Range extender generator cooling structure, automobile and assembling method

Abstract

The invention provides a range extender generator cooling structure, an automobile and an assembling method. The range extender generator cooling structure comprises a generator outer shell with an opening in the first end, a generator inner shell which is inserted from the first end of the generator outer shell and embedded in the generator outer shell, and a stator assembly installed in the generator inner shell. The generator outer shell is provided with a cooling water inlet and a cooling water outlet, and a first cooling flow channel and a second cooling flow channel are formed between the inner surface of the generator outer shell and the outer surface of the generator inner shell. A cooling cavity is defined by the end, opposite to the first end of the generator outer shell, of the generator outer shell and the end, inserted into the generator outer shell, of the generator inner shell, and the first cooling flow channel communicates with an inlet of the cooling cavity and the cooling water inlet. And the second cooling runner is respectively communicated with the outlet of the cooling cavity and the cooling water outlet. The heat dissipation effect of the range extender generator can be improved.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy vehicles, and in particular to a range extender generator cooling structure, a vehicle and an assembly method. Background Art

[0002] Common range extender structures include: engine assembly, engine output and connection device, generator assembly; the generator assembly is mainly composed of motor housing, stator assembly, rotor assembly, motor rotor assembly, motor stator assembly, rotary transformer assembly, three-phase terminal block assembly, motor rear end cover, and motor rear cover plate. The generator assembly is assembled on the motor housing and connected to the engine assembly, and the motor rotor assembly and motor stator assembly are installed inside the generator assembly. The motor stator assembly is installed in the inner cavity of the motor housing, and the motor rotor assembly spans the two bearing seats of the motor housing and the motor rear end cover. The protruding end of the motor rotor assembly shaft is installed with the engine output and connection device, the rotary transformer assembly and the three-phase terminal block assembly are respectively installed on the side of the motor rear end cover, and the motor rear cover plate is connected to the motor rear end cover.

[0003] During operation, the range extender generator generates significant heat, particularly at the ends of the motor stator assembly. This heat needs to be dissipated promptly and effectively to prevent damage. Furthermore, the entire range extender generator is installed within the enclosed environment of the engine compartment. This environment affects the overall heat dissipation, making it difficult to dissipate effectively. This heat is more likely to accumulate, thus affecting performance.

[0004] In the prior art, a corresponding cooling structure is designed inside the motor housing of the range extender generator to dissipate heat from the motor stator assembly. This cooling structure is usually covered on the motor stator core in an axial or radial reciprocating manner. The overall cooling effect of the cooling scheme is poor, and the end of the motor stator assembly cannot be effectively and timely dissipated. Summary of the Invention

[0005] The object of the present invention is to provide a range extender generator cooling structure, a vehicle and an assembly method to solve the problem of poor heat dissipation effect of existing range extender generators.

[0006] To solve the above technical problems, the present invention provides a range extender generator cooling structure, comprising a generator housing with an opening at a first end, a generator inner housing inserted into and nested in the generator housing from the first end of the generator housing, and a stator assembly installed in the generator inner housing. A cooling water inlet and a cooling water outlet are provided on the generator housing, and a first cooling channel and a second cooling channel are formed between the inner surface of the generator housing and the outer surface of the generator inner housing. A cooling cavity is formed between the end of the generator housing opposite to the first end of the generator housing and the end of the generator inner housing inserted into the generator housing. The first cooling channel is respectively connected to the inlet of the cooling cavity and the cooling water inlet, and the second cooling channel is respectively connected to the outlet of the cooling cavity and the cooling water outlet.

[0007] Optionally, a thermal pad is provided between the end of the generator inner shell inserted into the generator outer shell and the stator assembly.

[0008] Optionally, a heat-conducting boss is provided on a side of the end of the generator inner shell inserted into the generator outer shell facing the stator assembly and extending in the direction of the stator assembly, and the heat-conducting pad is located between the heat-conducting boss and the stator assembly.

[0009] Optionally, the thermally conductive boss is annular, the thermally conductive pad is annular, the stator assembly includes a winding, and the thermally conductive pad is in contact with the winding of the stator assembly.

[0010] Optionally, a heat dissipation portion is extended from the end portion of the generator inner shell inserted into the generator outer shell toward the generator outer shell on a side facing the generator outer shell and toward the generator outer shell.

