Range extending system for vehicle and vehicle

Abstract

The invention provides a range extending system for a vehicle and the vehicle. The range extending system for the vehicle comprises a shell, a crankshaft disc, a flexible disc and a motor which are assembled together. The shell is used for supporting and protecting other components. The crankshaft disc is used for being connected with a crankshaft of an engine and can rotate relative to the shell, and therefore the crankshaft disc can receive torque from the engine. The crankshaft disc is in transmission connection with a rotor of the motor through a flexible disc. In addition, the flange shaft is in transmission connection with the rotor all the time. Thus, in the process that the torque from the engine is transmitted to the rotor of the motor through the flexible disc, the damper spring can greatly reduce torsional vibration, and therefore the problem of NVH degradation of the range extending system caused by the fact that the torsional vibration of the engine is directly transmitted to the motor can be remarkably relieved or even eliminated. In addition, the range extending system for the vehicle is simple in structure, convenient to assemble and low in corresponding cost.

Description

Technical Field

[0001] The present application relates to the field of vehicles, and in particular to a range-extending system for a vehicle and a vehicle comprising the range-extending system for a vehicle. Background Art

[0002] In the prior art, there are extended-range vehicles that use an engine and a motor as power sources and a motor as a range extender. In a typical extended-range vehicle, when the vehicle speed is low or acceleration is required, the motor can be used to drive the vehicle; when the vehicle speed is high, the engine can be used to drive the vehicle, and the engine can also be used to drive the motor to charge the vehicle's battery at the same time. Therefore, the extended-range vehicle can reduce fuel consumption without affecting driving performance. However, in existing extended-range vehicles, the crankshaft of the engine is usually directly connected to the rotor of the motor. In this way, the torsional vibration generated by the engine is directly transmitted to the motor, resulting in the degradation of the NVH performance of the range-extended system including the motor. Summary of the invention

[0003] This application is made based on the defects of the above-mentioned prior art. One purpose of this application is to provide a vehicle range extender system, which can alleviate or even eliminate the problem of NVH degradation of the range extender system caused by the direct transmission of the torsional vibration of the engine to the motor. In addition, another purpose of this application is to provide a vehicle including the above-mentioned vehicle range extender system.

[0004] In order to achieve the above objectives, this application adopts the following technical solutions.

[0005] The present application provides a vehicle range-extending system as follows, comprising:

[0006] case;

[0007] a crankshaft disk, which is rotatable relative to the housing and is used to be connected to the crankshaft of the engine;

[0008] a flex plate connected to the crankshaft plate;

[0009] A motor, comprising a stator and a rotor, wherein the stator is fixed to the housing, the rotor is rotatable relative to the stator, and the rotor is always drivingly connected to the crankshaft disk via the flexible disk; and

[0010] The flange shaft is always drivingly connected to the rotor.

[0011] In an optional solution, the motor further includes a rotor bracket, wherein the rotor bracket is fixed to the rotor, and the rotor is drivingly connected to the flange shaft and the flexible disk via the rotor bracket.

[0012] In another optional solution, the rotor bracket includes an axial portion and a radial portion fixed to each other, the axial portion extends along the axial direction of the rotor and is fixed to the rotor, and the radial portion is bent from the axial portion toward the radial inside and is fixed to the flange shaft.

[0013] In another optional solution, it also includes a rotor position sensor and a support frame located radially inside the rotor.

[0014] The rotor position sensor includes a fixed part and a rotating part, wherein the fixed part is fixed to the housing, and the rotating part is fixed to the radial part via the support frame so that the rotating part can rotate together with the rotor support, and the fixed part and the rotating part are located at the same axial position.

[0015] In another alternative, at least a portion of the crankshaft disk and the flex disk are housed within the housing.

[0016] In another optional solution, the flange shaft includes a flange portion and a shaft portion fixed to each other, the flange portion is mounted and fixed to the rotor bracket, and the shaft portion extends from the flange portion along the axial direction of the rotor toward one axial side.

[0017] In another optional solution, along the radial direction of the rotor, the shaft portion at least partially overlaps with the rotor.

