Range extender and new energy vehicle

Abstract

The invention provides a range extender and a new energy vehicle. The range extender includes: an engine including a crankshaft; the motor comprises a shell and a rotor, and the rotor is arranged in the shell, arranged outside the crankshaft in a sleeving mode and connected with the crankshaft in a driving mode so as to rotate under driving of the crankshaft; the supporting device comprises a support and a bearing, the support is sleeved between the crankshaft and the rotor in a non-rotating mode, and the bearing is supported between the support and the rotor. Therefore, the chamber sweeping risk can be reduced, and the working reliability of the range extender is improved.

Description

Technical Field

[0001] The present application relates to the technical field of new energy vehicles, and in particular to a range extender and a new energy vehicle. Background Art

[0002] Range extenders generally include an engine and a motor, and are used to increase the mileage of new energy vehicles. With the rapid development of new energy technologies, range extenders are increasingly being used.

[0003] However, the rotor of the motor in the range extender is prone to eccentric wear against the stator of the motor during high-speed rotation, causing a "bore sweep" problem and affecting the working reliability of the range extender. Summary of the invention

[0004] A technical problem to be solved by the present application is to improve the working reliability of the range extender.

[0005] In order to solve the above technical problems, the present application provides a range extender, which includes:

[0006] Engine, including crankshaft;

[0007] The motor comprises a housing and a rotor, wherein the rotor is disposed in the housing and sleeved outside the crankshaft and is drivingly connected to the crankshaft so as to rotate under the drive of the crankshaft; and

[0008] The supporting device comprises a bracket and a bearing. The bracket is non-rotatably sleeved between the crankshaft and the rotor, and the bearing is supported between the bracket and the rotor.

[0009] In some embodiments, the supporting device includes two bearings, which are spaced apart along the axial direction of the rotor; and / or the bracket is connected to the housing and is non-rotatably sleeved between the crankshaft and the rotor.

[0010] In some embodiments, two bearings are arranged on both sides of the center of mass of the rotor; and / or, the connecting frame includes a first section and a second section, the first section is sleeved between the crankshaft and the rotor, the bearing is arranged on the first section, and the second section is connected to the front end of the first section and connected to the outer casing.

[0011] In some embodiments, the first section and the second section are integrally formed; and / or, the first section and the second section are connected in a Y shape.

[0012] In some embodiments, the range extender further includes a torsional vibration damper, which is disposed at the end of the crankshaft and drivingly connects the crankshaft and the rotor.

[0013] In some embodiments, the rear end surface of the torsional vibration damper is flush with the rear end surface of the rotor, or is closer to the rear end surface of the rotor.

[0014] In some embodiments, the range extender includes a first oil seal, which is disposed on the rotor and located between the rotor and the torsional vibration damper, and the torsional vibration damper seals the first oil seal.

[0015] In some embodiments, a water channel is provided on the outer casing, and the water channel is connected to the interior of the engine so that cooling water in the engine flows through the water channel to cool the motor; and / or, an oil channel is provided on the rotor, and the oil channel is connected to the oil guide groove on the crankshaft so that the crankshaft can throw the oil in the oil guide groove into the oil channel during rotation to cool the rotor and / or lubricate the bearing.

[0016] In some embodiments, the water channel is connected to the interior of the engine through the bracket; and / or the oil channel is connected to the oil guide groove through the bracket.

[0017] In addition, the present application also provides a new energy vehicle, which includes the range extender of any embodiment.

[0018] By extending the crankshaft into the rotor, arranging a non-rotatable bracket between the crankshaft and the rotor, and arranging a bearing between the bracket and the rotor, the risk of bore scouring can be reduced and the working reliability of the range extender can be improved.

[0019] Other features and advantages of the present application will become apparent from the following detailed description of exemplary embodiments of the present application with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art 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 paying creative work.

[0021] Figure 1 Schematic diagram of the range extender in the embodiment of the present application.

[0022] Description of reference numerals:

[0023] 10. Range extender;

[0024] 1. Engine; 11. Housing; 12. Crankshaft; 13. Oil guide groove;

[0025] 2. Motor; 21. Housing; 22. Stator; 23. Rotor; 24. Water channel; 25. Oil channel; 26. Bearing cavity; 27. Sleeve; 28. Back cover;

[0026] 3. Support device; 31. Bearing; 32. Bracket; 33. First section; 34. Second section; 35. Connecting arm; 36. Water flow channel; 37. Oil flow channel;

[0027] 4. Torsional vibration damper; 41. Inner plate; 42. Outer plate; 43. Pressing claw;

[0028] 51. First oil seal; 52. Second oil seal;

[0029] 61. first stopper; 62. second stopper; 63. third stopper;

[0030] 7. Resolver; 71. Resolver shaft; 72. Resolver rotor; 73. Resolver stator; 74. Resolver end cover;

[0031] 8. Bolts. DETAILED DESCRIPTION

[0032] 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 only part of the embodiments of the present application, rather than all of the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is by no means intended to limit the present application and its application or use. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without carrying out creative work are within the scope of protection of this application.