[0011] Optionally, there are multiple heat dissipation parts, the cooling cavity is an annular cavity with a gap, and the multiple heat dissipation parts are evenly spaced in the cooling cavity along the circumferential direction of the cooling cavity.

[0012] Optionally, a plurality of cooling ribs are provided on the outer surface of the generator inner shell, and the plurality of cooling ribs divide the gap between the inner surface of the generator outer shell and the outer surface of the generator inner shell into a first cooling channel and a second cooling channel, wherein the second cooling channel includes a cooling cavity section connected to the cooling cavity, a connecting section connected to the cooling cavity section, and an outlet section connected to the connecting section, the outlet section is connected to the cooling water outlet, the cooling cavity section is arranged at the end of the generator inner shell on one side close to the cooling cavity, the outlet section is arranged at the end of the generator inner shell on one side away from the cooling cavity, and the connecting section is distributed along the axial direction.

[0013] Optionally, the cooling cavity includes a first structural channel provided on a side close to the generator shell where the end portion of the generator inner shell is inserted into the generator shell, the first structural channel including a first annular groove, a first connecting groove and a first structural rib, the first connecting groove being distributed along the radial direction of the generator inner shell and extending from the first annular groove to a first structural edge, the first structural edge being an edge of the end portion of the generator inner shell inserted into the generator shell close to the generator shell, the first structural rib being located in the first annular groove and the first connecting groove and extending from the edge of the inner circle of the first annular groove to the first structural edge, the first structural rib dividing the first connecting groove and the first connecting groove into a first structural channel having a first structural inlet and a first structural outlet; the first structural rib is located at the periphery of the generator inner shell and extends into the first cooling channel axially bent and extending into the generator inner shell close to the end portion, forming a dividing guide rib for the cooling medium to enter and exit the cooling cavity.

[0014] The present invention also provides an automobile, comprising an engine, a rotor assembly and the above-mentioned range extender generator cooling structure, wherein the rotor assembly is mounted in the inner cavity of the stator assembly and can rotate relative to the stator assembly, and the output shaft of the engine is connected to the output shaft of the rotor assembly.

[0015] The present invention also provides an assembly method of a range extender generator cooling structure, comprising: Inserting the generator inner shell from the first end of the generator shell and nesting it in the generator shell having a cooling water inlet and a cooling water outlet, so as to form a first cooling channel and a second cooling channel between the inner surface of the generator shell and the outer surface of the generator inner shell, and enclosing a cooling cavity between the end of the generator shell opposite to the first end of the generator shell and the end of the generator inner shell inserted into the generator shell, wherein the first cooling channel is communicated with the inlet of the cooling cavity and the cooling water inlet, respectively, and the second cooling channel is communicated with the outlet of the cooling cavity and the cooling water outlet, respectively; Welding the generator inner shell to the generator outer shell; affix a thermal pad to a side of an end portion of the generator inner shell inserted into the generator outer shell and away from the generator outer shell; The stator assembly is installed in the generator inner shell by means of shrink fitting, and the end of the stator assembly is brought into contact with the thermal pad.

[0016] The present invention provides a range extender generator cooling structure, a vehicle, and an assembly method, which have the following beneficial effects: Since the first end of the generator housing is open, the generator inner housing is inserted into and nested in the generator housing from the first end of the generator housing, and the stator assembly is installed in the generator inner housing, a first cooling channel and a second cooling channel are formed between the inner surface of the generator housing and the outer surface of the generator inner housing, and a cooling cavity is formed between the end of the generator housing opposite to the first end and the end of the generator inner housing inserted into the generator housing. Therefore, the heat generated by the stator assembly can be transferred to the coolant in the first cooling channel and the second cooling channel between the generator housing and the generator inner housing, as well as in the cooling cavity through the generator inner housing; and the first The cooling channel is respectively connected to the inlet of the cooling cavity and the cooling water inlet, and the second cooling channel is respectively connected to the outlet of the cooling cavity and the cooling water outlet, so that the coolant in the first cooling channel, the second cooling channel and the cooling cavity can be discharged; in this way, the stator assembly can dissipate heat and cool down through the first cooling channel, the second cooling channel and the coolant in the cooling cavity, thereby avoiding heat accumulation in the generator assembly and affecting the performance of the range extender generator. In particular, the end of the stator assembly can also dissipate heat through the cooling cavity surrounded by the end of the generator housing and the end of the generator inner shell, thereby improving the cooling effect of the stator assembly and timely and effectively dissipating heat to the end of the stator assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a cross-sectional view of a generator assembly of a range extender according to an embodiment of the present invention; Figure 2 yes Figure 1 A local enlarged schematic diagram at point A; Figure 3 is a schematic structural diagram of a generator housing according to an embodiment of the present invention; Figure 4 is a cross-sectional view of a generator housing according to an embodiment of the present invention; Figure 5 is a cross-sectional view of the inner shell of the generator according to an embodiment of the present invention; Figure 6 2 is a schematic structural diagram of the inner shell of the generator according to an embodiment of the present invention; Figure 7 Schematic diagram of the cooling channel in an embodiment of the present invention.