[0018] The vehicle range extender system further includes two bearings disposed between the shaft portion and the housing such that the housing supports the shaft portion via the two bearings, and the two bearings are spaced apart in the axial direction.

[0019] In another optional solution, a pumping device is further included for pumping cooling fluid to the motor, and the pumping device includes a pumping rotor installed on one axial end of the shaft portion, so that the pumping rotor can rotate together with the flange shaft.

[0020] In another optional solution, the housing is formed with a flow path, the oil inlet of the pumping device is in communication with the flow path, and the flow path is used to be connected to a filter of the vehicle.

[0021] The present application also provides a vehicle, comprising an engine and a vehicle range extender system as described in any one of the above technical solutions, wherein the crankshaft of the engine is fixed to the crankshaft disk by welding or threaded connection.

[0022] By adopting the above technical solution, the present application provides a novel vehicle range extender system and a vehicle including the range extender system. In the vehicle range extender system of the present application, a housing, a crankshaft disc, a flexible disc and a motor are assembled together. The housing is used to support and protect other components. The crankshaft disc is used to be connected to the crankshaft of the engine and can rotate relative to the housing, so that the crankshaft disc can receive torque from the engine. The crankshaft disc is transmission-connected to the rotor of the motor via the flexible disc. In addition, the flange shaft is also transmission-connected to the rotor.

[0023] In this way, during the process of torque from the engine being transmitted to the rotor of the motor via the flexible disk, the damping spring can significantly reduce torsional vibration, thereby significantly alleviating or even eliminating the problem of NVH degradation of the range extender system caused by direct transmission of the engine's torsional vibration to the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 1 is a schematic cross-sectional view of a range extender system for a vehicle according to an embodiment of the present application, in which the section lines are omitted.

[0025] Figure 2A It shows Figure 1 A partial cross-sectional schematic diagram of a flexible disk of a range extender system for a vehicle.

[0026] Figure 2B It shows Figure 2A Schematic diagram of the front view of the flexible disk in.

[0027] Figure 2C It shows that along Figure 2B A schematic cross-sectional view taken along line SS in FIG.

[0028] Description of Reference Numerals

[0029] 1 housing; 11 housing body; 12 housing cover;

[0030] 2 crankshaft disc;

[0031] 3 flexible disk; 31 first rivet hole; 32 second rivet hole; 33 flexible hole;

[0032] 4 motor; 41 stator; 42 rotor; 43 rotor support; 431 axial part; 432 radial part;

[0033] 5 flange shaft; 51 flange portion; 52 shaft portion;

[0034] 6 rotor position sensor; 61 fixed part; 62 rotating part;

[0035] 7 Support frame;

[0036] 8 bearings;

[0037] 9 pumping rotor;

[0038] A is axial; R is radial. DETAILED DESCRIPTION

[0039] The exemplary embodiments of the present application are described below with reference to the accompanying drawings. It should be understood that these specific descriptions are only used to teach those skilled in the art how to implement the present application, and are not intended to exhaust all feasible methods of the present application, nor to limit the scope of the present application.

[0040] In this application, unless otherwise specified, "axial", "radial" and "circumferential" refer to the axial, radial and circumferential directions of the vehicle range extender system (rotor of the motor). "Axial side" refers to Figure 1 The right side of the axis refers to Figure 1 The “radially outer side” refers to the side radially away from the central axis of the vehicle range extender system (rotor of the motor), and the “radially inner side” refers to the side radially close to the central axis.

[0041] In the present application, "transmission connection" refers to the connection between two components in a manner capable of transmitting torque, including both direct connection and indirect connection.

[0042] A vehicle range extender system according to an embodiment of the present application is described below in conjunction with the accompanying drawings.

[0043] like Figure 1 As shown, a vehicle range extender system according to an embodiment of the present application includes a housing 1, a crankshaft disc 2, a flexible disc 3, a motor 4, a flange shaft 5, a rotor position sensor 6, a support frame 7, a bearing 8 and a pumping device assembled together, wherein the housing 1 is used to support and protect other components, and the crankshaft disc 2, the flexible disc 3, the motor 4, the flange shaft 5, the support frame 7 and the bearing 8 are arranged in a coaxial manner.