[0033] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered as part of the specification.

[0034] In the description of the present application, it should be understood that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present application.

[0035] In the present application, unless otherwise specified, “plurality” means at least two, that is, including cases of two and at least three.

[0036] In addition, the technical features involved in the different embodiments of the present application described below can be combined with each other as long as they do not conflict with each other.

[0037] With the world's increasing attention to environmental protection and sustainable development, the new energy vehicle market is showing a booming development trend. The range extender can increase the mileage of new energy vehicles, solve the mileage anxiety problem of pure electric new energy vehicles, and improve the performance and market competitiveness of new energy vehicles. Therefore, the application and development of the range extender has attracted much attention.

[0038] The range extender generally includes an engine and a motor, which are driven and connected so that the motor can run under the drive of the engine to charge the power battery, thereby increasing the mileage of the new energy vehicle.

[0039] In traditional technology, the motor of the range extender is generally connected to the flywheel of the engine set at the end of the crankshaft through the motor shaft to achieve the driving connection between the motor and the engine. However, in this case, the integration of the range extender is low, the axial length is long, and the transmission efficiency is low, which makes it difficult to meet the market demand for high-performance, low-noise and high-efficiency range extenders.

[0040] In order to meet the market demand for high-performance, low-noise and high-efficiency range extenders, a flywheel-rotor integrated range extender came into being. This flywheel-rotor integrated range extender eliminates the flywheel and the motor shaft, and replaces the flywheel with the motor's rotor, so that the motor's rotor is sleeved on the outside of the crankshaft to achieve a drive connection between the engine and the motor.

[0041] The above-mentioned flywheel rotor integrated range extender has eliminated the flywheel and the motor shaft, so it has a simpler structure, a higher degree of integration, a shorter axial length, and a higher transmission efficiency. It can better meet the market demand for high-performance, low-noise and high-efficiency range extenders, realize the development of range extenders in the direction of lightweight, miniaturization and low noise, improve the performance and reliability of new energy vehicles, optimize spatial layout, reduce costs, and provide consumers with more economical and efficient new energy vehicle solutions.

[0042] However, it is found in practice that the rotor of the motor of the flywheel rotor integrated range extender in the related technology is usually directly mounted on the crankshaft. In this case, the rotor of the motor is easily affected by the crankshaft, causing radial runout during high-speed rotation, and eccentric wear with the stator of the motor, causing the "bore sweeping" problem.

[0043] Among them, bore scraping refers to a fault form in which the rotor and stator wear eccentrically due to reasons such as rotor eccentricity or radial runout. This fault can cause the motor to run poorly or even be damaged.

[0044] Therefore, the motor sweeping phenomenon of the range extender will affect the working reliability of the range extender, which is also known as an important reason restricting the further promotion and application of the range extender, especially the flywheel rotor integrated range extender.

[0045] In order to reduce the risk of bore sweeping of the flywheel rotor integrated range extender, the relevant technology usually deliberately enlarges the rotor air gap (i.e. the distance between the rotor and the stator). However, this method goes against the original design intention of the flywheel rotor integrated range extender, which will not only increase the manufacturing cost but also reduce the system efficiency.

[0046] In view of the above situation, the present application provides a range extender.

[0047] Figure 1 The structure of the range extender in the present application is shown exemplarily.

[0048] See also Figure 1 In the present application, the range extender 10 includes an engine 1, a motor 2 and a support device 3. The engine 1 includes a crankshaft 12. The motor 2 includes a housing 21 and a rotor 23. The rotor 23 is disposed in the housing 21 and sleeved outside the crankshaft 12, and is drivingly connected to the crankshaft 12 to rotate under the drive of the crankshaft 12. The support device 3 includes a bracket 32 ​​and a bearing 31. The bracket 32 ​​is non-rotatably sleeved between the crankshaft 12 and the rotor 23, and the bearing 31 is supported between the bracket 32 ​​and the rotor 23.

[0049] In the above scheme, the rotor 23 of the motor 2 is sleeved outside the crankshaft 12 and rotates under the drive of the crankshaft 12. In this case, the crankshaft 12 can serve as the motor shaft and the rotor 23 can replace the flywheel. Therefore, the flywheel and the motor shaft can be omitted like the flywheel-rotor integrated range extender in the related art. In this way, the structure of the range extender 10 can be effectively simplified, the integration of the range extender 10 can be improved, the axial length of the range extender 10 can be shortened, and the transmission efficiency of the range extender 10 can be improved.

[0050] However, the range extender 10 in the above scheme is different from the flywheel rotor integrated range extender in the related art. The rotor 23 of its motor 2 is no longer directly mounted on the outside of the crankshaft 12, but is mounted on the outside of the bracket 32 ​​which is non-rotatably mounted on the outside of the crankshaft 12, and is supported by the bearing 31 arranged on the bracket 32. This does not affect the rotation of the rotor 23 driven by the crankshaft 12, and can increase the support for the rotor 23, thereby realizing full floating support of the rotor 23, transferring the force point of the rotor 23 from the crankshaft 12 to the bracket 32, reducing the influence of the eccentricity and radial runout of the crankshaft 12 on the rotor 23, reducing the radial runout of the rotor 23, etc., reducing the possibility of eccentric wear, and suppressing the bore sweeping phenomenon. Therefore, the running stability of the rotor 23 can be effectively improved, the running smoothness of the motor 2 can be improved, and the risk of damage to the motor 2 can be reduced, thereby effectively improving the working reliability of the range extender 10.

