Range extending module and vehicle

Abstract

The invention relates to a range-extending module for rigid connection to an engine of a vehicle, comprising an electric machine arrangement (2) directly connected to the engine and an electric machine housing (7), the electric machine arrangement (2) comprising an electric machine stator (22) and an electric machine rotor (23), the electric machine rotor (23) being directly connected to a crankshaft of the engine by means of a crankshaft adapter flange (4), the motor shell (7) comprises a front shell body (71) and a rear shell body (72), the motor stator (22) and the motor rotor (23) are contained in the front shell body (71), the rear shell body (72) is provided with a covering part (722) used for covering the crankshaft adaptive flange (4), the covering part (722) is provided with a bolt via hole (724) used for disassembling and assembling the crankshaft and the motor rotor, and the motor stator (22) and the motor rotor (23) are connected through the bolt via hole (724). And the bolt through hole (724) is only covered by a rear shell cover (721) of the rear shell (72) in the axial direction.

Description

Technical Field

[0001] The invention relates to a range extender module for connecting to a vehicle engine, the range extender module comprising a motor device and a motor controller device fixed directly above the motor device. An adaptor housing for connecting to the engine is provided at the output end of the motor device, 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] 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, there are great differences in the system structure, and different vehicle architectures require 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 the need to reserve space for the dual-mass flywheel of the engine. In addition, some engines may not be equipped with a dual-mass flywheel, so the range extender module needs to have a corresponding configuration design. Summary of the invention

[0005] Therefore, the technical problem to be solved by the present invention is to provide an extended-range module that can overcome the shortcomings of the above-mentioned prior art and can be platform-based, that is, it can be easily adapted to different vehicle architectures and engines according to needs, and has a compact layout to save structural space.

[0006] The technical problem is solved by a range extender module rigidly connected to a vehicle engine, which includes: a motor device and a motor housing directly connected to the engine, wherein the motor device includes a motor stator and a motor rotor, and the motor rotor is directly connected to the crankshaft of the engine through a crankshaft adapter flange, wherein the motor housing includes a front housing and a rear housing, the motor stator and the motor rotor are accommodated in the front housing, and the rear housing has a cover portion for covering the crankshaft adapter flange, and a bolt through hole that can be used to install and disassemble the crankshaft and the motor rotor is provided on the cover portion, and the bolt through hole is only covered by the rear shell cover of the rear housing in the axial direction. In order to further reduce the space occupied by the range extender module and adapt to a power system without a shock absorber, the range extender module according to the present invention is directly connected to the engine, and the engine crankshaft is rigidly connected to the motor rotor through the crankshaft adapter flange, so as to directly realize the torque transmission between the crankshaft and the motor rotor. The rear housing is used to support the bearing, install the oil pump and install the resolver stator, and at the same time provide a crankshaft connection bolt installation space. In order to better modularize the range extender module and make it easier to assemble and disassemble, bolt holes are provided on the cover portion of the crankshaft adapter flange. Therefore, the connection between the crankshaft and the motor rotor can be installed and removed by simply removing the rear cover plate of the rear housing, thereby making the assembly and disassembly of the power system and the range extender module more convenient and reducing the assembly cost.

[0007] According to a preferred embodiment of the present invention, a crankshaft connection bolt assembly space is formed between the cover portion and the rear shell cover, and the rear shell cover seals the crankshaft connection bolt assembly space. The rear shell provides the crankshaft connection bolt assembly space for installing and removing the bolts, and sealing only by the rear shell cover saves redundant sealing components and simplifies the assembly process.

[0008] According to a preferred embodiment of the present invention, two axially symmetrical bolt holes are provided on the cover portion. Although only one bolt hole may be provided, in order to save assembly time and better position the bolt hole and the crankshaft connecting plate, it is preferred to symmetrically provide two bolt holes, which can improve the efficiency of disassembly and assembly, and it is also easier to locate the bolt holes when rotating the crankshaft for assembly or disassembly. In addition, it can also be considered that the number of bolt holes is consistent with the number of crankshaft connecting bolts and corresponds one to one, so that there is no need to rotate the crankshaft to correspond to the bolt holes, and disassembly or installation can be performed directly, thereby improving assembly efficiency.

[0009] According to a preferred embodiment of the present invention, the motor rotor has a rotor shaft and a rotor bracket, wherein the flexible section of the crankshaft adapter flange is fixedly connected to the rotor bracket by rivets. Rivets are an economical and practical fixing method, and the crankshaft connecting bolts can also be easily operated through the bolt through holes. Since the range extender module according to the present invention is adapted to an engine without a shock absorber, in order to reduce the vibration of the engine, the flexible section is used to fix it to the rotor bracket, which can buffer the vibration and reduce the vibration damage to the motor device. It is further preferred that the cover portion has a center hole, and the rotor shaft passes through the center hole, thereby improving the space utilization of the range extender module.