[0018] Description of reference numerals: 100 - generator housing; 110 - cooling water inlet; 120 - cooling water outlet; 130 - second mounting surface; 140 - first reinforcing rib; 150 - second reinforcing rib; 160 - first housing friction welding surface; 170 - second housing friction welding surface; 181 - second annular groove; 182 - second connecting groove; 183 - second structural rib; 200 - generator inner shell; 210 - shoulder; 220 - first mounting and positioning surface; 230 - cooling rib; 250 - heat dissipation rib; 261 - first inner shell friction welding surface; 262 - second inner shell friction welding surface; 270 - heat conduction boss; 271 - first heat conduction boss; 272 - second heat conduction boss; 280 - heat dissipation portion; 291 - first annular groove; 292 - first connecting groove; 293 - first structural rib; 300- stator assembly; 400-first cooling channel; 500 - second cooling channel; 510 - cooling cavity section; 520 - connecting section; 530 - outlet section; 600-cooling chamber; 700-thermal pad. DETAILED DESCRIPTION

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0020] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort shall fall within the scope of protection of the present invention.

[0021] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0022] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" and the like indicate positions or locations based on the positions shown in the accompanying drawings, or the positions or locations in which the inventive product is typically placed when in use. These terms are intended solely to facilitate the description of the present invention and to simplify the description, and are not intended to indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third," etc., are used solely to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0023] In addition, the terms "horizontal" and "vertical" do not mean that the components must be absolutely horizontal or overhanging, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", not that the structure must be completely horizontal, but can be slightly tilted.

[0024] In the description of the present invention, it should also be noted that, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to mechanical connections or electrical connections; they may refer to direct connections or indirect connections through an intermediate medium; and they may refer to internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0025] refer to Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 and Figure 7 , Figure 1 is a cross-sectional view of a generator assembly of a range extender in an embodiment of the present invention, Figure 2 yes Figure 1 A local enlarged schematic diagram at point A, Figure 3 1 is a schematic structural diagram of a generator housing 100 according to an embodiment of the present invention. Figure 4 is a cross-sectional view of the generator housing 100 according to an embodiment of the present invention. Figure 5 is a cross-sectional view of the generator inner shell 200 according to an embodiment of the present invention. Figure 6 2 is a schematic structural diagram of the generator inner shell 200 according to an embodiment of the present invention. Figure 7 Schematic diagram of cooling channels in an embodiment of the present invention. This embodiment provides a range extender generator cooling structure, comprising a generator housing 100 with an open first end, a generator inner housing 200 inserted and nested within the generator housing 100 from the first end of the generator housing 100, and a stator assembly 300 mounted in the generator inner housing 200. A cooling water inlet 110 and a cooling water outlet 120 are defined on the generator housing 100. A first cooling channel 400 and a second cooling channel 500 are formed between the inner surface of the generator housing 100 and the outer surface of the generator inner housing 200. A cooling cavity 600 is defined between an end of the generator housing 100 opposite the first end thereof and an end of the generator inner housing 200 inserted into the generator housing 100. The first cooling channel 400 communicates with the inlet of the cooling cavity 600 and the cooling water inlet 110, respectively, and the second cooling channel 500 communicates with the outlet of the cooling cavity 600 and the cooling water outlet 120, respectively.