[0051] It can be seen that the above scheme provides an integrated full-floating range extender, which can not only retain the advantages of the flywheel rotor integrated range extender in terms of high integration, short axial length and high transmission efficiency, but also effectively suppress the bore sweeping phenomenon, reduce the risk of damage to the motor 2, and improve the working reliability of the range extender 10.

[0052] Moreover, in the above scheme, by providing the bracket 32 ​​and the bearing 31, the risk of bore scraping can be reduced without deliberately enlarging the stator-rotor air gap or improving the manufacturing process, thus helping to reduce manufacturing costs and improve system efficiency.

[0053] In addition, in the above scheme, the bearing 31 is arranged between the bracket 32 ​​and the rotor 23, rather than between the crankshaft 12 and other components of the motor 2 such as the casing 21. This can not only physically isolate the crankshaft 12 and the rotor 23, reduce the influence of the eccentricity and radial runout of the crankshaft 12 on the rotor 23, reduce the radial runout of the rotor 23, etc., reduce the risk of bore scraping, but also reduce the degree of over-constraint of the crankshaft 12, reduce the difficulty of assembly, and improve assembly efficiency. Specifically, when the bearing 31 is set between the crankshaft 12 and other parts of the motor 2 such as the housing 21, the rotor 23 is actually still directly mounted on the crankshaft 12. There is no physical isolation between the rotor 23 and the crankshaft 12. The eccentricity and radial runout of the crankshaft 12 will still have a significant impact on the rotor 23, increasing the risk of bore sweeping. Moreover, the crankshaft 12 is already subject to multiple constraints on one side of the engine 1, and there is over-constraint. If the bearing 31 is set between the crankshaft 12 and other parts of the motor 2 such as the housing 21, the constraint on the crankshaft 12 will be further increased, causing the over-constraint degree of the crankshaft 12 to increase, resulting in increased assembly difficulty and affecting assembly efficiency. The above scheme sets a bracket 32 ​​between the crankshaft 12 and the rotor 23, and sets a bearing 31 between the bracket 32 ​​and the rotor 23, which can effectively avoid the corresponding problems, reduce the assembly difficulty and improve assembly efficiency while reducing the risk of bore sweeping and improving structural reliability.

[0054] Moreover, the bearing 31 is arranged between the bracket 32 ​​and the rotor 23, rather than between the housing 21 and the crankshaft 12 or other components, which is also conducive to reducing the strength requirements of the housing 21 and reducing costs, because when the bearing 31 is arranged between the housing 21 and the crankshaft 12 or other components, the force is mainly borne by the housing 21. In this case, the strength requirements of the housing 21 are high and the cost is high. When the bearing 31 is arranged between the bracket 32 ​​and the rotor 23, the corresponding problems can be effectively avoided, the force on the housing 21 is reduced, the strength requirements of the housing 21 are reduced, and the cost is reduced.

[0055] It can be seen that by extending the crankshaft 12 into the rotor 23, and arranging a non-rotatable bracket 32 ​​between the crankshaft 12 and the rotor 23, and arranging a bearing 31 between the bracket 32 ​​and the rotor 23, the advantages of the flywheel rotor integrated range extender such as high integration, short axial length and high transmission efficiency can be retained, and based on a simpler structure and lower cost, the risk of bore sweeping can be effectively reduced, the working reliability of the range extender 10 can be improved, and the assembly difficulty of the range extender 10 can be reduced.

[0056] The number of bearings 31 disposed between the bracket 32 ​​and the rotor 23 is not limited, and may be one, two or more. Figure 1In some embodiments, the support device 3 includes two bearings 31, which are arranged at intervals along the axial direction of the rotor 23. In this way, the rotor 23 can be better supported, and the force uniformity of the rotor 23 can be more effectively improved, thereby more effectively reducing the risk of bore sweeping and improving the working reliability of the range extender 10.

[0057] Specifically, when the support device 3 includes two bearings 31, the two bearings 31 can be arranged on both sides of the center of mass of the rotor 23. In this way, the rotor 23 can be supported more stably, and the force uniformity of the rotor 23 can be improved more effectively, thereby further reducing the risk of bore scouring and more effectively improving the working reliability of the range extender 10.

[0058] In the above embodiments, the bracket 32 ​​is arranged to be non-rotatable, which is convenient for arranging the bearing 31 to support the rotatable rotor 23. The non-rotatable arrangement of the bracket 32 ​​can be achieved in a variety of ways.

[0059] For example, see Figure 1 In some embodiments, the bracket 32 ​​is connected to the housing 21 and is non-rotatably sleeved between the crankshaft 12 and the rotor 23. Since the housing 21 is non-rotatable, the bracket 32 ​​is connected to the housing 21, and the non-rotatable setting of the bracket 32 ​​can be conveniently realized, the structure is relatively simple, and the supporting effect is also better.

