Range extending module and vehicle

Abstract

The invention relates to a range-extending module for connection with a vehicle engine, comprising a motor device (2), a motor housing (7), an adapter housing (3), an adapter mount (4) and a cooling device (5), the motor housing (7) accommodating the motor device (2), a motor control device for controlling the motor device (2) and the range-extending module being in a split design, the adaptive shell (3) is used for being connected with the engine and can be matched with different engines, the adaptive suspension support (4) is used for supporting the range extending module and can be matched with different frames, the cooling device (5) is used for oil cooling of the motor device (2), and the motor device (2), the motor shell (7) and the cooling device (5) form a modular assembly.

Description

Technical Field

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

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

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

[0004] However, due to space requirements, it is not possible to integrate the motor control device above the motor device in many scenarios, which involves the field of split motor assembly. For example, a split motor assembly structure for extended-range new energy is known from CN 213341777U. The range extender module in the new energy field adopts a split motor assembly structure, which cannot meet the needs of sub-assembly on the assembly line and affects the rhythm of the production line; at the same time, the range extender module is difficult to assemble with the engine crankshaft and requires special tooling for assembly, which is time-consuming and increases labor costs.

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

[0006] Therefore, the technical problem to be solved by the present invention is to provide a range-extending module with a split motor control device, which can overcome the shortcomings of the above-mentioned prior art and can be platformized, that is, it can be easily adapted to different vehicle architectures and engines according to needs, and has a compact layout to save structural space.

[0007] The technical problem is solved by a range extender module for connecting to a vehicle engine, which includes a motor device, a motor housing, an adapter housing, an adapter suspension bracket and a cooling device, wherein the motor housing accommodates the motor device, a motor controller device of the motor device is used to control the motor device and is a split design with the range extender module, the adapter housing is used to connect to the engine and can match different engines, the adapter suspension bracket is used to support the range extender module and can match different frames, and the cooling device is used for oil-cooling the motor device, wherein the motor device, the motor housing and the cooling device constitute a modular component. According to the design of the present invention, the adapter housing is used to connect to the vehicle engine and can match different engines, the adapter suspension bracket is used to support the range extender module on the frame of the vehicle and can match the frames of different vehicles, and the cooling device is used for oil-cooling the motor device. The cooling device for motor cooling is an oil cooling system, which can save the size envelope space of the range extender structure through a compact arrangement. The adapter housing and the adapter suspension bracket can be designed separately to match different vehicle requirements. The adapter housing and the adapter suspension bracket are preferably fixed to the motor housing in a detachable manner to facilitate flexible assembly on the production line. Of course, a non-detachable connection method is not excluded. In addition, the motor controller device and the motor device adopt a split design, and the motor control device can be flexibly arranged within the envelope space of the motor vehicle. It is preferred that the motor control device can be integrated into the vehicle's integrated control system (GEU), so as to further save the space occupied by the range extender module. The motor device, the motor housing, and the cooling device constitute a modular component. A modular component means that several components can constitute a module to be used as a whole, and the motor device can be platformized to achieve different requirements. In the design scheme of the present invention, the motor device, the motor housing, and the cooling device are used as a module, which can be adaptively designed according to different vehicle models, so that it can be easily adapted to different vehicles and reduce development costs.

[0008] According to a preferred embodiment of the present invention, a high- and low-pressure installation cavity is integrated on the motor housing, wherein a high-pressure joint and a low-pressure joint are arranged in the high- and low-pressure installation cavity. The high-pressure cover plate is used to cover the high- and low-pressure installation cavity, and the high-pressure cover plate seals the high-pressure joint and the low-pressure joint in the installation cavity. Integrating the high- and low-pressure installation cavity on the motor housing can further improve the integration of the range extender module and save space. It is further preferred that the motor housing includes a main housing and a shell cover, the motor device includes a motor stator and a motor rotor, the motor stator and the motor rotor are accommodated in the main housing, the main housing and the shell cover are connected by bolts, and a motor cavity is formed between them, wherein the adapter housing is mounted on the main housing, and the adapter suspension bracket is mounted on the shell cover. The adapter housing and the adapter suspension bracket are preferably fixed and positioned by bolts and locating pins. Through this layout, the range extender module is stably supported, the overall structure is compact, and the reliability and adaptability of the module are better. Based on this arrangement, it can also be considered that the high-pressure joint is accommodated in the main housing, and the high-pressure cover plate seals the high-pressure joint and the low-pressure joint, thereby preventing foreign matter from entering the high- and low-pressure installation cavity. It can also be further considered that the low-voltage connector is installed in the main housing and extends out of the main housing through the plug, making the connection more convenient, and the low-voltage connector can extend in the direction of the motor control device, which can further save wiring space.