[0010] According to a preferred embodiment of the present invention, the range extender module has a motor control device for controlling the motor device, wherein the motor control device is fixed radially above the front housing and the rear housing. This arrangement minimizes the space occupation while ensuring the stability of the motor control device, and the motor control device is supported by the motor housing, which also eliminates other supporting components. It is further preferred that the range extender module has an adapter housing for fixed connection with the engine, and the adapter housing is fixed on the front housing, wherein a plurality of mounting holes are provided on the outer periphery of the adapter housing. The adapter housing can be used to adapt different types of engines, thereby improving the modularity of the range extender module. It is further preferred that there is a gap in the radial space between the motor control device and the motor housing, wherein the connecting bolts passing through the mounting holes can be operated through the gap, such as using a wrench to directly enter for installation and removal. Through this spatial layout, the installation and removal of the engine and the range extender module are more convenient, further reducing the assembly cost.

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

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

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

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

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

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

[0017] Figure 3b A rear perspective view of a range-extending module designed according to the present invention is shown;

[0018] Figure 4 An internal view showing a range extender module designed according to the present invention without being covered by a rear housing cover;

[0019] Figure 5 A rear view of a range extender module designed according to the present invention is shown. DETAILED DESCRIPTION

[0020] 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.

[0021] FIG1 shows the working principle of the range extender module designed according to the present invention. The range extender module includes a motor controller 1, a motor device 2, a motor housing 7 and a cooling device 5 for oil cooling. These four components constitute a modular component that can be replaced as a whole. The range extender module is directly connected to the engine ICE, and the shock absorber is omitted, thereby further reducing the demand for structural space. The range extender module has two main working modes. The first is the engine start mode (such as Figure 1a The second is the power generation mode (as shown in Figure 1b When the vehicle needs to restart the engine, the range extender module is in the first working mode, the motor controller device 1 sends a control command to the motor 2, and the power of the motor is directly transmitted to the engine ICE, thereby realizing the engine starting function. When the vehicle needs to generate electricity, the range extender module is in the second working mode, and the power of the engine drives the motor to generate electricity through the shock absorber. The direction of the arrow in Figure 1 indicates the direction of torque transmission.

[0022] like Figure 2 As shown, the range extender module includes a motor controller device 1, a motor device 2, a motor housing 7 and a cooling device 5. The motor controller device 1 is fixed above the motor housing 7. The motor device 2 has a motor stator 22 and a motor rotor 23, and the motor rotor 23 has a rotor shaft 231 and a rotor bracket 233. The rotor shaft 231 is connected to the rotor bracket 233 in a torsion-proof manner.

[0023] According to the design of the present invention, the engine is directly connected to the range extender module through the adapter housing 3, and no vibration damper (such as Figure 3a ). The motor rotor 23 is connected to the crankshaft of the engine via the crankshaft adapter flange 4. The rotor support 233 of the motor rotor 23 can be fixedly connected to the flexible section 42 of the crankshaft adapter flange 4 via rivets 41. The rivet 41 is preferably screwed in from one side of the flexible section 42 for easy disassembly.

[0024] The motor housing 7 includes a front housing 71 and a rear housing 72 (eg Figure 3a and Figure 3b As shown in FIG. 1 ). The motor stator 22, the motor rotor 23 and other components of the motor device 2 are placed in the front housing 71, and the open end of the front housing 71 is closed by the rear housing 72 to form a motor cavity 73. The motor stator 22 is fixed to the front housing 71 through a motor stator bracket. In the embodiment of the present invention, in order to reduce the occupied space, the motor stator 22 uses a concentrated round wire winding. The front housing 71 and the rear housing 72 jointly support the motor control device 1. The rear housing 72 has a rear housing cover 721, which can cover the inside of the motor.