[0026] Since the first end of the generator housing 100 is open, the generator inner housing 200 is inserted into and nested in the generator housing 100 from the first end of the generator housing 100, and the stator assembly 300 is installed in the generator inner housing 200, a first cooling channel 400 and a second cooling channel 500 are formed between the inner surface of the generator housing 100 and the outer surface of the generator inner housing 200, and a cooling cavity 600 is formed between the end of the generator housing 100 opposite to the first end and the end of the generator inner housing 200 inserted into the generator housing 100. Therefore, the heat generated by the stator assembly 300 can be transferred to the coolant in the first cooling channel 400 and the second cooling channel 500 between the generator housing 100 and the generator inner housing 200, and in the cooling cavity 600; and The first cooling channel 400 is respectively connected to the inlet of the cooling cavity 600 and the cooling water inlet 110, and the second cooling channel 500 is respectively connected to the outlet of the cooling cavity 600 and the cooling water outlet 120, so that the coolant in the first cooling channel 400, the second cooling channel 500 and the cooling cavity 600 can be discharged; in this way, the stator assembly 300 can dissipate heat and cool down through the first cooling channel 400, the second cooling channel 500 and the coolant in the cooling cavity 600, thereby avoiding heat accumulation in the generator assembly and affecting the performance of the range extender generator. In particular, the end of the stator assembly 300 can also dissipate heat through the cooling cavity 600 surrounded by the end of the generator housing 100 and the end of the generator inner housing 200, thereby improving the cooling effect of the stator assembly 300 and timely and effectively dissipating heat to the end of the stator assembly 300.

[0027] Preferably, reference Figure 2 A thermal pad 700 is provided between the end of the generator inner housing 200 inserted into the generator outer housing 100 and the stator assembly 300. This allows heat from the end of the stator assembly 300 to be conducted through the thermal pad 700 to the end of the generator inner housing 200 inserted into the generator outer housing 100, and thus into the cooling cavity 600, further improving the cooling effect of the stator assembly 300.

[0028] In addition, the thermal pad 700 has an insulating effect, which can shorten the distance between the end of the stator assembly 300 and the bottom of the generator inner shell 200, making the structure more compact and reducing the axial size of the range extender electric drive system.

[0029] refer to Figure 2The end of the generator inner housing 200 that is inserted into the generator outer housing 100 and faces the stator assembly 300 has a heat-conducting boss 270 extending toward the stator assembly 300. The heat-conducting pad 700 is located between the heat-conducting boss 270 and the stator assembly 300. The provision of the heat-conducting boss 270 allows the heat-conducting pad 700 to wrap around the heat-conducting boss 270, thereby increasing the heat conduction area and improving the heat dissipation effect. It also helps to secure the heat-conducting pad 700.

[0030] The thermally conductive boss 270 is annular, the thermally conductive pad 700 is annular, the stator assembly 300 includes a winding, and the thermally conductive pad 700 is in contact with the winding of the stator assembly 300. In this way, the heat of the winding, the main heat-generating part of the stator assembly 300, can be conducted away through the thermally conductive pad 700 and the thermally conductive boss 270, further improving the heat dissipation effect of the stator assembly 300.

[0031] The thermally conductive bosses 270 include a first thermally conductive boss 271 and a second thermally conductive boss 272, which are concentrically arranged. This prevents excessive thickness in certain areas of the generator inner housing 200, reduces material costs, and improves component manufacturability. Furthermore, the first and second thermally conductive bosses 271, 272 assist in securing the thermal pad 700, facilitating its securement and installation.

[0032] Furthermore, the thermal pad 700 is glued and fixed to the first thermal conductive boss 271 and the second thermal conductive boss 272 on the generator inner shell 200 .

[0033] The thermal pad 700 can be an integral structure or a split structure.

[0034] refer to Figure 6 The end of the generator inner shell 200 inserted into the generator outer shell 100 has a heat dissipation portion 280 extending toward the generator outer shell 100 on the side facing the generator outer shell 100, thereby increasing the contact area between the generator inner shell 200 and the coolant in the cooling cavity 600 through the heat dissipation portion 280, reducing heat accumulation at the end of the stator assembly 300, reducing the risk of overheating at the end of the stator assembly 300, and reducing the risk of overheating of the range extender generator with this structure.

[0035] There are multiple heat dissipation parts 280 .

[0036] The heat dissipation portion 280 is a structural boss.

[0037] Preferably, the cooling cavity 600 is an annular cavity with a gap, and the plurality of heat dissipation portions 280 are evenly spaced and distributed in the cooling cavity 600 along the circumferential direction of the cooling cavity 600 .