[0009] According to a preferred embodiment of the present invention, the cooling device has a heat exchanger, which is fixed in front of the main housing, that is, in the front direction of the vehicle. This arrangement of the heat exchanger can avoid occupying the axial space of the vehicle, and the pipeline of the whole vehicle is shorter. The cooling water of the whole vehicle enters the motor control device through the pipeline, and then enters the heat exchanger through the water pipe to cool the lubricating oil of the range extender, so that the space of the range extender module is more compact and the system efficiency is higher. It is further preferred that the low-pressure connector is on the same side as the heat exchanger. Since both the low-pressure connector and the heat exchanger protrude from the main housing, the same-side arrangement can save layout space as much as possible. It can also be considered that the range extender module is connected to the motor control device through the high-pressure connector, the low-pressure connector and the cooling pipe of the heat exchanger, thereby achieving a flexible layout while making the layout of the range extender module more compact.

[0010] In addition, the technical problem to be solved by the present invention is solved by a vehicle, which includes a range-extending module having the above technical features. This range-extending module realizes platformization through reasonable structural design and modular component layout, can adapt to various vehicle architectures through simple structural changes, and occupies less structural space as a whole, especially axial space, which can give full play to the performance of the motor and improve system reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Preferred embodiments of the present invention will be described with reference to the accompanying drawings. In all drawings, the same reference numerals indicate the same components or components with similar functions.

[0012] Figure 1a The first working mode of the range extender module designed according to the present invention is shown;

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

[0014] Figure 2 A cross-sectional view showing a range-extending module designed according to the present invention;

[0015] Figure 3a A front perspective view of a range extender module designed according to the present invention is shown;

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

[0017] Figure 4a A schematic diagram showing a high and low pressure installation cavity designed according to the present invention;

[0018] Figure 4b The internal schematic diagram of the high and low pressure installation cavity designed according to the present invention is shown. DETAILED DESCRIPTION

[0019] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The "axial" and "radial" referred to in the present invention are generally relative to the rotor shaft of the motor device. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be understood as limiting the present invention.

[0020] FIG1 shows the working mode of the range extender module designed according to the present invention. The range extender module 1 has a motor device 2, a motor housing 7 and a cooling device 5 for oil cooling. These components constitute a modular component and can be replaced as a whole. The range extender module is torsionally connected to the shock absorber 6 of the engine (ICE) through an adapter housing 3. The range extender module mainly has two working modes. The first working mode: engine start mode (such as Figure 1a As shown); and the second working mode: power generation mode (as shown Figure 1b When the vehicle is to start the engine, the range extender module is in the first working mode, the motor controller device of the range extender module sends a control command to the motor device 2, and the power from the motor drives the engine ICE through the shock absorber 6, thereby realizing the function of starting the engine. When the vehicle needs to generate electricity, the range extender module is in the second working mode, and the power of the engine drives the motor to generate electricity through the shock absorber 6. The direction of the arrow in Figure 1 indicates the flow direction of the torque.

[0021] like Figure 2As shown, the range extender module 1 includes a motor device 2, a motor housing 7, an adapter housing 3, an adapter suspension bracket 4 and a cooling device 5. The motor controller device of the motor device 2 is not installed on the motor housing 7, but is designed in a split type, thereby further reducing the space occupied by the range extender module 1. The motor device 2 has a motor stator 22 and a motor rotor 23. The motor housing 7 includes a main housing 71 and a housing cover 72. The motor stator 22, the motor rotor 23 and other components of the motor device 2 are placed in the main housing 71, and the open end of the main housing 71 is closed by the housing cover 72 to form a motor cavity 73. The motor stator 22 is fixed to the main housing 71 through a motor stator bracket. In an embodiment of the present invention, in order to reduce the occupied space, the motor stator 22 uses a centralized round wire winding. A rotary sensor 28 is also provided in the main housing 71 to measure the rotation speed of the motor rotor assembly.

