cover (130) and is configured to enable the cooling liquid pump inlet (31) and the second cavity (S2) to be in fluid communication; and a coolant distribution channel provided in the housing (110) and / or the first cover (120) and configured to fluidly communicate the coolant pump outlet (32) and the first cavity (S1).

Description

Technical Field

[0001] The present invention relates to the field of vehicles, and more particularly to a range extender for a vehicle. Background Art

[0002] Range-extended vehicles are vehicles that use fuel to generate electricity through a range extender and are driven by electricity. The range extender includes a motor that needs to be cooled during operation. In existing range extender designs, the cooling structure is very complex, with separate cooling systems for the stator and rotor. As a result, the range extender requires a larger axial space, its assembly process is complex, and its manufacturing cost is high.

[0003] Therefore, there is a need for a compact range extender for distributing coolant to an electric motor. Summary of the invention

[0004] One object of the present invention is to provide a range extender for distributing coolant to a motor having a compact structure. Another object of the present invention is to provide a range extender for distributing coolant to a motor that is easy to assemble. Another object of the present invention is to provide a range extender for distributing coolant to a motor that can be manufactured at low cost. Another object of the present invention is to provide a range extender for distributing coolant to a motor that can simplify the structure.

[0005] One aspect of the present invention provides a range extender, comprising: a motor; a housing, comprising a first axial end and a second axial end; a first cover, connected to the first axial end of the housing, wherein the first cover and the housing are configured to jointly define a first cavity for accommodating the motor and a second cavity for storing coolant; a second cover, connected to the second axial end of the housing; a coolant pump, which is arranged in the first cavity and comprises a coolant pump inlet and a coolant pump outlet; a coolant supply channel, which is arranged in the housing and / or the second cover and is configured to fluidically connect the coolant pump inlet of the coolant pump and the second cavity; and a coolant distribution channel, which is arranged in the housing and / or the first cover and is configured to fluidically connect the coolant pump outlet of the coolant pump and the first cavity to distribute coolant to the motor.

[0006] According to an embodiment of the present invention, the motor includes a stator and a rotor; and the coolant distribution channel includes: a first coolant distribution channel, which is arranged in a housing and includes a first liquid outlet, wherein the first liquid outlet is arranged adjacent to and opens toward the rotor to distribute coolant to the rotor; and a second coolant distribution channel, which is arranged in the housing and a second cover and includes a second liquid outlet arranged on the first cover, wherein the second liquid outlet is arranged adjacent to and opens toward the stator to distribute coolant to the stator, wherein the first coolant distribution channel and the second coolant distribution channel are configured to be fluidically connected.

[0007] According to an embodiment of the present invention, the electric motor further comprises a transmission shaft, and an input end of the coolant pump is connected to the transmission shaft in a rotationally fixed manner.

[0008] According to an embodiment of the present invention, the range extender further comprises: a heat exchanger mounted to the second cover, wherein an input port of the heat exchanger is configured to be in fluid communication with a coolant pump outlet, and an output port of the heat exchanger is configured to be in fluid communication with a coolant distribution channel.

[0009] According to an embodiment of the present invention, the range extender further comprises: a filter mounted to the housing, wherein an input port of the filter is configured to be in fluid communication with the second cavity, and an output port of the filter is configured to be in fluid communication with the coolant supply channel.

[0010] According to an embodiment of the present invention, the coolant supply channel includes: a first coolant supply channel, which is arranged in the housing and is configured to be in fluid communication with an output port of the filter; and a second coolant supply channel, which is arranged in the second cover and is configured to be in fluid communication with an inlet of the coolant pump, wherein the first coolant supply channel and the second coolant supply channel are configured to be in fluid communication.

[0011] According to an embodiment of the present invention, the input end of the coolant pump is an input shaft, and the input shaft is formed integrally with the transmission shaft of the motor.

[0012] According to an embodiment of the present invention, the first cavity is configured to be in fluid communication with the second cavity, and the second cavity is disposed below the first cavity.

[0013] According to an embodiment of the present invention, the heat exchanger is mounted to a side of the second cover that is remote from the housing.

[0014] One aspect of the present invention provides a vehicle including a range extender according to an embodiment of the present invention.

[0015] According to an embodiment of the present invention, a coolant pump is disposed in the internal cavity of the range extender, and the coolant pump is respectively in fluid communication with a coolant supply channel and a coolant distribution channel disposed in the housing of the range extender, which can make the structure of the range extender more compact and reduce the occupation of the axial space. The coolant distribution channel can distribute coolant to the stator and the rotor at the same time, thereby simplifying the cooling structure design and improving the cooling efficiency. By forming a coolant supply channel and a coolant distribution channel in the housing of the range extender, the number of parts of the range extender can be reduced, the assembly process can be simplified, and the manufacturing cost can be reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is an exploded schematic diagram of a range extender according to an embodiment of the present invention.