[0060] Specifically, see Figure 1 In some embodiments, the bracket 32 ​​includes a first section 33 and a second section 34, the first section 33 is sleeved between the crankshaft 12 and the rotor 23, the bearing 31 is arranged on the first section 33, and the second section 34 is connected to the front end of the first section 33 and connected to the housing 21. In this way, the setting requirements of the bearing 31 can be effectively met, and the non-rotatable setting of the bracket 32 ​​can be conveniently realized. It can be understood that the "front" here and in the following text refers to the upstream along the direction from the engine 1 to the motor 2, and the "rear" refers to the downstream along the direction from the engine 1 to the motor 2. On this basis, the front end of the first section 33 refers to the end of the first section 33 facing the engine 1.

[0061] The first section 33 and the second section 34 can be integrally formed. In this way, compared with the situation where the first section 33 and the second section 34 are processed separately and then connected, it is more conducive to improving the strength of the bracket 32, enhancing the support for the rotor 23, and reducing the risk of bore sweeping.

[0062] Also, see Figure 1 In some embodiments, the first section 33 and the second section 34 are connected in a Y-shape. In this way, the rotor 23 can be supported based on a relatively simple structure, and the bracket 32 ​​can be set to be non-rotatable.

[0063] As a further improvement to the above embodiments, see Figure 1 In some embodiments, a water channel 24 is provided on the housing 21, and the water channel 24 is connected to the inside of the engine 1, so that the cooling water in the engine 1 flows through the water channel 24 to cool the motor 2. At this time, the motor 2 has an integrated water cooling function, and the cooling water of the engine 1 can be used to cool the motor 2 to prevent the motor 2 from overheating, thereby improving the working reliability of the motor 2 and the range extender 10.

[0064] Specifically, see Figure 1 When the bracket 32 ​​is connected to the housing 21 , the water channel 24 is connected to the inside of the engine 1 through the bracket 32 ​​, so as to facilitate the cooling water in the engine 1 to enter and exit the housing 21 through the bracket 32 ​​to cool the motor 2 .

[0065] Also, see Figure 1 In some embodiments, the rotor 23 is provided with an oil passage 25, which is connected to the oil guide groove 13 on the crankshaft 12, so that the crankshaft 12 can throw the oil in the oil guide groove 13 into the oil passage 25 during the rotation process to cool the rotor 23 and / or lubricate the bearing 31. In this case, the motor 2 integrates the rotor oil cooling function and / or the bearing lubrication function, which can improve the working reliability of the motor 2 and the range extender 10.

[0066] Specifically, see Figure 1 , the oil passage 25 is connected to the oil guide groove 13 through the bracket 32. Since the bracket 32 ​​is sleeved between the crankshaft 12 and the rotor 23, the oil passage 25 on the rotor 23 can be easily connected to the oil guide groove 13 on the crankshaft 12 through the bracket 32, thereby conveniently realizing the cooling of the rotor 23 and / or the lubrication of the bearing 31. In addition, in this case, the oil passage 25 can be relatively short, which is not only conducive to simplifying the structure, but also conducive to reducing oil loss.

[0067] In the aforementioned embodiments, the driving connection between the crankshaft 12 and the rotor 23 can be achieved in various ways such as a hard connection or a flexible connection.

[0068] For example, see Figure 1 In some embodiments, the range extender 10 includes a torsional vibration damper 4 , which is disposed at the end of the crankshaft 12 and drivingly connects the crankshaft 12 and the rotor 23 .

[0069] Based on the above configuration, the crankshaft 12 and the rotor 23 are driven and connected via the torsional vibration damper 4. At this time, the connection between the crankshaft 12 and the rotor 23 is not a rigid connection, but a flexible connection. In this way, the torsional vibration damper 4 can be used to realize the driving connection between the crankshaft 12 and the rotor 23, so that the rotor 23 can rotate driven by the crankshaft 12. The torsional vibration damper 4 can also be used to reduce the torsional vibration of the crankshaft 12, reduce the adverse effects of the torsion and vibration of the crankshaft 12 on the rotor 23, extend the life of the crankshaft 12, reduce the torsional vibration of the rotor 23, and reduce the risk of chamber sweeping caused by the torsional vibration of the rotor 23, thereby improving the working reliability of the range extender 10.

[0070] Moreover, in the above arrangement, the torsional vibration damper 4 is arranged at the end of the crankshaft 12 (that is, the end of the crankshaft 12 away from the engine and the power mechanism for driving the crankshaft 12 to rotate), and is located on the rear side of the rotor 23, rather than being arranged on the front side of the rotor 23. At this time, the torsional vibration damper 4 adopts a rear setting method rather than a front setting method. In this case, the torsional vibration damper 4 is located between the rotor 23 and the rear cover 28 of the housing 21. If it is damaged, the rear cover 28 can be directly opened to replace or repair the torsional vibration damper 4 without disconnecting the engine 1 and the motor 2. Therefore, it is more convenient to disassemble and maintain the torsional vibration damper 4.