[0044] In this embodiment, if Figure 1 As shown, the housing 1 includes a housing body 11 and a housing cover 12 assembled together. The housing body 11 is cylindrical as a whole. The housing body 11 is formed with openings at both ends of its axial direction. The housing cover 12 is fixed to the housing body 11 and covers the opening of the housing body 11 located on one side of the axial direction, so that the housing body 11 and the housing cover 12 surround and form an installation space, and most other components are accommodated and installed in the installation space. The opening of the housing body 11 located on the other side of the axial direction is used to expose the crankshaft disc 2 so that it can be connected to the crankshaft of the engine.

[0045] In this embodiment, if Figure 1As shown, the crankshaft disc 2 is formed with a plurality of mounting holes extending along the axial direction A. The threaded mounting parts passing through the mounting holes can mount the crankshaft disc 2 on the crankshaft of the engine of the vehicle, so that the crankshaft disc 2 and the crankshaft of the engine are threadedly connected together. Thus, the torque from the engine can be transmitted to the vehicle range extender system via the crankshaft disc 2. Furthermore, the crankshaft disc 2 is also mounted together with the flexible disc 3 through a riveted connector, so that the torque from the engine can be directly transmitted to the flexible disc 3.

[0046] In this embodiment, if Figure 1 As shown, the flexible disk 3 is entirely located in the installation space of the housing 1, and is used to reduce the torsional vibration from the engine during the torque transmission process. FIG. 2A to FIG. 2C As shown, the flexible disk 3 is formed as a circular disk structure as a whole. The inner peripheral portion of the flexible disk 3 may be formed with a plurality of first rivet holes 31 penetrating along the axial direction A, and these first rivet holes 31 are evenly distributed along the circumferential direction, and the rivets passing through these first rivet holes 31 fix the flexible disk 3 and the crankshaft disk 2 together. The outer peripheral portion of the flexible disk 3 may be formed with a plurality of second rivet holes 32 penetrating along the axial direction A, and these second rivet holes 32 are evenly distributed along the circumferential direction, and the rivets passing through these second rivet holes 32 fix the flexible disk 3 and the rotor bracket 43 together. In addition, the flexible disk 3 may also be formed with a plurality of flexible holes 33, which is beneficial to the flexible deformation of the flexible disk 3 on the one hand, and can reduce the weight of the flexible disk 3 on the other hand.

[0047] In this embodiment, if Figure 1 As shown, the motor 4 is a radial magnetic field motor and is entirely located in the installation space of the housing 1. Specifically, the motor 4 includes a stator 41, a rotor 42 and a rotor support 43.

[0048] The stator 41 is fixed to the housing body 11 of the housing 1, and a cooling jacket may be provided between the stator 41 and the housing body 11 to reduce the temperature of the stator 41 during operation of the motor 4. The rotor 42 is located radially inside the stator 41 and is opposite to the stator 41 in the radial direction R, with a predetermined air gap therebetween, and the rotor 42 can rotate relative to the stator 41.

[0049] The rotor support 43 has a cylindrical shape as a whole, and the rotor support 43 is fixed to the rotor 42, for example, by interference fit, so as to support the rotor 42 and always be directly connected to the rotor 42 in driving. The rotor support 43 includes an axial portion 431 and a radial portion 432 formed as one body. Specifically, the axial portion 431 extends along the axial direction A and the circumferential direction, and the axial portion 431 is fixedly installed on the rotor 42 from the radial inner side to support the rotor 42. The length of the axial portion 431 in the axial direction A is substantially equal to the length of the rotor 42 in the axial direction A. The radial portion 432 extends from the other axial side end of the axial portion 431 toward the radial inner side, and the radial portion 432 is bent several times during the extension process. The radial portion 432 is not only fixedly installed with the flexible disk 3, but also fixedly installed with the flange portion 51 of the flange shaft 5 and the support frame 7 through rivets.