[0017] Figure 2is a cross-sectional schematic diagram of a range extender according to an embodiment of the present invention.

[0018] Figure 3 yes Figure 1 Schematic cross-sectional view of the range extender along AA according to an embodiment of the present invention.

[0019] Figure 4 yes Figure 1 FIG. 1 is a schematic cross-sectional diagram along the BB line of a range extender according to an embodiment of the present invention.

[0020] Figure 5 is a schematic diagram of a housing according to an embodiment of the present invention.

[0021] Figure 6 is a schematic diagram of a first cover according to an embodiment of the present invention. DETAILED DESCRIPTION

[0022] Hereinafter, embodiments of the present invention are described with reference to the accompanying drawings. The following detailed description and the accompanying drawings are used to exemplarily illustrate the principles of the present invention, and the present invention is not limited to the preferred embodiments described. The scope of the present invention is defined by the claims. The present invention is now described in detail with reference to exemplary embodiments, and some embodiments are illustrated in the accompanying drawings. The following description is made with reference to the accompanying drawings, and unless otherwise indicated, the same reference numerals in different drawings represent the same or similar elements. The schemes described in the following exemplary embodiments do not represent all schemes of the present invention. On the contrary, these schemes are merely examples of systems and methods of various aspects of the present invention involved in the appended claims.

[0023] The present invention provides a range extender. The range extender according to an embodiment of the present invention can be installed in a vehicle. Below, exemplary embodiments of the present invention are described with reference to the accompanying drawings. It should be understood that only certain embodiments of the present invention are shown in the accompanying drawings, and the scope of the present invention should be determined according to the claims. In this article, "axial" means the axial direction of the electric bridge drive system, which is parallel to the extension direction of the transmission shaft in the electric bridge drive system.

[0024] Figure 1 is an exploded schematic diagram of a range extender according to an embodiment of the present invention. Figure 2 is a cross-sectional schematic diagram of a range extender according to an embodiment of the present invention. Figure 3 yes Figure 1 Schematic cross-sectional view of the range extender along AA according to an embodiment of the present invention. Figure 4 yes Figure 1 FIG. 1 is a schematic cross-sectional diagram along the BB line of a range extender according to an embodiment of the present invention. Figure 5 is a schematic diagram of a housing according to an embodiment of the present invention. Figure 6 is a schematic diagram of a first cover according to an embodiment of the present invention.

[0025] like Figure 1 and Figure 2 As shown, the range extender may include a housing 10 , a motor 20 , a coolant pump 30 , a heat exchanger 40 , and a filter 50 .

[0026] The housing 10 may include one or more housing components. Figure 1 and Figure 2 As shown, the housing 10 may include a case 110, a first cover 120, and a second cover 130. In some embodiments, these housing components may be formed by casting or the like.

[0027] The housing 110 has a first axial end and a second axial end. The first cover 120 and the second cover 130 are respectively located on two axial sides of the housing 110 .

[0028] The first cover 120 is connected to the first axial end of the housing 110. For example, the housing 110 and the first cover 120 may be connected to each other by bolts, etc. In some embodiments, a sealant, such as a sealant, etc., may be further provided at the joint between the housing 110 and the first cover 120.

[0029] like Figure 2 As shown, the housing 110 and the first cover 120 may enclose a first cavity S1. In an exemplary embodiment, the stator 21 and the rotor 22 of the motor 20 may be disposed in the first cavity S1. Thus, the first cavity S1 constitutes a motor cavity for accommodating the stator 21 and the rotor 22 of the motor 20. Figure 2 As shown, the housing 110 and the first cover 120 can also enclose a second cavity S2. In an exemplary embodiment, the second cavity S2 is used to store cooling liquid. Thus, the second cavity S2 constitutes a cooling liquid storage cavity. In an exemplary embodiment, the first cavity S1 and the second cavity S2 are fluidically connected to each other. In an exemplary embodiment, the second cavity S2 is arranged below the first cavity S1.

[0030] The second cover 130 is connected to the second axial end of the housing 110. For example, the second cover 130 and the housing 110 may be connected to each other by bolts, etc. In some embodiments, a sealant, such as a sealant, etc., may be further provided at the joint between the second cover 130 and the housing 110.