[0071] In the related art, the flywheel rotor integrated range extender does not include the torsional vibration damper 4, and its rotor 23 is driven to rotate by the crankshaft 12 by being directly mounted on the crankshaft 12. In this case, the torsional vibration of the crankshaft 12 can easily cause the torsional vibration of the rotor 23, causing eccentric wear of the stator and rotor, resulting in bore scraping; and although some traditional non-flywheel rotor integrated range extenders are provided with a torsional vibration damper 4, the torsional vibration damper 4 is arranged between the rotor 23 and the engine 1, or in other words, it is arranged on the front side of the rotor 23. In this case, if the torsional vibration damper 4 is damaged, it is necessary to disconnect the engine 1 from the motor 2, and remove many components such as the rotor 23 that block the torsional vibration damper 4 before the torsional vibration damper 4 can be disassembled and maintained, which is more troublesome and inconvenient to disassemble and maintain the torsional vibration damper 4.

[0072] By arranging the torsional vibration damper 4 between the rotor 23 sleeved on the outside of the crankshaft 12 and the end of the crankshaft 12, it is possible to conveniently realize the driving connection between the crankshaft 12 and the rotor 23, and effectively reduce the torsional vibration of the crankshaft 12 and the rotor 23, reduce the risk of bore sweeping, improve working reliability, and also help to reduce the difficulty of disassembly and maintenance of the torsional vibration damper 4, and improve the convenience of disassembly and maintenance of the torsional vibration damper 4.

[0073] Further, see Figure 1In some embodiments, the rear end face of the torsional vibration damper 4 is flush with the rear end face of the rotor 23, or is closer to the rear end face of the rotor 23. It can be understood that the rear end faces of the torsional vibration damper 4 and the rotor 23 refer to the end faces of the two closest to the rear cover 28, respectively. The rear end face of the torsional vibration damper 4 is flush with the rear end face of the rotor 23, or is closer to the rear end face of the rotor 23, which means that in the axial direction of the crankshaft 12 (which is also the axial direction of the rotor 23, the engine 1, the motor 2 and the range extender 10), the torsional vibration damper 4 does not exceed the rear end face of the rotor 23. In this case, the torsional vibration damper 4 does not occupy additional axial space and does not increase the axial length. Therefore, the flexible driving connection between the rotor 23 and the crankshaft 12 can be achieved while the range extender 10 maintains a shorter axial length. The shorter axial length of the range extender 10 is conducive to reducing the volume of the range extender 10 and realizing the miniaturization of the range extender 10, so that the range extender 10 can be more easily placed in a narrow vehicle space, thereby improving the adaptability of the range extender 10 to narrow spaces. Moreover, the shorter axial length of the range extender 10 is also conducive to reducing the cantilever length, reducing the risk of bore sweeping, and improving structural reliability.

[0074] Also, see Figure 1 In the case where the range extender 10 includes the torsional vibration damper 4, in some embodiments, the range extender 10 further includes a first oil seal 51, which is disposed on the rotor 23 and located between the rotor 23 and the torsional vibration damper 4, and the torsional vibration damper 4 seals the first oil seal 51. In this way, the torsional vibration damper 4 can not only play a role in resisting the vibration of the torsional vibration damper, but also play a role in sealing the first oil seal 51, and can achieve a better oil sealing effect together with the first oil seal 51, reduce the leakage of oil in the rotor 23 (for example, the bearing cavity 26 for accommodating the bearing 31), and achieve better bearing lubrication and rotor cooling effects. Moreover, when the torsional vibration damper 4 does not extend beyond the rear end surface of the rotor 23, the first oil seal 51 is arranged between the rotor 23 and the torsional vibration damper 4, which also means that the first oil seal 51 does not extend beyond the rear end surface of the rotor 23. In other words, the torsional vibration damper 4 and the first oil seal 51 are both integrated within the length range of the rotor 23. This is conducive to further shortening the axial length of the range extender 10, thereby further improving the adaptability of the range extender 10 to a narrow space, reducing the cantilever length, reducing the risk of bore sweeping, and improving structural reliability.

[0075] Next, combine Figure 1 The embodiments shown are used to further introduce the present application.

[0076] like Figure 1 As shown, in this embodiment, the range extender 10 includes an engine 1, a motor 2, a support device 3, a torsional vibration damper 4 and a rotary transformer 7.

[0077] The engine 1 is used to provide power. Figure 1As shown, the engine 1 includes a housing 11 and a crankshaft 12. The crankshaft 12 extends from the rear end of the housing 11 and extends into the rotor 23 of the motor 2, and is drivingly connected to the rotor 23 to drive the rotor 23 to rotate. An oil guide groove 13 is provided on the outer surface of the crankshaft 12. The oil guide groove 13 is spirally shaped and is used to supply oil. During the rotation of the crankshaft 12, the oil in the oil guide groove 13 can be thrown out.