[0038] refer to Figure 5 The generator inner shell 200 has a shoulder 210 for axial positioning of the stator assembly 300. By adjusting the axial processing depth of the shoulder 210 of the generator inner shell 200, it can be matched with stator assemblies 300 with different stacking heights, meeting different performance requirements while realizing product series platformization, effectively reducing the subsequent industrialization investment.

[0039] refer to Figure 2 、 Figure 3 、 Figure 4 and Figure 5 The generator inner shell 200 has a first mounting positioning surface 220 , and the generator outer shell 100 has a second mounting positioning surface 130 , and the first mounting positioning surface 220 and the second mounting positioning surface 130 are in contact with each other.

[0040] refer to Figure 6 and Figure 7 In this embodiment, the first cooling channel 400 and the second cooling channel 500 are distributed in a radial reciprocating manner between the inner surface of the generator housing 100 and the outer surface of the generator inner housing 200 .

[0041] Specifically, a plurality of cooling ribs 230 are provided on the outer surface of the generator inner shell 200, and the plurality of cooling ribs 230 divide the gap between the inner surface of the generator outer shell 100 and the outer surface of the generator inner shell 200 into a first cooling channel 400 and a second cooling channel 500, wherein the second cooling channel 500 includes a cooling chamber section 510 connected to the cooling chamber 600, a connecting section 520 connected to the cooling chamber section 510, and an outlet section 530 connected to the connecting section 520, the outlet section 530 is connected to the cooling water outlet 120, the cooling chamber section 510 is arranged at the end of the generator inner shell 200 close to the cooling chamber 600, and the outlet section 530 is arranged at the end of the generator inner shell 200 away from the cooling chamber 600, and the connecting section 520 is distributed along the axial direction.

[0042] Furthermore, the generator inner shell 200 is provided with heat dissipation ribs 250 protruding into the first cooling channel 400 at the connecting section 520 to increase the contact area between the generator inner shell 200 and the coolant, improve the heat dissipation effect, and at the same time guide the coolant to further improve the heat dissipation effect.

[0043] refer to Figure 6 , the number of the heat dissipation ribs 250 is two.

[0044] The generator inner shell 200 and the stator assembly 300 are interference-fitted, and the stator assembly 300 is installed by shrink fitting.

[0045] The end portion of the generator inner shell inserted into the generator outer shell has a first structural channel on a side close to the generator outer shell and / or the end portion of the generator outer shell opposite to the first end of the generator outer shell has a first structural channel on a side close to the generator inner shell. The first structural channel is connected to the first cooling channel through a first structural inlet, and the first structural channel is connected to the second cooling channel through a first structural outlet. The first structural channel forms the cooling cavity.

[0046] If only the end of the generator inner casing inserted into the generator outer casing, near the generator outer casing, has the first structural channel, then the end of the generator outer casing opposite the first end, near the generator inner casing, may have the first structural channel or be flat. If the end of the generator inner casing inserted into the generator outer casing, near the generator outer casing, has a flat surface, then the end of the generator outer casing opposite the first end, near the generator inner casing, has the first structural channel. This provides three types of cooling cavities.

[0047] Specifically, when the first structural channel is located on the side of the end of the generator inner casing inserted into the generator outer casing that is close to the generator outer casing, the first structural channel includes a first annular groove 291, a first connecting groove 292, and a first structural rib 293. The first connecting groove 292 is distributed radially along the generator inner casing and extends from the first annular groove 291 to the first structural edge. The first structural edge is the edge of the end of the generator inner casing inserted into the generator outer casing that is close to the generator outer casing. The first structural rib 293 is located in the first annular groove 291 and the first connecting groove 292 and extends from the inner edge of the first annular groove 291 to the first structural edge. The first structural rib 293 divides the first connecting groove 292 and the first connecting groove 292 into a first structural channel having a first structural inlet and a first structural outlet. By dividing the first connecting groove 292 and the first connecting groove 292 into the first structural channel having a first structural inlet and a first structural outlet through the first structural rib 293, the design of the generator inner casing can be simplified and the manufacturability of the generator inner casing can be improved. The first structural rib 293 is located at the periphery of the generator inner shell and is bent axially into the first cooling channel 400 (annular cooling channel along the circumferential surface) near the end of the generator inner shell, forming a dividing guide rib for the cooling medium to enter and exit the cooling cavity ( Figure 6As shown), the first axial structural rib portion constitutes a dividing guide portion for medium circulation in the first cooling channel 400. It can be understood that the first structural rib 293 includes a radial portion in the cooling cavity and an axial portion in the first cooling channel.