[0031] The motor 20 includes a stator 21 fixed relative to the housing 10 and a rotor 22 rotatable relative to the stator 21. The rotor 22 is located radially inside the stator 21. In the exemplary embodiment, the motor 20 also includes a transmission shaft 23. The transmission shaft 23 is disposed radially inside the rotor 22 and is connected to the rotor 22 in a rotationally fixed manner.

[0032] The coolant pump 30 is used to pump the coolant so that the coolant can be pumped from the second cavity S2 to the coolant distribution channel (described in detail below). Thereafter, the coolant can be used to cool the motor 20. The coolant can be lubricating oil. In an exemplary embodiment, Figure 1 As shown, the coolant pump 30 is disposed on a side of the housing 110 away from the second cover 130. In an exemplary embodiment, Figure 2 As shown, the coolant pump 30 is disposed in the first cavity S1 .

[0033] The coolant pump 30 includes a coolant pump inlet 31 and a coolant pump outlet 32. Figure 2 The coolant pump inlet 31 is in fluid communication with the second chamber S2 through a coolant supply channel (described in detail below). The coolant pump outlet 32 ​​is in fluid communication with the coolant distribution channel.

[0034] In an exemplary embodiment, the motor 20 and the coolant pump 30 are coaxially arranged. The input end of the coolant pump 30 is connected to the transmission shaft 23 in a torsionally fixed manner. In an exemplary embodiment, the coolant pump 30 includes an input shaft, so that the input end of the coolant pump 30 is the input shaft. In some embodiments, the coolant pump 30 is a mechanical pump, such as a cycloidal rotor pump. In an exemplary embodiment, the input shaft of the coolant pump 30 is integrally formed with the transmission shaft 23 of the motor 20.

[0035] The heat exchanger 40 is used to cool the coolant flowing therethrough. In an exemplary embodiment, the heat exchanger 40 is mounted on the second cover 130. In some embodiments, the heat exchanger 40 is mounted on the outer side of the second cover 130, that is, on the side away from the housing 110, such as Figure 2 As shown. The heat exchanger 40 includes an input port and an output port. The input port of the heat exchanger 40 is in fluid communication with the coolant pump outlet 32 ​​of the coolant pump 30. The output port of the heat exchanger 40 is in fluid communication with the coolant distribution channel. Figure 2 and Figure 3 As shown by the middle arrow C2 , the coolant output from the coolant pump 30 via the coolant pump outlet 32 ​​may flow into the input port of the heat exchanger 40 , and then flow out from the output port of the heat exchanger 40 after the temperature is reduced by the heat exchanger 40 .

[0036] The filter 50 is used to filter the coolant flowing therethrough. In an exemplary embodiment, the filter 50 is mounted on the housing 110 and is disposed in the second cavity S2. Figure 2 The input port of the filter 50 is in fluid communication with the second chamber S2. The output port of the filter 50 is in fluid communication with the coolant supply channel.

[0037] When the coolant pump 30 is working, the coolant can be pumped from the second cavity S2 to the heat exchanger 40 via the filter 50, and after flowing out of the heat exchanger 40, it is distributed to the motor 20. The second cavity S2 (or the filter 50) and the coolant pump 30, the coolant pump 30 and the heat exchanger 40, and the heat exchanger 40 and the motor 20 are connected to each other through coolant channels. These coolant channels can be provided in the housing 10. The coolant channels formed by the housing 10 will be described below with reference to the accompanying drawings.

[0038] In an exemplary embodiment, the range extender further includes a coolant distribution channel and a coolant supply channel.

[0039] The coolant supply passage is used to fluidically connect the second chamber S2 and the coolant pump 30. The coolant supply passage is disposed in the housing 110 and / or the second cover 130. In an exemplary embodiment, as shown in FIG. Figure 2 As shown, the coolant supply passage includes a first coolant supply passage 61 provided in the housing 110 and a second coolant supply passage 62 provided in the second cover 130 .

[0040] like Figure 2 As shown, the first coolant supply channel 61 and the second coolant supply channel 62 are in fluid communication. The first coolant supply channel 61 is in fluid communication with the second cavity S2. In an exemplary embodiment, the first coolant supply channel 61 is in fluid communication with the outlet of the filter 50, and is in fluid communication with the second cavity S2 through the filter 50. The second coolant supply channel 62 is in fluid communication with the coolant pump inlet 31 of the coolant pump 30. Figure 2 As shown by the middle arrow C1 , when the coolant pump 30 is working, the coolant can flow from the second cavity S2 through the filter 50 , sequentially through the first coolant supply channel 61 and the second coolant supply channel 62 , and then flow into the coolant pump 30 through the coolant pump inlet 31 .