[0078] The motor 2 is connected to the engine 1 to run under the drive of the engine 1, supplying power to the power battery and increasing the driving mileage. Figure 1 As shown, the motor 2 includes a housing 21, a stator 22 and a rotor 23. The housing 21 includes a sleeve 27 and a rear cover 28. The rear cover 28 is arranged at the rear end of the sleeve 27 (i.e., the end away from the engine 1) to close the rear end opening of the sleeve 27. The stator 22 and the rotor 23 are both arranged in the housing 21. The stator 22 is fixed to the inner wall of the sleeve 27 by a shrink fit. The rotor 23 is located radially inside the stator 22 and can rotate relative to the stator 22 to convert mechanical energy into electrical energy.

[0079] Depend on Figure 1 It can be seen that in this embodiment, the rotor 23 is sleeved outside the crankshaft 12 and is drivingly connected to the crankshaft 12 through the torsional vibration damper 4, so that it rotates relative to the stator 22 under the drive of the crankshaft 12. Specifically, Figure 1 As shown, in this embodiment, the end of the crankshaft 12 passes through the rotor 23, and the torsion damper 4 is arranged at the end of the crankshaft 12, and the inner plate 41 and the outer plate 42 of the torsion damper 4 are respectively fixedly connected to the crankshaft 12 and the rotor 23 by bolts 8 and other connecting parts. In this way, the torsion damper 4 drives and connects the crankshaft 12 and the rotor 23 together. Since the drive connection between the engine 1 and the motor 2 can be realized without the need for a flywheel and a motor shaft, the structure is simpler, the integration is higher, the axial length is shorter, and the transmission efficiency is higher. Moreover, since the torsion damper 4 can perform torsional vibration attenuation, the vibration and noise of the whole machine can be reduced, and the risk of bore sweeping can be reduced.

[0080] And, if Figure 1 As shown, in this embodiment, the rear end surface of the torsional vibration damper 4 is flush with the rear end surface of the rotor 23, that is, the distance between the rear end surface of the torsional vibration damper 4 and the rear end surface of the rotor 23 and the rear cover 28 is approximately equal. Therefore, the axial length of the range extender 10 can be prevented from increasing due to the provision of the torsional vibration damper 4, so that the range extender 10 can maintain a shorter axial length, a smaller volume and a shorter cantilever length, thereby improving the adaptability of the range extender 10 to a narrow space, reducing the risk of bore sweeping, and improving the working reliability of the range extender 10.

[0081] The rotary transformer 7 is used to detect the rotation parameters such as the rotation speed of the motor 2. Figure 1As shown, in this embodiment, the rotary transformer 7 is arranged on the rear side of the torsional vibration damper 4, and includes a rotary transformer shaft 71, a rotary transformer rotor 72, a rotary transformer stator 73 and a rotary transformer end cover 74. The rotary transformer shaft 71 is connected to the inner disk 41 of the torsional vibration damper 4 by connecting parts such as bolts 8. The rotary transformer rotor 72 is sleeved on the rotary transformer shaft 71, and the rotary transformer rotor 72 is axially positioned by shrink sleeve. The rotary transformer rotor 73 is sleeved on the outside of the rotary transformer rotor 72 and is located at the center of the rear cover 28. The rotary transformer end cover 74 is covered on the outside of the rotary transformer rotor 73 and connected to the rear end surface of the rear cover 28. In this way, the rotary transformer 7 can detect the rotation speed and angular position of the crankshaft 12 and the rotor 23, and then the corresponding detection results can be converted into electrical signals for identification, so as to control the operation of the range extender 10.

[0082] The supporting device 3 is used to support the rotor 23. Figure 1 As shown, in this embodiment, the support device 3 includes a bracket 32 ​​and two bearings 31. The bracket 32 ​​is sleeved between the crankshaft 12 and the rotor 23, and includes a first section 33 and a second section 34 that are connected and integrally formed from back to front. The first section 33 is located between the crankshaft 12 and the rotor 23, and is fixedly connected to the housing 21 through the second section 34, so that the bracket 32 ​​is non-rotatably sleeved between the crankshaft 12 and the rotor 23. The two bearings 31 are axially spaced and arranged on the outer surface of the first section 33 to support the rotor 23.

[0083] Specifically, Figure 1 As shown, in this embodiment, the second section 34 includes two connecting arms 35, which are located on both radial sides of the crankshaft 12, and both extend obliquely from the front end of the first section 33 to the radial outside, and are connected to the housing 21 through connecting parts such as bolts 8. At this time, the bracket 32 ​​is roughly Y-shaped, which not only conveniently meets the support requirements of the rotor 23 and the connection requirements with the housing 21, but also the first section 33 and the second section 34 are connected to form a step, and the bearing 31 can also be axially positioned.

[0084] Two bearing cavities 26 are provided on the rotor 23. The front bearing cavity 26 of the two bearing cavities 26 is located between the rotor 23 and the first section 33 and the second section 34, and the rear bearing cavity 26 is located between the rotor 23 and the first section 33 and the torsional vibration damper 4. Two bearings 31 are respectively provided in the two bearing cavities 26 to support the rotor 23. In this way, the two bearings 31 are arranged at intervals along the axial direction and are located on both sides of the axial direction of the center of mass of the rotor 23, which can stably support the rotor 23, improve the running stability of the rotor 23, improve the stress state of the rotor 23, reduce the eccentric wear between the rotor 23 and the stator 22, reduce the risk of bore sweeping, and improve the working reliability of the range extender 10.