[0050] Here, the radial part 432 can be fixed together with the flange part 51 of the flange shaft 5 and the support frame 7 by the same fixing component (for example, a rivet), and the fixing position can be located radially inside and axially on one side of the fixing position of the flexible disk 3 fixed with the radial part 432 of the rotor support 43, thereby achieving full utilization of space and compact structure.

[0051] In this embodiment, if Figure 1 As shown, the flange shaft 5 is always in driving connection with the rotor 42. The flange shaft 5 includes a flange portion 51 and a shaft portion 52 formed as one piece. The flange portion 51 is fixed to the rotor bracket 43, and the flange portion 51 protrudes from the shaft portion 52 toward the radial outside, and the shaft portion 52 extends from the flange portion 51 toward one axial side along the axial direction A. Along the radial direction R of the rotor 42 (that is, observed along the radial direction R), the shaft portion 52 partially overlaps with the rotor 42, so that the flange shaft 5 is basically arranged on the radial inside of the rotor, thereby reducing the axial size of the system.

[0052] In this embodiment, if Figure 1As shown, the rotor position sensor 6 and the support frame 7 are located radially inside the rotor 42. The rotor position sensor 6 can be a rotary transformer, and the rotor position sensor 6 can include a fixed part 61 (sensor coil) and a rotating part 62 (signal coil). The fixed part 61 is fixed to the housing 1. The rotating part 62 is fixedly mounted on the support frame 7, and the support frame 7 is fixed to the rotor bracket 43, so that the rotating part 62 is always connected to the rotor 42 via the support frame 7 and the rotor bracket 43. In addition, the fixed part 61 and the rotating part 62 are located at the same axial position, that is, the fixed part 61 and the rotating part 62 overlap each other when viewed along the radial direction R in the figure. In this way, the axial space occupied by the installation of the rotor position sensor 6 can be greatly reduced, thereby shortening the axial size of the entire system. The fixed part 61 and the rotating part 62 are located at the same axial position, so that as the rotating part 62 rotates with the rotor 42, the fixed part 61 and the rotating part 62 cooperate to sense the rotation speed and position of the rotor 42. Moreover, the fixing part 61 of the rotor position sensor 6 can be directly fixed to the housing 1 by the mounting member, so that the fixing part 61 can be installed and fixed without additional components, thereby simplifying the relevant installation structure. In one example, the fixing part 61 can be installed to the housing cover 12.

[0053] In this embodiment, if Figure 1 As shown, both bearings 8 are ball bearings. The two bearings 8 are located between the housing 1 (here, it can be the housing cover 12) and the shaft portion 52 of the flange shaft 5, the outer ring of the bearing 8 is fixed to the housing 1, and the inner ring of the bearing 8 is fixed to the shaft portion 52, so that the housing 1 supports the flange shaft 5 via the bearing 8. The two bearings 8 are arranged at a predetermined distance in the axial direction A, so that the support effect via the bearing 8 is stable.

[0054] In this embodiment, if Figure 1 As shown, the pumping device is used to pump cooling fluid (such as oil) to the motor 4, and the pumping device includes a pumping rotor 9 installed at one axial end of the shaft portion 52, so that the pumping rotor 9 can rotate with the flange shaft 5. Further, the housing 1 is formed with a flow path, and the oil inlet of the pumping device is connected to the flow path, and the flow path is used to connect to the filter of the vehicle. In this way, it is helpful to shorten the length of the oil path between the oil inlet of the pumping device and the filter, so that the pressure loss of the cooling fluid is small during the flow of the flow path.

[0055] The present application is not limited to the above embodiments, and those skilled in the art can make various modifications to the above embodiments of the present application under the guidance of the present application without departing from the scope of the present application. In addition, the following supplementary explanation is made.

[0056] i. The present application also provides a vehicle, which includes an engine and a vehicle range extender system according to the present application, wherein the crankshaft of the engine is fixed to the crankshaft disk 2 of the range extender system by welding or threaded connection as described in the above embodiments, so that the torque from the engine can be transmitted to the range extender system via the crankshaft disk 2. In the process of transmitting torque, the flexible disk 3 connected to the crankshaft disk 2 in the range extender system can effectively reduce torsional vibration.