[0041] The coolant distribution channel is used to distribute the coolant to the motor 20 to cool the motor 20. The coolant distribution channel is disposed in the housing 110 and / or the first cover 120. In an exemplary embodiment, Figure 3 As shown, the coolant distribution channel includes a first coolant distribution channel 71 and a second coolant distribution channel 72 .

[0042] The first cooling liquid distribution channel 71 is used to distribute cooling liquid to the rotor 22 of the motor 20 to cool the rotor 22. The first cooling liquid distribution channel 71 includes a first liquid outlet 73, such as Figure 2 , Figure 3 and Figure 5 The first liquid outlet 73 is disposed adjacent to and opens toward the rotor 22 of the motor 20 .

[0043] In an exemplary embodiment, if Figure 3 As shown, the first coolant distribution channel 71 is disposed in the housing 110. Figure 1 and Figure 2 As shown, the first liquid outlet 73 is disposed on the side of the housing 110 facing the motor 20. The first coolant distribution channel 71 is in fluid communication with the first chamber S1 through the first liquid outlet 73. In addition, the first coolant distribution channel 71 is in fluid communication with the output port of the heat exchanger 40, as shown in FIG. Figure 3 As shown. Thus, the coolant flowing out of the heat exchanger 40 can flow through the first coolant distribution channel 71 (as shown Figure 3 The liquid is then ejected through the first liquid outlet 73 to cool the rotor 22 of the motor 20 (as shown by the arrow C3). Figure 2 (as indicated by arrow C4).

[0044] The second coolant distribution channel 72 is used to distribute coolant to the stator 21 of the motor 20 to cool the stator 21. The second coolant distribution channel 72 is in fluid communication with the first coolant distribution channel 71. Figure 3 The second cooling liquid distribution channel 72 includes a second liquid outlet 74, as shown in FIG. Figure 4 The second liquid outlet 74 is disposed adjacent to and opens toward the stator 21 of the motor 20 . In an exemplary embodiment, the second liquid outlet 74 is disposed on the first cover 120 .

[0045] In an exemplary embodiment, the second coolant distribution channel 72 includes a first segment (eg, Figure 3 and Figure 5 ) and a second segment (as shown in FIG. 1 ) disposed in the first cover 120 Figure 4 and Figure 6 The first segment of the second coolant distribution channel 72 is in fluid communication with the first coolant distribution channel 71, as shown in FIG. Figure 3 In an exemplary embodiment, as shown in Figure 4 As shown, the second liquid outlet 74 is disposed on the side of the first cover 120 facing the motor 20, that is, disposed on the second segment of the second coolant distribution channel 72. The second coolant distribution channel 72 is in fluid communication with the first chamber S1 through the second liquid outlet 74. Thus, the coolant can flow through the second coolant distribution channel 72 (such as Figure 3 The liquid is ejected through the second liquid outlet 74 to cool the stator 21 of the motor 20 (as shown by the arrow C5). Figure 4 (as indicated by arrow C6).

[0046] The following will describe the circulation of the coolant in the range extender according to an embodiment of the present invention with reference to the accompanying drawings. When the coolant pump 30 is working, the coolant in the second cavity S2 can enter the coolant supply channel through the filter 50, and more specifically, flow through the first coolant supply channel 61 and the second coolant supply channel 62 in sequence, and then enter the coolant pump 30 (such as the coolant pump inlet 31 of the coolant pump 30). Figure 2 Then, the coolant outputted from the coolant pump 30 via the coolant pump outlet 32 ​​can enter the input port of the heat exchanger 40 (as shown by the arrow C1). Figure 2 and Figure 3 The coolant flows through the heat exchanger 40 and then flows out of the outlet of the heat exchanger 40 after being cooled by the heat exchanger 40. Then, the coolant output from the heat exchanger 40 flows through the coolant distribution channel, more specifically, flows through the first coolant distribution channel 71 (as shown in FIG. Figure 3 As shown by the arrow C3, a portion of the coolant is ejected through the first liquid outlet 73 to cool the rotor 22 of the motor 20 (as shown in FIG. Figure 2 The other part of the coolant continues to flow through the coolant distribution channel, more specifically, through the second coolant distribution channel 72 (as shown by the arrow C4). Figure 3 The liquid is ejected through the second liquid outlet 74 to cool the stator 21 of the motor 20 (as shown by the arrow C5 in the middle). Figure 4 As shown by the arrow C6 in the middle). Thus, the coolant can cool the motor 20 in the range extender. In addition, the coolant can flow from the first cavity S1 to the second cavity S2 after cooling the motor 20. Thus, the coolant can circulate in the coolant flow circuit of the range extender.