[0085] Depend on Figure 1It can be seen that, of the two bearings 31 in this embodiment, the bearing 31 located at the front side has its two axial ends positioned by the steps between the first section 33 and the second section 34 of the bracket 32 ​​and the shaft shoulder of the rotor 23, respectively, while the bearing 31 at the rear side has its one axial end positioned by the shaft shoulder of the rotor 23, and its other axial end positioned by the first stopper 61. Exemplarily, the first stopper 61 includes a round nut, which performs axial positioning and axial clearance adjustment on the rear side bearing 31.

[0086] like Figure 1 As shown, in this embodiment, a water channel 24 is provided in the housing 21, and a water flow channel 36 is provided on the second section 34. The water channel 24 is connected to the inside of the engine 1 through the water flow channel 36, so that Figure 1 As shown by the middle arrow, the cooling water in the engine 1 can flow into and out of the housing 21 through the water passage 36 and the water passage 24 to cool the motor windings and prevent the windings from overheating and affecting the working reliability.

[0087] And, if Figure 1 As shown, in this embodiment, an oil passage 25 is provided in the rotor 23, and the oil passage 25 includes a portion extending along the radial direction of the rotor 23 and a portion extending along the axial direction of the rotor 23, and the oil passage 25 is connected with two bearing cavities 26. At the same time, an oil passage 37 is provided on the first section 33, and the oil passage 37 is connected with the oil passage 25 and the oil guide groove 13 on the crankshaft 12. In this way, during the rotation of the crankshaft 12, the oil in the oil guide groove 13 can be thrown into the oil passage 37, and flow into the oil passage 25 through the oil passage 37. The oil flowing into the oil passage 25 can flow inside the rotor 23 along the oil passage 25 to cool the rotor 23, and can also flow into the two bearing cavities 26 through the oil passage 25 to lubricate the two bearings 31, thereby improving the working reliability of the rotor 23 and the two bearings 31, and thus improving the working reliability of the motor 2 and the range extender 10. In the process of cooling the rotor 23 , the oil takes away the heat generated by the rotor 23 and flows to the oil cooler (not shown) of the engine 1 to be cooled by the oil cooler so as to cool the rotor 23 again.

[0088] In order to prevent the oil from leaking into the rotor 23, Figure 1As shown, in this embodiment, an oil seal is respectively provided on the front and rear sides of the rotor 23, wherein the oil seals located on the rear side and the front side are respectively referred to as a first oil seal 51 and a second oil seal 52. The first oil seal 51 is arranged at the rearward bearing cavity 26 of the rotor 23, and its front end face is axially limited by the shaft shoulder of the rotor 23 located on the rear side of the corresponding bearing cavity 26, and its rear end face is axially limited by the second stopper 62 (such as a spacer) arranged between the first oil seal 51 and the torsional vibration damper 4. At the same time, its outer lip is pressed on the rotor 23, and its inner lip cooperates with the torsional vibration damper 4 to form a seal. Specifically, the torsional vibration damper 4 includes a pressure claw 43, which is roughly L-shaped, connected to the front end face of the inner disk 41 of the torsional vibration damper 4, and extends radially outward from the inner disk 41, pressing on the inner lip of the first oil seal 51 to seal the first oil seal 51. In this way, the oil in the rearward bearing cavity 26 can be effectively prevented from leaking, the oil waste can be reduced, and the rear bearing 31 can be better lubricated. The second oil seal 52 is arranged at the bearing cavity 26 that is closer to the front of the rotor 23. The rear end face of the second oil seal 52 is axially limited by the shaft shoulder of the rotor 23 located at the front side of the corresponding bearing cavity 26, and the front end face of the second oil seal 52 is axially limited by the third stopper 63 (such as a pressure plate) arranged on the rotor 23. At the same time, its outer lip is pressed on the rotor 23, and its inner lip cooperates with the bracket 32 ​​to form a seal. In this way, the oil leakage in the bearing cavity 26 that is closer to the front can be effectively prevented, the oil waste can be reduced, and the front bearing 31 can be better lubricated.