[0025] like Figure 4 As shown, the rear housing 72 also has a cover portion 722, which can cover the crankshaft adapter flange 4. The cover portion 722 has a center hole 723 to facilitate the rotor shaft 231 to pass through. Two bolt through holes 724 symmetrical about the center hole 723 are set on the outer peripheral side of the center hole 723. The crankshaft connecting bolts 43 can be installed or removed through the bolt through holes 724, so that the installation / removal of the range extender module and the engine crankshaft is very convenient. As long as the rear shell cover 721 of the rear housing 72 is opened, the crankshaft connecting bolts 43 can be directly operated. Of course, multiple bolt through holes 724 can be set, and the number of pairs of bolt through holes 724 can also be consistent with the number of crankshaft connecting bolts 43. The advantage of only setting two bolt through holes 724 is that the processing steps are reduced and it is easy to assemble. After removing the crankshaft connecting bolts 43 corresponding to the two bolt through holes 724, the crankshaft can be rotated to remove the remaining crankshaft connecting bolts 43. Therefore, it is also possible to provide only one bolt through hole 724 .

[0026] Figure 5 The rear view of the range extender module is shown. As can be seen from the figure, the adapter housing 3 has a plurality of mounting holes 31 on the periphery for being bolted through to connect with the engine. From the rear view, the motor housing 7 does not block the mounting holes 31 of the adapter housing 3. A particularly advantageous design is that in the radial direction, a gap is provided between the motor control device 1 and the rear housing 72, and the gap allows a tool to be inserted to operate the connecting bolts 32 that cooperate with the adapter housing 3.

[0027] 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.

[0028] Reference numerals list

[0029] 1 Motor controller device

[0030] 2 Motor device

[0031] 22 Motor stator

[0032] 23 Motor rotor

[0033] 231 Rotor shaft

[0034] 233 rotor bracket

[0035] 3 Adapter housing

[0036] 31 Mounting holes

[0037] 32 Connecting bolts

[0038] 4 Crankshaft adapter flange

[0039] 41 Rivet

[0040] 42 Flexible section

[0041] 43 Crankshaft connecting bolt

[0042] 5 Cooling device

[0043] 6 Crankshaft connecting bolt assembly space

[0044] 7 Motor housing

[0045] 71 front housing

[0046] 72 rear housing

[0047] 721 Back cover

[0048] 722 Covering

[0049] 723 center hole

[0050] 724 Bolt hole

[0051] 73 Motor cavity

[0052] ICE Engine

Claims

1. A range extender module for connecting to a vehicle engine, include: A motor device (2) and a motor housing (7) directly connected to the engine, wherein the motor device (2) comprises a motor stator (22) and a motor rotor (23), and the motor rotor (23) is directly connected to the crankshaft of the engine via a crankshaft adapter flange (4), wherein the motor housing (7) comprises a front housing (71) and a rear housing (72), the motor stator (22) and the motor rotor (23) are accommodated in the front housing (71), and the rear housing (72) has a covering portion (722) for covering the crankshaft adapter flange (4), and a bolt through hole (724) that can be used to assemble the crankshaft and the motor rotor is provided on the covering portion (722), and the bolt through hole (724) is only covered by the rear housing cover (721) of the rear housing (72) in the axial direction.

2. The range-extending module according to claim 1, It is characterized in that A crankshaft connecting bolt assembly space (6) is formed between the cover portion (722) and the rear housing cover (721), wherein the rear housing cover (721) seals the crankshaft connecting bolt assembly space (6).

3. The range-extending module according to claim 1, It is characterized in that Two axially symmetrical bolt through holes (724) are arranged on the cover portion (722).

4. The range-extending module according to claim 1, It is characterized in that The number of the bolt through holes (724) is consistent with and corresponds to the number of the crankshaft connecting bolts (43) used to connect the crankshaft adapter flange (4) and the crankshaft.

5. The range-extending module according to claim 2, It is characterized in that The motor rotor (23) has a rotor shaft (231) and a rotor support (233), and the crankshaft adapter flange (4) has a flexible section (42), wherein the flexible section (42) is fixedly connected to the rotor support (233) via rivets (41).

6. The range-extending module according to claim 5, It is characterized in that The cover portion (722) has a central hole (723), and the rotor shaft (231) passes through the central hole (723).

7. The range extender module according to any one of claims 1 to 6, It is characterized in that The range extender module comprises a motor control device (1) for controlling the motor device (2), wherein the motor control device (1) is fixed radially above the front housing (71) and the rear housing (72).

8. The range-extending module according to claim 7, It is characterized in that The range extender module comprises an adapter housing (3) for fixedly connecting to the engine, wherein the adapter housing (3) is fixed to the front housing (71), wherein a plurality of mounting holes (31) fixedly connected to the engine are provided on the outer periphery of the adapter housing (3).

9. The range-extending module according to claim 8, It is characterized in that A gap is left in the radial space between the motor control device (1) and the motor housing (7), wherein a connecting bolt (32) passing through the mounting hole (31) can be operated through the gap.

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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