[0047] Although the present invention has been described with reference to exemplary embodiments, it should be understood that the present invention is not limited to the configuration and method of the above-described embodiments. On the contrary, the present invention is intended to cover various modifications and equivalent configurations. In addition, although the various elements and method steps of the disclosed invention are shown in various exemplary combinations and configurations, other combinations including more or less elements or methods also fall within the scope of the present invention.

[0048] Reference numerals list

[0049] 10. Shell;

[0050] 20 motors;

[0051] 21 stator;

[0052] 22 rotors;

[0053] 23 transmission shaft;

[0054] 30 Coolant pump;

[0055] 31 Coolant pump inlet;

[0056] 32 Coolant pump outlet;

[0057] 40 heat exchanger;

[0058] 50 filters;

[0059] 61 first coolant supply channel;

[0060] 62 second coolant supply channel;

[0061] 71 first coolant distribution channel;

[0062] 72 second coolant distribution channel;

[0063] 73 first liquid outlet;

[0064] 74 second liquid outlet;

[0065] 110 housing;

[0066] 120 first cover;

[0067] 130 second cover;

[0068] S1 first cavity;

[0069] S2 second cavity.

Claims

1. A range extender, comprising: Motor (20); A housing (110) comprising a first axial end and a second axial end; a first cover (120) connected to the first axial end of the housing (110), wherein the first cover (120) and the housing (110) are configured to jointly define a first cavity (S1) for accommodating the motor (20) and a second cavity (S2) for storing a coolant; a second cover (130) connected to the second axial end of the housing (110); A coolant pump (30) disposed in the first cavity (S1) and comprising a coolant pump inlet (31) and a coolant pump outlet (32); a coolant supply passage disposed in the housing (110) and / or the second cover (130) and configured to fluidically connect the coolant pump inlet (31) of the coolant pump (30) and the second chamber (S2); and A coolant distribution channel is provided in the housing (110) and / or the first cover (120) and is configured to connect the coolant pump outlet (32) of the coolant pump (30) to the first cavity (S1) in fluid communication so as to distribute coolant to the motor (20).

2. The range extender according to claim 1, wherein: The motor comprises a stator (21) and a rotor (22); and The coolant distribution channel comprises: a first coolant distribution channel (71) disposed in the housing (110) and comprising a first liquid outlet (73), wherein the first liquid outlet (73) is disposed adjacent to and opens toward the rotor (22) to distribute coolant to the rotor (22); and a second coolant distribution channel (72) disposed in the housing (110) and the second cover (120) and comprising a second liquid outlet (74) disposed on the first cover (120), wherein the second liquid outlet (74) is disposed adjacent to and opens toward the stator (21) to distribute coolant to the stator (21), Wherein, the first coolant distribution channel (71) and the second coolant distribution channel (72) are configured to be fluidically connected.

3. The range extender according to claim 2, wherein: The motor (20) further comprises a transmission shaft (23), and an input end of the coolant pump (30) is connected to the transmission shaft (23) in a rotationally fixed manner.

4. The range extender according to any one of claims 1 to 3, further comprising: A heat exchanger (40) is mounted to the second cover (130), wherein an input port of the heat exchanger (40) is configured to be in fluid communication with the coolant pump outlet (32), and an output port of the heat exchanger (40) is configured to be in fluid communication with the coolant distribution channel.

5. The range extender according to any one of claims 1 to 3, further comprising: A filter (50) is mounted to the housing (110), wherein an input port of the filter (50) is configured to be in fluid communication with the second chamber (S2), and an output port of the filter (50) is configured to be in fluid communication with the coolant supply channel.

6. The range extender according to any one of claims 1 to 3, wherein: The coolant supply channel comprises: a first coolant supply passage (61) disposed in the housing (110) and configured to be in fluid communication with an output port of the filter (50); and a second coolant supply passage (62) disposed in the second cover (130) and configured to be in fluid communication with the coolant pump inlet (31), Wherein, the first coolant supply channel (61) and the second coolant supply channel (62) are configured to be fluidically connected.

7. The range extender according to any one of claims 1 to 3, wherein: The input end of the coolant pump (30) is an input shaft, and the input shaft and the transmission shaft (23) of the motor (20) are formed integrally.

8. The range extender according to any one of claims 1 to 3, wherein: The first cavity (S1) and the second cavity (S2) are configured to be in fluid communication, and the second cavity (S2) is disposed below the first cavity (S1).

9. The range extender according to claim 4, wherein: The heat exchanger (40) is mounted to a side of the second cover (130) that is away from the housing (110).

10. A vehicle comprising the range extender according to any one of claims 1 to 9.

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