[0089] Based on the above structural arrangement, the range extender 10 of this embodiment has the following advantages:

[0090] (1) By sleeve-mounting the rotor 23 on the outside of the crankshaft 12, and arranging a non-rotatable bracket 32 ​​between the crankshaft 12 and the rotor 23, and arranging two bearings 31 between the bracket 32 ​​and the rotor 23, the rotor is fully floated, and the advantages of the flywheel rotor integrated range extender such as high integration, short axial length and high transmission efficiency can be retained, and the bore sweeping phenomenon can be effectively suppressed, thereby improving the working reliability of the range extender 10;

[0091] (2) By providing a torsional vibration damper 4 at the end of the crankshaft 12 extending from the rotor 23, the rotor 23 and the crankshaft 12 are flexibly connected, so that the drive connection between the crankshaft 12 and the rotor 23 can be conveniently realized, and the torsional vibration of the crankshaft 12 and the rotor 23 can be effectively reduced, the risk of bore sweeping can be reduced, and the working reliability of the range extender 10 can be improved;

[0092] (3) The torsional vibration damper 4 is rear-placed, between the rotor 23 and the rear cover 28, so that when the torsional vibration damper 4 is damaged, it is not necessary to disassemble the rotor 23 and other components, and the torsional vibration damper 4 can be disassembled and maintained, which can effectively reduce the difficulty of disassembly and maintenance of the torsional vibration damper 4 and improve the disassembly and maintenance efficiency of the torsional vibration damper 4;

[0093] (4) The torsional vibration damper 4, the two bearings 31, the first oil seal 51 and the second oil seal 52 are all integrated within the length of the rotor 23 and do not extend beyond the rotor 23 in the axial direction. Therefore, the overall axial length of the range extender 10 is relatively short, which is not only conducive to reducing the space occupied by the range extender 10 and realizing the miniaturization of the range extender 10, but also conducive to further reducing the risk of bore sweeping;

[0094] (5) The rotor 23 integrates oil cooling and bearing lubrication functions, and the housing 21 integrates water cooling function, which can further improve the working reliability of the range extender 10.

[0095] It can be seen that the range extender 10 of this embodiment is an integrated full-floating range extender, which has the advantages of uniform force, short axial length, simple and reliable structure, and high maintainability.

[0096] Based on the range extenders 10 of the aforementioned embodiments, the present application further provides a new energy vehicle, which includes the range extender 10 of any of the aforementioned embodiments. Specifically, the new energy vehicle can be a pure electric vehicle, or a hybrid vehicle, and the new energy vehicle can be a household, commercial or engineering vehicle.

[0097] The above description is only an exemplary embodiment of the present application and is not intended to limit the present application. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A range extender (10), characterized in that: include: An engine (1), including a crankshaft (12); The motor (2) comprises a housing (21) and a rotor (23), wherein the rotor (23) is arranged in the housing (21) and is sleeved outside the crankshaft (12), and is drivingly connected to the crankshaft (12) so as to rotate under the drive of the crankshaft (12); and The support device (3) comprises a bracket (32) and a bearing (31), wherein the bracket (32) is non-rotatably sleeved between the crankshaft (12) and the rotor (23), and the bearing (31) is supported between the bracket (32) and the rotor (23).

2. The range extender (10) according to claim 1, characterized in that: The support device (3) comprises two bearings (31), wherein the two bearings (31) are arranged at intervals along the axial direction of the rotor (23); and / or the bracket (32) is connected to the housing (21) and is non-rotatably sleeved between the crankshaft (12) and the rotor (23).

3. The range extender (10) according to claim 2, characterized in that: The two bearings (31) are arranged on both sides of the center of mass of the rotor (23); and / or the connecting frame (33) comprises a first section (33) and a second section (34), the first section (33) being sleeved between the crankshaft (12) and the rotor (23), the bearing (31) being arranged on the first section (33), and the second section (34) being connected to the front end of the first section (33) and connected to the housing (21).

4. The range extender (10) according to claim 3, characterized in that: The first section (33) and the second section (34) are integrally formed; and / or the first section (33) and the second section (34) are connected in a Y shape.

5. The range extender (10) according to any one of claims 1 to 4, characterized in that: The range extender (10) further comprises a torsional vibration damper (4), wherein the torsional vibration damper (4) is arranged at the end of the crankshaft (12) and drivingly connects the crankshaft (12) and the rotor (23).

6. The range extender (10) according to claim 5, characterized in that: The rear end surface of the torsional vibration damper (4) is flush with the rear end surface of the rotor (23), or is located forward of the rear end surface of the rotor (23).

7. The range extender (10) according to claim 5, characterized in that: The range extender (10) comprises a first oil seal (51), wherein the first oil seal (51) is arranged on the rotor (23) and is located between the rotor (23) and the torsional vibration damper (4), and the torsional vibration damper (4) seals the first oil seal (51).

8. The range extender (10) according to any one of claims 1 to 4, characterized in that: The housing (21) is provided with a water channel (24), the water channel (24) being in communication with the interior of the engine (1), so that cooling water in the engine (1) flows through the water channel (24) to cool the motor (2); and / or the rotor (23) is provided with an oil channel (25), the oil channel (25) being in communication with an oil guide groove (13) on the crankshaft (12), so that the crankshaft (12) can throw oil in the oil guide groove (13) into the oil channel (25) during rotation, so as to cool the rotor (23) and / or lubricate the bearing (31).

9. The range extender (10) according to claim 8, characterized in that: The water channel (24) is in communication with the interior of the engine (1) via the bracket (32); and / or the oil channel (25) is in communication with the oil guide groove (13) via the bracket (32).

10. A new energy vehicle, characterized in that: It comprises a range extender (10) as claimed in any one of claims 1 to 9.

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