[0048] When the first structural channel is arranged on a side of the generator inner shell at the end portion opposite to the first end of the generator shell, the first structural channel includes a second annular groove 181, a second connecting groove 182 and a second structural rib 183. The second connecting groove 182 is distributed along the radial direction of the generator shell and extends from the second annular groove 181 to the second structural edge. The second structural edge is the edge of the generator shell at the end portion opposite to the first end of the generator shell, close to the generator inner shell. The second structural rib 183 is located in the second annular groove 181 and the second connecting groove 182 and extends from the edge of the inner circle of the second groove to the second structural edge. The second structural rib 183 divides the second connecting groove 182 and the second connecting groove 182 into a first structural channel having a second structural inlet and a second structural outlet.

[0049] When the first structural channel is located on the side of the end of the generator inner housing where it is inserted into the generator outer housing, and when the first structural channel is located on the side of the generator inner housing opposite the first end of the generator outer housing, the first annular groove 291 and the second annular groove 181 are arranged opposite each other, the first connecting groove 292 and the second connecting groove 182 are arranged opposite each other, and the first structural rib 293 and the second structural rib 183 are aligned and abutted. The two first structural channels merge into the cooling cavity. The first structural inlet and the second structural inlet are arranged opposite each other to form an inlet that communicates with the first cooling channel, and the first structural outlet and the second structural outlet are arranged opposite each other to form an outlet that communicates with the second cooling channel. Since the first and second structural channels are combined into the cooling cavity, the volume of the cooling cavity can be increased, improving the cooling effect. Since the first and second structural inlets are arranged opposite each other to form an inlet that communicates with the first cooling channel, and the first and second structural outlets are arranged opposite each other to form an outlet that communicates with the second cooling channel, the cross-sectional area of ​​the inlet and outlet of the cooling cavity can be increased, ensuring smooth flow of coolant within the cooling cavity.

[0050] The generator housing 100 includes a plurality of first reinforcing ribs 140 arranged along the axial direction. The plurality of first reinforcing ribs 140 are evenly arranged along the circumference of the generator housing 100 , thereby enhancing the stability of the external structure of the motor housing, improving NVH (Noise, Vibration, Harshness) performance, and increasing the heat dissipation area of ​​the generator housing 100 . The cooling medium circulates in the first cooling channel 400 and the second cooling channel 500 formed by the generator housing 100 and the generator inner housing 200 , thereby increasing the heat dissipation capacity of the range extender generator.

[0051] The generator housing 100 includes a plurality of annular second reinforcing ribs 150 arranged along the circumference. The plurality of second reinforcing ribs 150 are evenly arranged along the axial direction of the generator housing 100 to enhance the stability of the motor housing's external structure, improve NVH (Noise, Vibration, Harshness) performance, and increase the heat dissipation area of ​​the generator housing 100. The cooling medium circulates through the first cooling channel 400 and the second cooling channel 500 formed by the generator housing 100 and the generator inner housing 200, thereby increasing the heat dissipation capacity of the range extender generator. A cooling cavity 600 is formed between the end of the generator housing 100 opposite to the first end and the end thereof. The generator outer shell 100 has a first outer shell friction welding surface 160 and a second outer shell friction welding surface 170, and the generator inner shell 200 has a first inner shell friction welding surface 261 and a second inner shell friction welding surface 262. The first outer shell friction welding surface 160 and the first inner shell friction welding surface 261 are friction welded, and the second outer shell friction welding surface 170 and the second inner shell friction welding surface 262 are friction welded.

[0052] The generator housing 100 contains multiple mounting structure interfaces and range extender system-related mounting interfaces, specifically including engine mounting and positioning structure, vehicle suspension point, vehicle wiring harness mounting point, vehicle wiring harness mounting point, grounding threaded hole, motor rear end cover mounting and positioning structure, cooling cavity 600 body structure, friction welding structure, coolant inlet, coolant outlet, bearing chamber hole, oil seal hole and other structures.