[0057] ii. It can be understood that in the vehicle range extender system of the present application, the flange shaft 5 can be used to output torque to the outside and receive torque from the outside, and other components can also be set to achieve such functions. The motor 4 can receive torque from the engine to generate electricity, and can also output torque to the outside as a motor.

[0058] iii. It can be understood that in the vehicle range-extending system of the present application, due to the use of the architecture described in the above embodiment, the range-extending system has a simple structure, is easy to assemble and has a correspondingly low cost. In addition, the rotor position sensor 6 and the structural layout of the pumping device and the motor 4 save axial space, making the axial size of the system smaller, and greatly reducing the installation space required for the range-extending system.

Claims

1. A vehicle range extender system, characterized in that: include: Housing (1); A crankshaft disk (2) which is rotatable relative to the housing (1) and is used to be connected to the crankshaft of the engine; A flexible disk (3) connected to the crankshaft disk (2); A motor (4), comprising a stator (41) and a rotor (42), wherein the stator (41) is fixed to the housing (1), the rotor (42) is rotatable relative to the stator (41), and the rotor (42) is always drivingly connected to the crankshaft disc (2) via the flexible disc (3); and The flange shaft (5) is always drivingly connected to the rotor (42).

2. The vehicle range extender system according to claim 1, characterized in that: The motor (4) further comprises a rotor support (43), wherein the rotor support (43) is fixed to the rotor (42), and the rotor (42) is drivingly connected to the flange shaft (5) and the flexible disk (3) via the rotor support (43).

3. The vehicle range extender system according to claim 2, characterized in that: The rotor support (43) comprises an axial portion (431) and a radial portion (432) fixed to each other, wherein the axial portion (431) extends along the axial direction (A) of the rotor (42) and is fixedly mounted on the rotor (42), and the radial portion (432) is bent from the axial portion (431) toward the radial inside and is fixedly mounted on the flange shaft (5).

4. The vehicle range extender system according to claim 3, characterized in that: It also includes a rotor position sensor (6) and a support frame (7) located radially inside the rotor (42), The rotor position sensor (6) comprises a fixed part (61) and a rotating part (62), wherein the fixed part (61) is fixed to the housing (1), and the rotating part (62) is fixed to the radial part (432) via the support frame (7), so that the rotating part (62) can rotate together with the rotor support (43), and the fixed part (61) and the rotating part (62) are located at the same axial position.

5. The vehicle range extender system according to any one of claims 1 to 4, characterized in that: At least a portion of the crankshaft disc (2) and the flexible disc (3) are accommodated in the housing (1).

6. The vehicle range extender system according to any one of claims 2 to 4, characterized in that: The flange shaft (5) comprises a flange portion (51) and a shaft portion (52) fixed to each other, the flange portion (51) being mounted and fixed to the rotor bracket (43), and the shaft portion (52) extending from the flange portion (51) along the axial direction (A) of the rotor (42) toward one axial side.

7. The vehicle range extender system according to claim 6, characterized in that: Along the radial direction (R) of the rotor (42), the shaft portion (52) at least partially overlaps with the rotor (42). The vehicle range extender system further comprises two bearings (8), wherein the two bearings (8) are arranged between the shaft portion (52) and the housing (1), so that the housing (1) supports the shaft portion (52) via the two bearings (8), and the two bearings (8) are arranged spaced apart in the axial direction (A).

8. The vehicle range extender system according to claim 7, characterized in that: It also includes a pumping device for pumping cooling fluid to the motor (4), wherein the pumping device includes a pumping rotor (9) mounted on one axial end of the shaft portion (52), so that the pumping rotor (9) can rotate together with the flange shaft (5).

9. The vehicle range extender system according to claim 8, characterized in that: The housing (1) is formed with a flow path, the oil inlet of the pumping device is in communication with the flow path, and the flow path is used to be connected to a filter of the vehicle.

10. A vehicle, characterized in that: The invention comprises an engine and a vehicle range extender system according to any one of claims 1 to 8, wherein the crankshaft of the engine is fixed to the crankshaft disk (2) by welding or threaded connection.

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