[0022] FIG. 3 shows a perspective view of the range extender module 1 according to the present invention. Figure 3a FIG. 1 shows a perspective view of the range extender module 1 viewed from the engine side. Figure 3b The three-dimensional view of the range extender module 1 observed from the side facing away from the engine is shown. A high-pressure and low-pressure installation cavity 8 is integrated on the motor housing 7. The high-pressure and low-pressure installation cavity 8 has a high-pressure connector 81, a low-pressure connector 82 and a high-pressure cover plate 83. The high-pressure connector 81 is accommodated in the main housing 71, and the high-pressure cover plate 83 seals the high-pressure connector 81 and the low-pressure connector 82. Figure 4a and Figure 4b A partial enlarged view of the high and low pressure installation cavity 8 is shown. Figure 4a The high and low pressure installation chamber shown has a cover. Figure 4b The high and low pressure installation chambers shown are without the covers. Figure 3a It can be seen that the low-pressure connector 82 extends out through the plug in the main housing 71. The heat exchanger 51 of the cooling device 5 is fixed in front of the main housing 71 and on the same side as the low-pressure connector 82, thereby reducing space occupation. Due to this arrangement of the high and low pressure installation chambers 8, the range extender module 1 can be conveniently connected to the motor control device through the high-pressure connector 81, the low-pressure connector 82 and the cooling pipe of the heat exchanger 51.

[0023] Although possible embodiments are described by way of example in the above description, it should be understood that there are still a large number of variations of embodiments through the combination of all known and easily conceivable technical features and embodiments by the skilled person. It should also be understood that the exemplary embodiment is only an example and that such embodiment in no way limits the scope of protection, application and configuration of the present invention. The foregoing description is more to provide a technical guide for converting at least one exemplary embodiment to the skilled person, wherein various changes can be made, especially changes in the functions and structures of the components, as long as they do not depart from the scope of protection of the claims.

[0024] Reference numerals list

[0025] 1 Range Extender Module

[0026] 2 Motor device

[0027] 22 Motor stator

[0028] 23 Motor rotor

[0029] 3 Adapter housing

[0030] 4. Adapter bracket

[0031] 5 Cooling device

[0032] 51 Heat exchanger

[0033] 6 Shock absorbers

[0034] 7 Motor housing

[0035] 71 Main housing

[0036] 72 Shell cover

[0037] 73 Motor cavity

[0038] 8 Motor power supply unit

[0039] 81 High pressure connector

[0040] 82 Low pressure connector

[0041] 83 High voltage cover

[0042] ICE engine.

Claims

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

2. The range-extending module according to claim 1, It is characterized in that The motor control device is integrated into an integrated control system of the vehicle.

3. The range-extending module according to claim 1, It is characterized in that A high- and low-pressure installation cavity (8) is integrated on the motor housing (7), wherein a high-pressure connector (81) and a low-pressure connector (82) are provided in the high- and low-pressure installation cavity.

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

5. The range-extending module according to claim 3, It is characterized in that The high-pressure joint (81) is accommodated in the main housing (71), and the high-pressure joint (81) and the low-pressure joint (82) are sealed by a high-pressure cover plate (83).

6. The range-extending module according to claim 3, It is characterized in that The low-pressure connector (82) is installed in the main housing (71) and extends out of the main housing (71) through a plug.

7. The range extender module according to any one of claims 3 to 6, It is characterized in that The cooling device (5) has a heat exchanger (52) which is fixed in front of the main casing (71).

8. The range-extending module according to claim 7, It is characterized in that The low-pressure joint (82) is on the same side as the heat exchanger (52).

9. The range-extending module according to claim 7, It is characterized in that The range extender module is connected to the motor control device via the high-pressure connector (81), the low-pressure connector (82) and a cooling pipe of the heat exchanger (52).

10. A vehicle, It is characterized in that The vehicle has a range extender module according to any one of claims 1 to 9.

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