[0053] The stator assembly 300 is primarily composed of a stator core and flat copper wire. The stator assembly 300 is installed with the generator inner housing 200 using an interference fit and shrink fit. The motor stator assembly positioning and mounting structure of the generator inner housing 200 is used to limit and axially secure the stator assembly 300.

[0054] Optionally, the stator assembly 300 may be a flat wire stator or a round wire stator.

[0055] This embodiment also provides an automobile, including an engine and a rotor assembly and the range extender generator cooling structure in the above embodiment, the rotor assembly is installed in the inner cavity of the stator assembly 300, and the rotor assembly can rotate relative to the stator assembly 300, and the output shaft of the engine is connected to the output shaft of the rotor assembly.

[0056] This embodiment also provides a method for assembling a range extender generator cooling structure, comprising: Inserting the generator inner shell 200 from the first end of the generator shell 100 and nesting it in the generator shell 100 having a cooling water inlet 110 and a cooling water outlet 120, so as to form a first cooling channel 400 and a second cooling channel 500 between the inner surface of the generator shell 100 and the outer surface of the generator inner shell 200, and enclosing a cooling cavity 600 between the end of the generator shell 100 opposite to the first end of the generator shell 100 and the end of the generator inner shell 200 inserted into the generator shell 100, wherein the first cooling channel 400 is respectively in communication with the inlet of the cooling cavity 600 and the cooling water inlet 110, and the second cooling channel 500 is respectively in communication with the outlet of the cooling cavity 600 and the cooling water outlet 120; Welding the generator inner shell 200 to the generator outer shell 100; Attach the thermal pad 700 to the end of the generator inner shell 200 inserted into the generator outer shell 100 and away from the end of the generator outer shell 100; The stator assembly 300 is installed in the generator inner shell 200 by shrink fitting, and the end of the stator assembly 300 is in contact with the thermal pad 700 .

[0057] The range extender generator cooling structure in the above embodiment has the following effects: First, the generator outer shell 100 and the generator inner shell 200 in the range extender generator cooling structure in this embodiment adopt a split structure, and the split shell structure can be changed at will for flexible and free combination of different shell assemblies, reducing the later development cost and cycle of the shell.

[0058] Secondly, the range extender generator cooling structure in this embodiment, if the generator housing 100 of this structure is retained, the installation structure of the motor stator assembly of the generator inner housing 200 can be changed to flexibly match motor stators and rotors with different stack lengths, meet different performance requirements, and realize product series platformization, effectively reducing the later industrialization investment.

[0059] Secondly, if the range extender generator cooling structure in this embodiment retains the generator inner shell 200 of this structure, by changing the motor housing structure, engine mounting interface, etc. of this structure, the range extender system can be quickly formed to match the layout envelope requirements of various new energy vehicle models of different customers, thereby shortening the development cycle of the range extender series products.

[0060] Secondly, in the cooling structure of the range extender generator in this embodiment, after the thermal pad 700 is installed, the thermal pad 700 will directly contact the end of the stator assembly 300. The thermal pad 700 can effectively transfer the heat from the stator end to the generator inner shell 200. The heat is taken away by the cooling medium, thereby significantly reducing the temperature of the end of the stator assembly 300.

[0061] Furthermore, in the range extender generator cooling structure of this embodiment, the thermal pad 700 provides both insulation and thermal conductivity. Once installed, the pad 700 directly contacts the end of the stator assembly 300 and the generator inner housing 200, shortening the distance between the end of the stator assembly 300 and the bottom of the generator inner housing 200. This reduces the axial dimension of the housing structure, resulting in a more compact structure and improved cost performance.

[0062] The above description is only a description of the preferred embodiments of the present invention and does not limit the scope of the present invention. Any changes and modifications made by ordinary technicians in the field of the present invention based on the above disclosure shall fall within the scope of protection of the claims.

Claims

1. A range extender generator cooling structure, comprising a generator housing with an open first end, a generator inner housing inserted into and nested within the generator housing from the first end of the generator housing, and a stator assembly mounted in the generator inner housing, characterized in that: A cooling water inlet and a cooling water outlet are provided on the generator housing. A first cooling channel and a second cooling channel are formed between the inner surface of the generator housing and the outer surface of the generator inner housing. A cooling cavity is formed between the end of the generator housing opposite to the first end of the generator housing and the end of the generator inner housing inserted into the generator housing. The first cooling channel is respectively communicated with the inlet of the cooling cavity and the cooling water inlet, and the second cooling channel is respectively communicated with the outlet of the cooling cavity and the cooling water outlet.

2. The range extender generator cooling structure according to claim 1, characterized in that: A heat conducting pad is provided between the end of the generator inner shell inserted into the generator outer shell and the stator assembly.

3. The range extender generator cooling structure according to claim 2, characterized in that: A heat-conducting boss is provided on a side of the end of the generator inner shell inserted into the generator outer shell facing the stator assembly and extending in the direction of the stator assembly. The heat-conducting pad is located between the heat-conducting boss and the stator assembly.

4. The range extender generator cooling structure according to claim 3, characterized in that: The heat-conducting boss is annular, the heat-conducting pad is annular, the stator assembly includes a winding, and the heat-conducting pad is in contact with the winding of the stator assembly.

5. The range extender generator cooling structure according to claim 1, characterized in that: A heat dissipation portion is extended from the end portion of the generator inner shell inserted into the generator outer shell toward the generator outer shell on a side thereof facing the generator outer shell and toward the generator outer shell.

6. The range extender generator cooling structure according to claim 5, characterized in that: There are multiple heat dissipation parts, the cooling cavity is an annular cavity with a gap, and the multiple heat dissipation parts are evenly spaced in the cooling cavity along the circumferential direction of the cooling cavity.

7. The range extender generator cooling structure according to claim 1, characterized in that: A plurality of cooling ribs are provided on the outer surface of the generator inner shell, and the plurality of cooling ribs divide the gap between the inner surface of the generator outer shell and the outer surface of the generator inner shell into a first cooling channel and a second cooling channel, wherein the second cooling channel includes a cooling cavity section connected to the cooling cavity, a connecting section connected to the cooling cavity section, and an outlet section connected to the connecting section, the outlet section is connected to the cooling water outlet, the cooling cavity section is provided at the end of the generator inner shell on one side close to the cooling cavity, the outlet section is provided at the end of the generator inner shell on the side away from the cooling cavity, and the connecting sections are distributed along the axial direction.

8. The range extender generator cooling structure according to claim 1, characterized in that: The cooling cavity includes a first structural channel provided on a side of the end portion of the generator inner shell inserted into the generator outer shell close to the generator outer shell, the first structural channel including a first annular groove, a first connecting groove and a first structural rib, the first connecting groove being distributed along the radial direction of the generator inner shell and extending from the first annular groove to a first structural edge, the first structural edge being the edge of the end portion of the generator inner shell inserted into the generator outer shell close to the generator outer shell, the first structural rib being located in the first annular groove and the first connecting groove and extending from the edge of the inner circle of the first annular groove to the first structural edge, the first structural rib dividing the first connecting groove and the first connecting groove into a first structural channel having a first structural inlet and a first structural outlet; the first structural rib is located at the periphery of the generator inner shell and extends into the first cooling channel close to the end portion of the generator inner shell along the axial direction, forming a dividing guide rib for the cooling medium to enter and exit the cooling cavity.

9. An automobile, characterized in that: It comprises an engine, a rotor assembly and the range extender generator cooling structure as claimed in claim 1, wherein the rotor assembly is mounted in the inner cavity of the stator assembly and can rotate relative to the stator assembly, and the output shaft of the engine is connected to the output shaft of the rotor assembly.

10. A method for assembling a range extender generator cooling structure, characterized in that: include: Inserting the generator inner shell from the first end of the generator shell and nesting it in the generator shell having a cooling water inlet and a cooling water outlet, so as to form a first cooling channel and a second cooling channel between the inner surface of the generator shell and the outer surface of the generator inner shell, and enclosing a cooling cavity between the end of the generator shell opposite to the first end of the generator shell and the end of the generator inner shell inserted into the generator shell, wherein the first cooling channel is communicated with the inlet of the cooling cavity and the cooling water inlet, respectively, and the second cooling channel is communicated with the outlet of the cooling cavity and the cooling water outlet, respectively; Welding the generator inner shell to the generator outer shell; affix a thermal pad to a side of an end portion of the generator inner shell inserted into the generator outer shell and away from the generator outer shell; The stator assembly is installed in the generator inner shell by means of shrink fitting, and the end of the stator assembly is brought into contact with the thermal pad.

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